Aksa ALP 8 User manual

INSTALLATION RECOMMENDATIONS
&
OPERATION MANUAL
OF DIESEL GENERATING SETS
www.aksa.com.tr
Lister Petter & Perkins
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Dear Aksa Generating Set Operator
First of all, we would like to thank you for your choice of Aksa Power
Generator.
This operating and maintenance manual is designed and developed to
make you familiar with the generator system.
This manual gives general information about mounting, operation and
maintenance of the generating set. Tables and diagrams are also available
outlining your generating set.
ever operate, maintain or repair your generating set without taking
general safety precautions.
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I
CONTENTS
INTRODUCTION.........................................................................................
SAFETY .......................................................................................................
2.1 General ...........................................................................................
2.2 Installation, Handling and Towing .........................................................
2.3 Fire and Explosion ..................................................................................
2.4 Mechanical ..........................................................................................
2.5 Chemical ................................................................................................
2.6 oise .....................................................................................................
2.7 Electrical ................................................................................................
2.8 First aid For Electric Shock ...................................................................................
GENERAL DESCRIPTION.....................................................................................
3.1 Generating Set Description and Identification......................................
3.2 Diesel Engine .........................................................................................
3.3 Engine Electrical System .......................................................................
3.4 Cooling System ......................................................................................
3.5 Alternator ..........................................................................................
3.6 Fuel Tank and Baseframe ......................................................................
3.7 Vibration Isolation .................................................................................
3.8 Silencer and Exhaust System ...........................................................
3.9 Control System ..................................................................................
INSTALLATION, HANDLING AND STORAGE...........................................
4.1 General .................................................................................................
4.2 Canopies ......................................................................................
4.3 Location ................................................................................................
4.4 Moving the Generating Set ................................................................
4.5 Foundations Vibration Isolation ...................................................
4.6 Combustion Air Inlet ...........................................................................
4.7 Cooling and Ventilation ......................................................................
4.8 Exhaust ..................................................................................................
4.9 Fuel System ..........................................................................................
4.9.1 Day Tank ....................................................................................
4.9.2 Bulk Storage Tank .......................................................................
4.9.3 Fuel Lines ..........................................................................................
4.10 Lubrication Oil ...................................................................................
4.10.1 Oil Performance Properties .......................................................
4.10.2 Recommended Oil Properties for Perkins Diesel Engines........
4.10.3 Lubrication Oil Recommendations by Lister Petter
4.11 Batteries ..............................................................................................................
4.11.1 Maintenance Batteries ..........................................................................
4.11.1.1 First Filling of Acid Water to The Battery ....................................
4.11.1.2 Battery Maintenance .....................................................................
4.11.1.3 Testing the Battery.............................................................................................
4.11.1.4 Hydrometer Test ........................................................................................
4.11.2 Maintenance Free Batteries..........................................................................
4.12 Electrical Connection .......................................................................................
4.12.1 Cabling ...................................................................................................
4.12.2 Protection ......................................................................................................
4.12.3 Loading ................................................................................................................
4.12.4 Power Factor .......................................................................................................
4.12.5 Grounding / Earthing Requirements ............................................
4.12.6 Alternator Reconnection ...... .............................................................
4.12.7 Parallel Running .....................................................................................
4.12.8 Insulation Test ........................................................................................
4.13 Acoustic Silencing................................................................................
4.13.1 Exhausts Silencers .....................................................................
4.13.2 Canopies ..........................................................................................................
4.13.3 Other Sound Attenuation...................................................................
4.14 Engine Jacket Water Heater.........................................................
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II
4.15 Towing (Mobile Generating Sets)..........................................
4.15.1 Preparing to Low ........................................................................
4.15.2 Towing ....................................................................................
4.15.3 Parking .....................................................................................
4.16 Storage.....................................................................................
4.16.1 Engine Storage .........................................................................
4.16.2 Alternator Storage ...................................................................
4.16.3 Battery Storage ...................................................................
GENERATING SET MAINTENANCE ...............................................................
GENERAL PRECATIONS AND CONTROLS WHICH MUST BE DONE
BEFORE STARTING UP THE GENERATING SET ........................................
GENERATING SET CONTROL SYSTEMS .............................................................
7.1 Starting with ME 40 Manual Control Panel ...................................................................
7.3 Starting With P 300 Autostart Control Panel ....................................................
7.3.1 Manual Operation .......................................................................................................
7.3.2 Automatic Mode of Operation .........................................................................
7.3.3 Test Mode of Operation .........................................................................
7.4 Starting With P 2010 Autostart Control Panel ....................................................
7.4.1 Manual Operation .......................................................................................................
7.4.2 Automatic Mode of Operation .........................................................................
7.5 Starting with P 2020 Automatic Control Panel .....................................................
7.5.1 Manual Operation ..........................................................................................
7.5.2 Automatic Mode of Operation .....................................................................
7.5.3 Test Operation ............................................................................................................
GENERAL PRECATIONS AND CONTROL WHICH MUST BE DONE
AFTER STARTING UP THE GENSET ...........................................................................
STOPPING THE GENERATING SETS .......................................................................
9.1 At Manual Models ........................................................................................
9.2 At Automatic Models ..................................................................................................
GENERATING SET CONTROL SYSTEMS ...............................................
10.1 Control Panels ..................................................................................................
10.2 Manual Control System ME40................................................................
10.2.1 DSE 701 Module Features ...............................................................
10.2.2 DSE 701 Module Emergency Leds ...............................................................
10.3 Automatic Control System P 300 Panel Specifications .................
10.3.1 DSE 720 Module Features ...........................................................
10.4 Automatic Control System P 2020 Panel Specification .................
10.4.1 DSE 5220 Module Features ................................................................
10.5 Autostart Control System P 2010 Panel Specification .................
10.5.1 DSE 5210 Module Features ..............................................................................
10.6. Panel Equipments .....................................................................................
10.6.1 AC Voltmeter ......................................................................................................
10.6.2 Voltmeter Selector Switch .....................................................................................
10.6.3 AC Ampermeter ......................................................................................................
10.5.4 Frequencymeter ......................................................................................................
10.6.5 Hoursrunmeter ......................................................................................................
10.6.6 Water Temperature Gauge ....................................................................
10.6.7 Oil Pressure Gauge .................................................................................................
10.6.8 Emergency Stop Pushbutton .............................................................................
THE PLACEMENT AND INSTULATION OF TRANSFER SWITCH .....
DSE 53 MODEL FULL AUTOMATIC TRANSFER SWITCH CONTROL
SYSTEM ....................................................................................................................
12.1 Automatic Mode of Operation ..........................................................
12.2 Manual Restore Mode of Operation ..........................................................
12.3 Manual Operation...................................................................................................
12.4 Indications ....................................................................................................................
ALTERNATOR TROUBLESHOOTING................................................................
ENGINE TROBLESHOOTING...........................................................................
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6.
7.
8.
9.
1 .
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14.
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1. INTRODUCTION
1
Aksa Generating set is designed to be
commissioned, when delivered, as soon as the
necessary cooling water, antifreeze, fuel,
lubrication oil and fully charged battery are
provided.
With its long years of experience, Aksa
manufactures efficient, reliable and quality
generating set.
This operating and maintenance manual is
prepared to assist the operator in operation and
maintenance of the generating set. Observing
the advices and rules in this manual will ensure
that the generating set operates in maximum
performance and efficiency for a long time.
Care should be taken to perform more frequent
maintenance in dirty and dusty environments in
order to keep the generating set in good working
condition.
ecessary adjustments and repairs should be
made only by authorized and qualified persons.
Each generating set has a model and a serial
number indicated on a label on the base frame.
This plate also indicates the manufacturing date,
voltage, current, power in kVA and kW,
frequency, power factor and weight of the
generating set. These datas are necessary in
spare part orders, for warranty validity and for
service calls.
Figure 1.1 AKSA Generating set label
Gülbahar Cad. 1. Sokak 34212 Günesli Istanbul / Türkiye
Tel: + 0 212 478 66 66 (pbx) Fax: + 0 212 657 55 16
e-mail: [email protected] www.aksa.com.tr
PHASE
Cosj
RPM
STANDBY kVA.
STANDBY A.
DIMENSIONS
FUEL TANK CAPACITY L.
LWH
TS EN 9001 : 000
CERTIFICATION NO: 16197
CERTIFICATION NO: 16197/1
0 5-4
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Engine exhaust emissions are hazardous to
personnel. The engine exhaust for all indoor
generating sets must be piped outdoors via leak-
free piping in compliance with relevant Codes,
Standards and other requirements. Ensure that
hot exhaust silencers and piping are clear of
combustible material and are guarded for
personnel protection per safety requirements.
Ensure that fumes from the exhaust
outlet will not be a hazard.
ever lift the generating set by
attaching to the engine or alternator
lifting lugs, instead use the lifting
points on the baseframe or canopy.
Ensure that the lifting rigging and
supporting structure is in good condition and
has a capacity suitable for the load.
Keep all personnel away from the generating set
when it is suspended.
2
2. SAFETY
2.1 GENERAL
The generating set is designed to be safe when
used in the correct manner. However
responsibility for safety rests with the personnel
who install, use and maintain the set. If the
following safety precautions are followed, the
possibility of accidents will be minimized. Before
performing any procedure or operating
technique, it is up to the user to ensure that it
is safe. The generating set should only be
operated by personnel who are authorized and
trained.
!
!
!
WARNING
Read and understand all safety precautions and
warnings before operating or performing
maintenance on the generating set.
Failure to follow the instructions, procedures, and
safety precautions in this manual may increase the
possibity of accidents and injuries.
Do not attempt to operate the generating set with
a known unsafe condition.
If the generating set is unsafe, put danger notices
and disconnect the battery negative (-) lead so that
it cannot be started until the condition is corrected.
Disconnect the battery negative (-) lead prior to
attempting any repairs or cleaning inside the
enclosure.
Install and operate this generating set only in full
compliance with relevant ational, Local, or Federal
Codes, Standards or other requirements.
!
!
!
Fuel and fumes associated with generating sets
can be flammable and potentially explosive.
Proper care in handling these materials can
dramatically limit the risk of fire or explosion.
However, safety dictates that fully charged BC
and ABC fire extinguishers are kept on hand.
Personnel must know how to operate them.
2.3 FIRE AND EXPLOSION
!
!
Chapter 4 of this manuel covers procedures for
installation, handling, and towing of generating
sets. That chapter should be read before installing,
moving and lifting the generating set or towing
a mobile set. The following safety precautions
should be noted:
2.2 INSTALLATION,
HANDLING AND TOWING
WARNING
Make electrical connections in compliance with
relevant Electrical Codes, Standards or other
requirements. This includes requirements for
grounding and ground/earth faults.
For stationary generating sets with remote fuel
storage systems, make sure such systems are
installed in compliance with relevant Codes,
Standards or other requirements.
!
!
!
!
!
!
!
!
WARNING
Ensure that the generating set room is properly
ventilated.
Keep the room, the floor and the generating set
clean. When spills of fuel, oil, battery electrolyte
or coolant occur, they should be cleaned up
immediately.
ever store flammable liquids near the engine.
Do not smoke or allow sparks, flames or other
sources of ignition around fuel
or batteries. Fuel vapours are
explosive. Hydrogen gas
generated by charging batteries
is also explosive.
!
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WARNING
Do not attempt to operate the generating set
with the safety guards removed. While the
generating set 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
jewellery away from
pulleys, belts and other
moving parts.
Attention: Some moving
parts can not be seen
clearly when the set is
running.
If equipped keep access
doors on enclosures
closed and locked when
not required to be open.
Avoid contact with hot
oil, hot coolant, hot
exhaust gases, hot surfaces and sharp edges and
corners.
Wear protective clothing including gloves and
hat when working around
the generating set.
Do not remove the
radiator filler cap until the
coolant has cooled. Then
loosen the cap slowly to
relieve any excess pressure before removing the
cap completely.
Turn off or disconnect the power to the battery
chargen before making or breaking connections
with the battery.
To avoiding arcing keep grounded conductive
objects (such as tools) away from exposed live
electrical parts (such as terminals). Sparks and
arcing might ignite fuel or vapours.
Avoid refiling the fuel tank while the engine is
running.
Do not attempt to operate
the generating set with any
known leaks in the fuel
system.
WARNING
Do not swallow or allow skin contact with fuel,
oil, coolant, lubricants or battery electrolyte. If
swallowed, seek medical treatment immediately.
Do not induce vomiting if fuel is swallowed. For
skin contact, wash with soap and water.
Do not wear clothing that
has been contaminated by
fuel or lube oil.
Wear an acid resistant apron
and face shield or goggles
when servicing the battery.
If electrolyte is spilled on
skin or clothing, flush immediately with large
quantities of water.
3
!
Fuels, oils, coolants, lubricants and battery
electrolyte used in this generating set are typical
of the industry. However, they can be hazardous
to personnel if not treated properly.
!
!
2.6 NOISE
!
!
!
!
2.4 MECHANICAL
The generating set is designed with guards for
protection from moving parts. Care must still
be taken to protect personnel and equipment
from other mechanical hazards when working
around the generating set.
!
!
!
!
!
2.5 CHEMICAL
!
Generating sets that are not equipped with sound
attenuating enclosures can produce noise levels
in excess of 105 dBA. Prolonged exposure to
noise levels above 85 dBA is hazardous to hearing.
WARNING
Ear protection must be
worn when operating or
working around an operating
generating set
!
2.7 ELECTRICAL
Safe and efficient operation of electrical
equipment can be achieved only if the equipment
is correctly installed, operated and maintained.
WARNING
The generating set must be connected to the
load only by trained and qualified electricians
who are authorized to do so, and in compliance
with relevant Electrical Codes, Standards and
other requlations.
Ensure that the generating set, including a mobile
set is effectively grounded/earthed in accordance
with all relevant regulations priorts operation.
!
!
!
!
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Tilt the victims head back
and lift the chin upwards.
Remove objects from the
mouth or throat (including
false teeth, tobacco, or
chewing gum).
Check that the victim is
breathing by looking, listening and feeling for the
breath.
Check for pulse in the
victims neck.
Pinch the victims nose firmly.
Take a deep breath and seal your lips around
the victims lips.
Blow slowly into the mouth
watching for the chest to
rise. Let the chest fall
completely. Give breaths at
a rate of 10 per minute.
If the victim must be left to
get help, give 10 breaths first and then return
quickly and continue.
Check for pulse after every 10 breaths.
When breathing restarts, place the victim into
the recovery position described later in this
section.
4
The generating set should be shutdown with the
battery negative (-) terminal 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.
Do not touch electrically
energized parts of the
generating set and/or
interconnecting cables or
conductors with any part of
the body or with any non
insulated conductive object.
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 securely in
place.
Connect the generating set only to loads and/or
electrical systems that are compatible with its
electrical characteristics and that are within its
rated capacity.
Keep all electrical equipment clean and dry.
Replace any wiring where the insulation is
cracked, cut, abraded or otherwise degraded.
Replace terminals that are worn, discolored or
corroded. Keep terminals clean and tight.
Insulate all connections and disconnected wires.
Use only Class BC or Class ABC extinguishers
on electrical fires.
!
!
OPEN THE AIRWAY
!
!
!
!
!
!
2.8 FIRST AID FOR ELECTRIC SHOCK
WARNING
Do not touch the victims skin with bare hands
until the source of electricity has been turned
off.
Switch off power if possible other wise pull the
plug or the cable away from the viation.
If this is not possible, stand on dry insulating
material and pull the victim clear of the
conductor, preferably using insulated material
such as dry wood.
If victim is breathing, turn thi victim clear of the
conductor, preferably using insulated material
such as dry wood.
If victim is breathing, turn the victim into the
recovery position described below.
If victim is unconscious, perform resuscitation
as required:
!
!
!
!
!
BREATHING
CIRCULATION
1
2
6
3
4
5
IF NO BREATHING BUT
PULSE IS PRESENT
!
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5
Call or telephone for
medical help.
Give two breaths and start
chest compresion as follows:
Place heel of hand 2 fingers
breadth above ribcage /
breastbone junction.
Place other hand on top and
interlock fingers.
Keeping arms straight, press
down 4-5 cm (1.5-2 inch) at
a rate of 15 times per
minute.
Repeat cycle (2 breaths and
15 compressions) until
medical help takes over.
If condition improves,
confirm pulse and continue
with breaths. Check for
pulse after every 10 breaths.
When breathing restarts, place the victim into
the recovery position described below.
Turn the victim onto the
side.
Keep the head tilted with
the jaw forward to maintain
the open airway.
Make sure the victim cannot
roll forwards or backwards.
Check for breathing and pulse regularly. If either
stops, proceed as above.
WARNING
Do not give liquids until victim is conscious.
!
IF NO BREATHING AND NO PULSE RECOVERY POSITION
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6
3. GENERAL DESCRIPTION
Aksa Generating Set has been designed as a
complete package to provide superior
performance and reliability.
Figure 3.1 identifies the major components. This
figure is of a typical generating set. However,
every set will be slightly different due to the size
and configuration of the major components. This
section briefly describes the parts of the
generating set. Further information is provided
in later sections of thi manual.
Each generating set is provided with a Rating
Label (item 1) generally fixed to the base frame.
This label contains the information needed to
identify the generating set and its operating
characteristics. This information includes the
model number, serial number, output
characteristics such as voltage and frequency,
output rating in kVA and kW, product date and
weight.
The model and serial numbers uniquely identify
the generating set and are needed when ordering
spare parts or obtaining service or warranty
work for the set.
3.1. GENERATING SET DESCRIPTION
AND IDENTIFICATION
3.2. DIESEL ENGINE
3.3. ENGINE ELECTRICAL SYSTEM
The diesel engine powering the generating set
(Item 2) has been chosen for its reliability and
the fact that it has been specifically designed for
powering generating sets. The engine is of the
heavy duty industrial type with 4 stroke
compression ignition and is fitted with all
accessories to provide a reliable power supply.
These accessories include, among others, a
cartridge type dry air filter (item 3) and a
mechanical or an electronic engine speed
governor.
The engine, electrica system is 12 volts or 24
volts DC, negative ground/earth. This system
includes an electric engine starter, a battery
(item 4) and a battery charging alternator (item
5). For 12 volts electrical system one battery is
given. For 24 volt system two lead-acid batteries
are given. Other types of batteries may be fitted
if they were specified.
The engine cooling system is either air cooled
or water cooled. The air cooled system consists
of a high capacity fan to pull cool air across the
engine to cool it. The water cooled system is
comprised of a radiator (item 6), a pusher fan
and a thermostat. The alternator has its own
internal fan to cool the alternator components.
3.4. COOLING SYSTEM
3.5. ALTERNATOR
3.6. FUEL TANK AND BASEFRAME
3.8 SILENCER AND EXHAUST SYSTEM
3.9 CONTROL SYSTEM
The output electrical power is normally produced
by a screen protected and drip-proof, self-
exciting, self-regulating, brushless alternator
(item 7) fine tuned to the output of this generating
set. Mounted on top of the alternator is a sheet
steel terminal box (item 8)
The engine and alternator are coupled together
and mounted on a heavy duty steel bareframe
(item 9). This baseframe includes a fuel tank
(item 10) with a capacity of approximately 8
hours operation at full load.
3.7. VIBRATION ISOLATION
The generating set is fitted with vibration isolators
(item 11) which are designed to reduce engine
vibration being transmitted to the foundation
on which the generating set is mounted. These
isolators are fitted between the engine/alternator
feet and the baseframe.
An exhaust silencer is provided loose for
installation with the generating set. The silencer
and exhaust system reduce the noise emission
from the engine and can direct exhaust gases to
safe outlets.
One of several types of control systems and
panels (item 12) may be fitted to control the
operation and output of the set and to protect
the set from possible malfunctions. Section 7 of
this manual provides detailed information on
these systems and will aid in identification of the
control system fitted on the generating set.
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