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Safety

 

and

 

Warning

 

Before

 

operation

 

and

 

maintenance

 

for

 

the

 

generator

 

sets,

 

please

 

read

 

carefully

 

about

 

this

 

manual

 

and

 

make

 

sure

 

a

 

good

 

understanding

 

of

 

this

 

operation

 

manual

 

and

 

other

 

documents

 

which

 

attached

 

with

 

the

 

engine.

 

Correct

 

installation

 

of

 

the

 

generator

 

set

 

is

 

the

 

precondition

 

of

 

normal

 

operation.

 

Qualified

 

spare

 

parts

 

shall

 

be

 

used

 

for

 

maintenance

 

to

 

ensure

 

good

 

running

 

condition

 

and

 

long

 

life

 

expectancy

 

of

 

the

 

generator

 

sets.

 

The

 

generator

 

set

 

shall

 

be

 

operated

 

only

 

by

 

the

 

staffs

 

who

 

have

 

received

 

training

 

on

 

the

 

operation

 

and

 

the

 

repair

 

shall

 

be

 

made

 

by

 

the

 

authorized

 

staffs.

 

Operator

 

and

 

maintenance

 

staff

 

shall

 

be

 

clear

 

about

 

safety

 

and

 

preventive

 

actions

 

and

 

operation

 

maintenance

 

procedure.

 

The

 

generator

 

sets

 

can

 

only

 

be

 

started

 

under

 

safety

 

conditions.

 

Please

 

do

 

not

 

start

 

the

 

generator

 

sets

 

when

 

any

 

abnormal

 

condition

 

has

 

been

 

found

 

so

 

that

 

to

 

avoid

 

accidents.

 

When

 

clean,

 

maintain

 

and

 

repair

 

the

 

generator

 

sets,

 

please

 

shut

 

down

 

the

 

generator

 

set

 

and

 

cut

 

off

 

the

 

connection

 

of

 

negative

 

polar

 

of

 

the

 

battery

 

or

 

dismantle

 

battery

 

connecting

 

cable,

 

and

 

place

 

warning

 

label

 

at

 

the

 

relative

 

place

 

so

 

that

 

to

 

avoid

 

accident.

 

The

 

exhaust

 

air

 

discharged

 

from

 

engine

 

is

 

harmful

 

for

 

people’s

 

health.

 

All

 

of

 

the

 

generator

 

sets

 

installed

 

indoors

 

shall

 

discharge

 

the

 

exhaust

 

gas

 

to

 

outside

 

doors.

 

During

 

the

 

period

 

of

 

generator

 

set

 

running,

 

the

 

exhaust

 

pipe

 

and

 

silencer

 

will

 

generate

 

high

 

temperature.

 

Therefore

 

when

 

the

 

generator

 

set

 

is

 

installed,

 

these

 

parts

 

need

 

to

 

be

 

covered

 

with

 

insulation

 

materials

 

and

 

be

 

kept

 

far

 

away

 

from

 

inflammable

 

materials.

 

Please

 

ensure

 

good

 

ventilation

 

and

 

organized

 

environment

 

for

 

the

 

generator

 

set’s

 

installation

 

room.

 

Please

 

do

 

not

 

place

 

inflammable

 

materials

 

and

 

explosives

 

(liquid)

 

near

 

the

 

engine.

 

Smoking,

 

spark

 

over,

 

and

 

other

 

fire

 

lighting

 

behaviors

 

are

 

not

 

allowed

 

in

 

the

 

area

 

which

 

is

 

close

 

to

 

the

 

battery

 

and

 

fuel

 

because

 

the

 

mixture

 

of

 

volatilization

 

from

 

fuel

 

and

 

hydrogen

 

generated

 

by

 

battery

 

charging

 

process

 

will

 

cause

 

explosion

 

when

 

it

 

meets

 

sparkle

 

or

 

naked

 

flame.

 

The

 

generator

 

set

 

installation

 

room

 

shall

 

be

 

facilitated

 

with

 

BC

 

and

 

ABC

 

fire

 

extinguisher,

 

and

 

operators

 

shall

 

be

 

familiar

 

with

 

the

 

knowledge

 

on

 

how

 

to

 

use

 

it.

 

When

 

fan

 

protection

 

cover

 

or

 

other

 

protection

 

cover

 

has

 

been

 

detached,

 

please

 

do

 

not

 

try

 

to

 

start

 

the

 

generator

 

set;

   

and

 

when

 

the

 

generator

 

set

 

has

 

to

 

be

 

started,

   

please

 

don’t

 

put

 

your

 

hand

 

in

 

the

 

area

 

where

 

the

 

protection

 

cover

 

is

 

missing

 

or

 

make

 

repair

 

around

 

these

 

areas.

 

Please

 

keep

 

your

 

palm,

 

arm,

 

long

 

hair,

 

jewelry

 

and

 

loose

 

clothes

 

far

 

away

 

from

 

belt

 

pulley,

 

belt

 

and

 

other

 

power

 

transmission

 

parts.

 

When

 

working

 

in

 

the

 

generator

 

set

 

installation

 

room,

 

please

 

ware

 

working

 

clothes,

 

gloves

 

and

 

hat.

 

After

 

the

 

generator

 

set

 

being

 

started,

 

please

 

don’t

 

try

 

to

 

open

 

the

 

cover

 

of

 

the

 

radiator

 

before

 

the

 

anti

freeze

 

fully

 

cooled

 

down,

 

so

 

that

 

to

 

avoid

 

steam

 

(hot

 

water)

 

burst

 

forth

 

to

 

hurt

 

people.

 

Please

 

don’t

 

swallow

 

or

 

let

 

your

 

skin

 

contact

 

with

 

the

 

harmful

 

materials

 

such

 

as

 

fuel,

 

anti

freeze,

 

lubricant

 

and

 

electrolyte.

 

When

 

you

 

skin

 

is

 

spattered

 

with

 

these

 

kinds

 

of

 

liquids,

 

please

 

use

 

plenty

 

of

 

water

 

to

 

rinse.

 

Long

 

time

 

stay

 

in

 

high

 

noise

 

level

 

environment

 

will

 

cause

 

harm

 

to

 

your

 

hearing.

 

If

 

you

 

have

 

to

 

work

 

around

 

the

 

generator

 

set

 

frequently,

 

you’d

 

better

 

ware

 

the

 

device

 

to

 

protect

 

your

 

ear.

 

When

 

the

 

generator

 

set

 

need

 

to

 

make

 

cable

 

connections

 

to

 

output

 

power,

 

the

 

operation

 

shall

 

conform

 

to

 

the

 

condition,

 

specification,

 

standard

 

related

 

to

 

power

 

distribution.

 

Qualified

 

cable

 

shall

 

be

 

used

 

to

 

make

 

power

 

distribution.

 

When

 

the

 

installation

 

of

 

generator

 

set

 

involves

 

with

 

welding,

 

please

 

do

 

not

 

connect

 

to

 

the

 

ground

 

circuit

 

or

 

make

 

grounding

 

through

 

generator

 

set

 

(engine)

 

so

 

that

 

to

 

avoid

 

the

 

big

 

current

 

generated

 

from

 

welding

 

operation

 

hurt

 

the

 

electric

 

appliance,

 

bearing

 

and

 

bearing

 

bush

 

etc.

 

inside

 

of

 

the

 

generator

 

set.

 

Please

 

ensure

 

the

 

safety

 

of

 

generator

 

set

 

and

 

reliable

 

grounding.

 

Summary of Contents for DHY34KSE

Page 1: ... REGULATION STARTING METHOD DISPLACEMENT cc OIL CAPACITY L ALTERNATOR RATED POWER kW kVA POWER FACTOR Cosφ VOLTAGE REGULATION LOW OIL PRESSURE BLOCK ON START UP LOW BATTERY HIGH TEMPERATURE ON WATER LOW OIL LEVEL LOW RUNNING ON ENGINE EMERGENCY STOP N G kg G W kg PRODUCT DIMENSIONS mm CAPACITY units container 25 31 28 34 50 230 400 45 IL NT MRS 10 INCLUDED 1x12v 60Ah 93 10 5 2 9 3 18 10 68 HY4102 ...

Page 2: ...DIESEL GENERATOR Models Hyundai Engine Series Operation and Maintenance manual ...

Page 3: ...tock and property Some or all of the following PPE warning signs and symbols may appear throughout this manual and you must adhere to their warning s Failure to do so may result in personal injury Warning Signs and Symbols FOLLOW safety messages to avoid or reduce risk of injury or death DANGER indicates a hazard which if not avoided could result in serious injury or death WARNING indicates a haza...

Page 4: ...e even if doors and windows are open If you think you or someone around you has been affected by carbon monoxide poisoning Leave the affected area and get fresh air immediately Open doors and windows and turn the machine off See your doctor immediately or go to hospital let them know that you suspect carbon monoxide poisoning DO NOT use in an enclosed area or a moving vehicle General fuel safety C...

Page 5: ...rior to carrying out any maintenance work Prior to use and with all electrical supplies isolated check all electrical cables plugs and connections for the following Are intact and have no signs of damage to include but not limited to bare wires chaffing cuts and loose wiring If there are any signs of damage you should stop using the equipment The damaged item must repaired by an electrically compe...

Page 6: ... starting DO NOT pour water directly over the generator nor wash it with water For each use make sure that the generator has been electrically grounded earthed Failure to do so can be fatal DO NOT smoke while charging a battery The battery emits flammable hydrogen gas which can explode if exposed to electric arcing or open flame Keep the area well ventilated and keep open flames sparks away when c...

Page 7: ...is close to the battery and fuel because the mixture of volatilization from fuel and hydrogen generated by battery charging process will cause explosion when it meets sparkle or naked flame The generator set installation room shall be facilitated with BC and ABC fire extinguisher and operators shall be familiar with the knowledge on how to use it When fan protection cover or other protection cover...

Page 8: ...t is running do not attempt to reach under or around the guards to do maintenance or for any other reason Keep hands arms long hair loose clothing and jewelers away from pulleys belts and other moving parts SAFEGUARD WARNING Generating sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 105 dB A Prolonged exposure to noise levels above 85 dB A is haza...

Page 9: ...nal disconnected prior to attempting to connect or disconnect load connections Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground Make sure connect generator set to earth Replace the generating set terminal box cover as soon as connection or disconnection of the load cables is complete Do not operate the generating set without the cover secur...

Page 10: ...erator Set Working Room 4 2 5 Installation of Generator Set 5 2 6 Cooling system 7 2 7 Lubricant system 8 2 8 Fuel system 8 2 9 Battery 10 2 10 Electrical Connection 11 2 11 Power distribution system 11 3 Operation 3 1 Inspect Before Operation 12 3 2 Generator set s running 12 3 3 After Running 13 3 4 Record for running 13 3 5 Matters need attention 13 3 6 Operation for control system 14 3 7 ATS c...

Page 11: ...tandby power supply to provide continue electric power for non invariable loads The generator set is suitable for the area where must ensure continue power supply such as hospitals industrial facilities airports etc Keep the generator set standby state at any time and start to run when the mains supply is abnormal Emergency service Used as auxiliary power supply to solve energy interruptions that ...

Page 12: ...a pusher fan and thermostat The alternator has its own internal fan to cool the alternator components 1 6 Electrical System The engine electrical system is 12 volt or 24 volts DC negative ground earth This system includes an electric engine starter a battery and a battery charging alternator For DC 12 volts electrical system one battery is given For 24 volt system two lead acid batteries are given...

Page 13: ...ilitated onnect direc valve is an UNDAI Pow n for the rplus lubrica t by openin ransportatio been designe Standard ca fting hole o enerator set canopy roo me which b o have stati the generato Optional S ed with heat l the pre hea n be started gency cases 3 y with ctly to nother wer It users ant or g the on ed for anopy on the ts we of and better ionary or set Spare ter for ater is under s and al d...

Page 14: ...nect to other architecture s foundation The width and depth of foundation shall meet requirement Ensure foundation s levelness and smoothness If possible waste discharge sink can be sued so that the waste oil can be discharged in a timely manner Cable channel for generator power output cable need to be reserved Normally concrete foundation is reliable simple and preferable When pouring the concret...

Page 15: ...set to outside For example corrugated vibration reduction pipe has been used to connect exhaust pipes air exhaust path fuel inlet pipe fuel return pipe and busbar cable etc all of these parts need to use soft connections Only in this way we can reduce the adverse effect caused by the vibration of generator set to the minimum extent 2 5 2 Ventilation When a generator set with a complete set of radi...

Page 16: ...essure and side stress Reserve some space for hot shrinkage and cold expansion Reserve space for generator set vibration Reduce exhaust noise level Overload of exhaust backpressure will cause following adverse effect Output power loss Fuel efficiency reduce Exhaust gas temperature rise Note When more than one generator set are installed try not to discharge all of the generator sets gas from one e...

Page 17: ... the liquids in a separate container evenly and then add the mixture into the radiator ensure the anti freeze will not freeze under low temperature In the area when there is low possibility of freezing the coolant can be a mixture of water and anti rust according to the anti rust which recommended by the engine supplier and refer to its operation manual mix the liquids in a separate container even...

Page 18: ... specification as that existing in the radiator For some generator sets installed with coolant filter please open the filter s valve before put into use 2 7 Lubricant system Lubricant system is composed of oil pan oil pump strainer oil pipe oil cooling unit oil filter unit and the oil path inside of the engine and all kinds of lubricant parts which are in relative motion etc The main purpose of th...

Page 19: ...tor sets provide base frame style fuel tank for customer The base frame style fuel tank is installed with fuel tank fuel pipes and fuel level indicator This fuel supply system does not need customer to make other installations Customers only need to add fuel to the base frame Users who intend to self manufacture the fuel tank shall use stainless steel or steel plate to make the backup tank do not ...

Page 20: ...s are required to correctly connect the signal line to this control panel details see the control panel operation manual Automatic transfer panel optional is the automatic transfer switch for transfer between generator set and mains details refer to control panel operation manual 2 9 Battery Our generator set standard configuration provides start battery as accessory parts According to user s diff...

Page 21: ...must be connected to an earth ground Since the set is mounted on vibration isolators the ground connection must be flexible to avoid possible breakage due to vibration Ground connection cables or straps should have at least full load current carrying capacity and meet applicable regulations 2 10 3 Insulation Test Before starting the generating set after installation test the insulation resistance ...

Page 22: ...Start Part of the generator set control panel has been furnished with idle speed full speed transfer switch users can choose if the engine need to be started in idle speed or in one time full speed Usually the time period for idle speed shall not exceed five minutes Do not run the generator set in idle speed in a long time period Press on the start button the duration shall not exceed 30 seconds e...

Page 23: ...ning situation and if there is any malfunction warning generator set shut down etc Only when the correct and complete record for running maintenance has been kept very well the user can get correct and excellent after sales warranty service 3 5 Matters need attention Warning When engine s temperature is very low the time period for idle speed shall be properly extended However when the generator s...

Page 24: ...s number 3 times the Alarm LCD would flash If you need to restart wait at least 30 seconds before the retry 8 Check the reading of Voltage Meter and Frequency Meter by operating the Voltmeter Change Over Switch Once the generator set is running at the correct voltage and frequency Turn the Generator set main circuit breaker to ON 9 Turn on every switch or circuit breaker of loads from heavy to lig...

Page 25: ...light means AMF controller is active then user can select operation type OFF MAN AUTO MEASUREMENT A OFF mode Start stop mains power on off generator set power on off is inactive in this mode B MAN mode 1 Press start pushbutton to start engine 2 When output voltage is in the set range a Press mains power on off pushbutton to turn on the switch b Press mains power on off pushbutton the switch will b...

Page 26: ... if generator set is used for self start standby power In order to achieve full automatic transfer between mains power and generator set power to guarantee all load present our ATS panel select the best ATS for all generator set And to the most possibility to serve our customers demand we prepare two types of ATS MRS and AMF Besides MRS and AMF can be jointed to a double standby ATS after a little...

Page 27: ...TO that is OK detail operate step refer module control system ATS PANEL introduction No MODEL 1 ATS switch 2 panel lock 3 mains power output hole 4 generator power output hole 5 communicate with generator module port 6 load power cable output 7 panel on ground leg Maintenance inspect or exchange parts attention Attention All operator must be professional electrician Turn switch on OFF position mak...

Page 28: ... battery For each 50 600 hours of running or at least each 12 months Change lubricant and lubricant filter Because the quality of lubricant oil sulfur content of the fuel and lubricant consumption rate of each engine is different the interval for lubricant oil change for each generator set will be different When change the lubricant oil at the same time oil filter needs to be changed otherwise the...

Page 29: ... refer to Control Panel Operation Manual for details 4 5 Start battery Batteries which have been stored in a long time shall be properly charged before being used so that to ensure normal capacitance of the battery Densimeter can be used to check the actual capacitance of the battery Normal operation and battery charging will cause some water inside of the battery being vaporized And therefore con...

Page 30: ...liminate the malfunction s Especially important for new generator set s customer One thing must to be emphasized most of the malfunctions are caused by user s improper installation operation and maintenance Users are entitled to doubt that the malfunction s is caused by the generator set s manufacture failure but this conclusion shall be based on correct installation operation and periodically mai...

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Page 39: ...APPENDIX E 1 ...

Page 40: ...2 ...

Page 41: ...3 ...

Page 42: ...t running record TIME ENGINE PARAMETER GENERATOR PARAMETER IF RECORD FOR MALFUNCTION IS AVAILABLE OPERATOR REMARK Start stop generator set time Accumulated running time Oil pressure Temperature Voltage Current Frequency Power ...

Page 43: ...t serial No Engine serial No Alternator serial No Accumulated running hours Maintenance cycle Reasons for maintenance periodic maintenance or malfunction maintenance Inspection and repair Inspection and adjustment Change of parts Clean and maintenance Others Conclusion for maintenance Maintenance staff signature ...

Page 44: ...APPENDIX H ...

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