Aksa GE08TI User manual

DOOSAN NATURAL GAS ENGINE
GENERATING SETS
MAINTENANCE AND
USER MANUAL

DOOSAN NATURAL GAS ENGINE
GENERATING SETS
MAINTENANCE AND USER
MANUAL
HEAD OFFICE
AKSA JENERATÖR SAN. A.Ş.
Rüzgarlıbahçe Mah. Özalp Çıkmazı No:10
34805, Kavacık - Beykoz / İSTANBUL
T : [phone]
F : [phone]
[email protected]
AUTHORIZED SERVICE
AKSA SERVICE & SPARE PARTS
Muratbey Beldesi, Güney Girişi Caddesi
No: 8 34540 Çatalca / ISTANBUL
T: [phone]
F: +90 2I2 887 10 20
[email protected]

DEAR AKSA GENERATOR SET USERS
Thank you for purchasing this quality-built Aksa Natural Gas Generator. When operated and maintained
according to the instructions in the operator’s manual, your Aksa generator will provide many years of
dependable service.
This manual is designed and developed to make you familiar with the generating system. Please read the fol-
lowing instructions carefully before starting to use your machine.
This manual contains safety information to make you aware of the hazards and risks associated with genera-
tor systems and how to avoid them.
Never operate, maintain or repair your generating set without taking general safety precautions.
The manufacturer reserves the right to change, alter or otherwise improve the system at any time without
prior notice.

1. INTRODUCTION .................................................................................................................. 1
2. GENERAL SAFETY PRECAUTIONS........................................................................................................... 2
2.1. General....................................................................................................................................................................... 2
2.2. Handling..................................................................................................................................................................... 2
2.3. Fire and Explosion................................................................................................................................................ 2
2.4. Mechanical................................................................................................................................................................ 3
2.5. Chemical.................................................................................................................................................................... 3
2.6. Noise ........................................................................................................................................................................... 3
2.7. Electrical..................................................................................................................................................................... 3
2.8. First Aid For Electric Shock............................................................................................................................. 4
3. GENERAL DESCRIPTION.................................................................................................... 5
3.1. Generator Set Description And Identification..................................................................................... 5
3.2. Generator Set Main Parts................................................................................................................................ 5
3.3. Natural Gas Engine.............................................................................................................................................. 6
3.4. Engine Electrical System.................................................................................................................................... 6
3.5. Cooling System...................................................................................................................................................... 6
3.6. Synchronous Alternator.................................................................................................................................... 6
3.7. Coupling..................................................................................................................................................................... 6
3.8. Base Frame............................................................................................................................................................... 6
3.9. Vibration Isolation ................................................................................................................................................ 6
3.10. Silencer And Exhaust System........................................................................................................................ 6
3.11. Control System...................................................................................................................................................... 6
4. ELECTRIC STARTING SYSTEM.......................................................................................... 7
4.1. Battery Systems ..................................................................................................................................................... 7
4.2. Maintenance Batteries........................................................................................................................................ 7
4.3. Battery Maintenance........................................................................................................................................... 7
4.4. Maintenance Free Batteries ............................................................................................................................ 7
4.5. Control of the Battery....................................................................................................................................... 7
4.6. Starting Aids............................................................................................................................................................. 7
5. HEALTHY AND SAFETY...................................................................................................... 7
5.1. Fire Protection........................................................................................................................................................ 7
5.2. Exhaust Gases......................................................................................................................................................... 8
5.3. Moving Parts............................................................................................................................................................ 8
5.4. Hazardous Voltages ............................................................................................................................................ 8
5.5. Water.......................................................................................................................................................................... 9
5.6. Coolant....................................................................................................................................................................... 9

6. WATER TREATMENT........................................................................................................... 9
6.1. General....................................................................................................................................................................... 9
6.2. Engine Coolant....................................................................................................................................................... 9
7. LUBRICATING OIL................................................................................................................ 9
7.1. Oil Performance Properties ........................................................................................................................... 9
7.2. Lubrication Oil Recommendations for Doosan Engines................................................................ 9
8. General precautions and controls which must be done before starting up the generating set.... 11
9. GENERATING SET CONTROL SYSTEMS....................................................................... 11
9.1. Control Panel.......................................................................................................................................................... 12
9.1.1. Control System P 732....................................................................................................................................... 12
9.1.2. Static Battery Trickle Charger........................................................................................................................ 13
9.2. Control System Options.................................................................................................................................. 13
9.2.1. Heaters....................................................................................................................................................................... 13
9.2.2. Speed/voltage control........................................................................................................................................ 13
10. General precautions and controls which must be done after starting up the generating set........ 13
11. GENERATING SET MAINTENANCE ............................................................................... 13
11.1. Maintenance Schedule For Gen-set........................................................................................................... 13
12. ENGINE TROUBLESHOOTING......................................................................................... 16
13. ALTERNATOR DESCRIPTION........................................................................................... 16
13.1. General....................................................................................................................................................................... 16
13.2. Construction and Components................................................................................................................... 16
13.3. Operation ................................................................................................................................................................. 17
13.4. Automatic Voltage Regulator........................................................................................................................ 17
14. VENTS AND DUCTS............................................................................................................. 17
15. MECCALTE ALTERNATOR TROUBLESHOOTING.................................................... 18
16. STORAGE OF THE GENERATOR................................................................................................. 18
16.1. Storage ..................................................................................................................................................................................... 18
16.2. Preparing for Operation After Storage.................................................................................................... 18
General precautions about warranty .......................................................................................................................
ATTACHMENTS
- CONTROL PANEL WIRING DIAGRAM
- AKSA JENERATÖR AUTHORIZED SERVICE POINTS
- AKSA JENERATÖR WHERE TO BUY ABROAD
- CERTIFICATIONS
- WARRANTY CERTIFICATE

1
1. INTRODUCTION
Aksa Generating set is designed to be commissioned,
when delivered, as soon as the necessary cooling wa-
ter, antifreeze, gas fuel, lubrication oil and fully charged
battery are provided. With its long years of experi-
ence, Aksa manufactures efficient; reliable and quality
generating set This user and maintenance manual is
prepared to assist the operator in operation and main-
tenance 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,
- Necessary adjustment 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 pow-
er in kVA, frequency, power factor and weight of the
generating set. These data are necessary in spare part
orders, for warranty validity and for service calls.
Attach unit to base-frame with suitable diameter ma-
sonry anchor bolts long enough to retain the unit.
The generating set is designed to be safe when used
in 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 person-
nel who are authorized and trained.
Only people that have the right skills should be allowed
to operate, adjust, perform maintenance or repair on
Aksa Power Generation equipment. It is the respon-
sibility of management to appoint operators with the
appropriate training and skill for each category of job.
Skill level I: Operator
An operator is trained in all aspects of operating the
unit with the push- buttons, and trained to know the
safety aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit
the same as the operator. In addition, the mechani-
cal technician is also trained to perform maintenance
and repair, as describe in the instruction manual, and
is allowed to change settings of the control and safety
system. A mechanical technician does not work on live
electrical components.
Skill level 3: Electrical technician
An electrical technician has the same qualifications as
both the operator and the mechanical technician. In
addition, the electrical technician may carry out elec-
trical repairs within the various enclosures of the unit.
This includes work on live electrical components.
Skill level 4: Specialist from the manufacturer
This is skilled specialist sent by the manufacturer or its
agent to perform complex repairs or modifications to
the equipment In general it is recommended that not
more than two people operate the unit, more oper-
ators could lead to unsafe operating conditions. Take
necessary steps to keep unauthorized person away
from the unit and eliminate all possible source of dan-
ger at the unit.
The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and
for modifications, additions or conversions made with-
out the manufacturer’s approval in writing,

2
2. GENERAL SAFETY PRECAUTIONS
2.I. GENERAL
1- The owner is responsible ‘for maintaining the unit
in a safe operating condition. Unit parts and accesso-
ries must be replaced if missing or unsuitable for safe
operation.
2- Operate the unit only for the intended purpose and
within its rated limits (pressure, temperature, speeds,
etc).
3- Gen-set and equipment shall be kept clean, i.e. as
free as possible from oil, dust or other deposits.
4- To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly.
5- Take precautions against fire. Handle gas fuel, oil
and anti-freeze with care because they are inflamma-
ble substances. Do not smoke or approach with naked
flame when handling such substances. Keep a fire-ex-
tinguisher in the vicinity.
WARNING
! Read and understand all safety precautions and warn-
ings before operating or performing maintenance on
the generating set.
! Failure to follow the instructions, procedures, and
safety precautions in this manual may increase the pos-
sibility of accedents 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 can-
not be started until the condition is corrected.
! Disconnect the battery negative (-) lead prior to at-
tempting any repairs for cleaning inside the endosure.
! Install and operate this generating set only in full com-
pliance with relevant National, Local or Federal Codes;
Standards or other requirements.
2.2. HANDLING
The following safety precautions should be noted:
WARNING
! Make electrical connections in compliance with rele-
vant Electrical Codes; Standards or other requirements.
This includes requirements for grounding and ground/
earth faults.
! 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 require-
ments. Ensure that hot exhaust silencers and piping are
clear of combustible material and are guarded for per-
sonnel protection per safety requirements. Ensure that
furmes from the exhaust outlet will not be a hazard
! Never lift the generating set by attach-
ing to the engine or alternator lifting lugs,
instead use the lifting points on the base
ame or canopy.
! Ensure that the lifting rigging and sup-
porting 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.
2.3. Fire and Explosion
Warning
• Natural Gas is extremely ammable and explosive.
• Fire or explosion can cause severe burns or death.
• Install the gas fuel supply system according to appli-
cable fuel-gas codes.
• Before placing the generator into ser-
vice, the fuel system lines must be prop-
erly purged and leak tested.
• After the generator is installed, you
should inspect the gas fuel system periodically.
• NO leakage is permitted.
• DO NOT operate engine if smell of fuel is present or
other explosive conditions exist.
• DO NOT smoke around the generator.Wipe up any
oil spills immediately. Ensure that no combustible ma-
terials are left in the generator compartment Keep the
area near the generator clean and free of debris.
However, safety dictates that fully charged BC and ABC
re extinguishers are kept on hand. Personnel must
know how to operate them.
WARNING
! Ensure that the generating set room is properly ven-

3
tilated.
! Keep the room, the oor and the generating set clean.
When spills of oil, battery electrolyte or coolant occur,
they should be cleaned up immediately.
! Do not smoke or allow sparks, ames or other sourc-
es of ignition around gas line or batteries.
! Turn off or disconnect the power to the battery char-
ger 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).
2.4. Mechanical
The generating set is designed with guards for pro-
tection from moving parts. Care must still be taken to
protect personnel and equipment from other mechan-
ical hazards when working around the generating set
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 jewelry
away from pulleys, belts and other moving parts.
Attention: Some moving parts cannot 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 surfaces
and sharp edges and corners.
! Wear protective clothing includ-
ing gloves and hat when working
around the generating set.
! Do not remove the radiator ller
cap until the coolant has cooled.
Then loosen the cap slowly to relieve any excess pres-
sure before removing.
2.5. Chemical
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.
WARNING
! Do not swallow or allow skin contact with oil, cool-
ant lubricants or battery electrolyte. If swallowed, seek
medical treatment immediately.
! Do not wear clothing that has been contaminated
by lube oil.
! Wear an acid resistant apron and lace shield or gog-
gles when servicing the battery.
If electrolyte is spilled on skin or
clothing ush immediately with large
quantities of water.
2.6. Noise
Generating sets that are not equipped with sound
attenuating enclosures can produce
noise levels in excess of 105 dB(A).
Prolonged exposure to noise lev-
els above 85 dB(A) is hazardous to
hearing.
WARNING
Ear protection must be worn when operating or work-
ing around an operating generating set.
2.7. Electrical
Effective and safe operation of electrical equipment,
it is only ensured by the correct placement, use and
maintenance of equipment.
WARNING
! The generating set must be connected to the load
only by trained and qualied electricians who are au-
thorized to do so, and in compliance with relevant
Electrical Codes, Standards and other regulations.
! Ensure that the generator set is effectively earthed/
grounded in accordance with all relevant regulations
before starting.
! The generating set should be shutdown with the
battery negative (-) terminal disconnected prior to at-
tempting to connect or disconnect load connections.
! Do not attempt to connect or disconnect load con-
nections while standing in water or on wet or soggy
ground.

4
! Do not touch electrically energized
parts of the generating set and/or in-
terconnecting 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 ca-
bles 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 elec-
trical characteristics and that are within its rated ca-
pacity.
! Keep all electrical equipment clean and dry. Replace
any wiring where the insulation is cracked, cut abrad-
ed or otherwise degraded, Replace terminals that are
worn, discolored or corroded. Keep terminals dean
and tight
! Insulate all connections and disconnected wires.
! Use only Class BC or Class ABC extinguishers on
electrical res.
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 otherwise pull the plug
or the cable away from the victim.
! 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, moving the victim away from
conductor, preferably using insulated material such as
dry wood.
! If victim is breathing, turn the victim into the recov-
ery position described below. If victim is unconscious,
perform resuscitation as required;
Open the airway
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).
Breathing
Check that the victim is
breathing by looking, listening
and feeling for the breath.
Circulation
Check for pulse in the victim’s neck.
If no breathing but pulse is present
• Pinch the victim’s nose rmly.
• 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
rst 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.
If no breathing and no pulse
• Call or telephone for medical help.
• Give two breaths and start chest
compression as follows:
• Place heel of hand 2 ngers breadth
above ribcage/breastbone junction.
• Place other hand on top and inter-
lock ngers,
• Keeping arms straight, press down
4-5 cm at a rate of 15 times per min-
ute.
• Repeat cycle (2 breaths and 15 compressions) until
medical helps takes over.
• If condition improves, conrm
pulse and continue with breaths.
Check for pulse
after every 10 breaths.
• When breathing restarts, place the victim into the
recovery position described below.
Recovery position
• 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.

5
3. GENERAL DECRIPTION
3.1. Generating Set Description and Identification
Natural gas generators are independent units for the
production of electric power basically; they comprise
a constant voltage synchronous driven by a gas engine.
The sets are used for two main purposes;
a- Continuous duty sets,
Used to produce electric power for countless require-
ments (motive power, lighting heating etc) in areas
where other sources or power are unavailable.
b- Emergency duty sets,
Used during public network failures, when such failures
are liable to cause serious trouble to persons or mate-
rial or financial damage (i.e. in hospitals, industrial plants
with non-stop operating cycles, etc) or to meet peak
energy demands.
According to their application, the sets are further di-
vided into:
• set for use on land
The sets for use on land can be
• stationary sets (fixed installation),
These sets are available in a vast range of versions, for
every operating requirement the main ones being:
01. hand control generating sets
02. stand-by generating sets
The standard stationary generating set comprises;
• natural gas engine
• synchronous generator
• coupling
• metal sub-base with vibration isolators
• starter batteries
• instrument panel
• exhaust gas silencer.
Aksa Generating Set has been designed as a complete
package to provide superior performance and reliabil-
ity. Figure. 3.1. identifies the major components. This
figure is of atypical generating set. However, every set
will be slightly different due to the size and configu-
ration of the major components. This section briefly
describes the parts of the generating set. Further in-
formation is provided in later sections of this manual.
Each generating set is provided with a Rating Label
(item I) generally fixed to the base frame. This label
contains the information needed to identify the gener-
ating set and its operating characteristics. This informa-
tion 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
Aksa generating sets are an Alternating Current gen-
erator, built for continuous running at sites where no
electricity is available (some models are excepted) or
as stand-by in case of interruption of the mains.
The generator operates at 50 Hz 230/220 V. in line-
to-neutral mode and 400/380 V in line-to-line mode.
3.2. Generating Set Main Parts
Figure 3.1.Typical Engine Generator Set
No Description
1 Aksa Generating Set Rating Label
2 Natural Gas Engine
3 Air Filter
4 Radiator
5 Alternator
6 Terminal Box
7 Base Frame
8 Control Panel