Green Power AgriQuip GP33TR/S User manual

INSTRUCTION & MAINTENANCE HANDBOOK
After-Sales Support – Phone: [phone] or Email: [email protected]
03/23
Models: GP33TR/S – GP115TR/SF
PTO DRIVEN
GENERATOR SET

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Manufactured by:
ITALY

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Contents
1. INTRODUCTION TO THE MANUAL ...................................................................................................... 5
2. DESCRIPTION OF THE GENERATING SET .............................................................................................6
2.1 IDENTIFICATION OF THE GENERATING SET ..................................................................................6
2.2 GENERAL FEATURES......................................................................................................................6
2.3 TECHNICAL FEATURES...................................................................................................................7
2.4 ALTERNATOR.................................................................................................................................7
2.5 ELECTRIC CONTROL PANEL ........................................................................................................... 7
2.6 GEARBOX.......................................................................................................................................8
2.7 CANOPY......................................................................................................................................... 8
4. DANGER ZONES AND SAFETY GEAR ....................................................................................................8
3.1 DANGER ZONES............................................................................................................................. 9
3.2 RESIDUAL RISKS...........................................................................................................................10
4. MOVING THE GENERATING SET........................................................................................................11
4.1 GENERAL PRECAUTIONS FOR MOVING THE UNIT ......................................................................11
4.2 MOVING METHOD ......................................................................................................................11
4.2.1. MOVING THE GENERATING SET VIA FORKLIFT ...................................................................11
4.2.2. MOVING THE GENERATING SET VIA TRACTOR ...................................................................11
4.2.3 MOVING THE GENERATING SET VIA MOTOR VEHICLE ........................................................11
5. GENERATOR SET USE CONDITIONS...................................................................................................12
5.1. WORKSPACE AND OPERATOR’S SPACE......................................................................................12
5.1.1 WORKSPACE......................................................................................................................... 12
5.1.2 DESCRIPTION OF WORKING PLACE ......................................................................................12
5.2. PERMISSIBLE GENSET USES........................................................................................................12
5.3. GENSET USES NOT PERMITTED..................................................................................................13
5.4 PERSONNEL IN CHARGE OF HANDLING THE GENSETS................................................................13
5.5. ENVIRONMENTAL CONDITIONS.................................................................................................13
6. LOAD CONDITIONS............................................................................................................................ 13
6.1 ANALYSIS OF THE FEATURES OF THE INSTALLATION..................................................................13
6.1.1. NON LINEAR LOADS ............................................................................................................13
6.1.2. RESISTIVE LOADS (bulbs, heaters, resistances, etc.)...........................................................13
6.1.3. CAPACITIVE LOADS (condensers, discharge lamps, X-ray equipment, etc.).......................13
6.1.4. INDUCTIVE LOAD.................................................................................................................14
6.2. LOAD APPLICATION.................................................................................................................... 14
6.3. CONNECTION TO ALTERNATOR .................................................................................................14

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6.3.1. STAR CONNECTION ............................................................................................................. 14
6.3.2. PHASES CYCLICAL DIRECTION .............................................................................................14
7. INSTALLATION INSTRUCTION............................................................................................................15
7.1. GENERAL INSTALLATION CRITERIA ............................................................................................15
7.2 SAFE DISTANCE ...........................................................................................................................15
7.3 INSTALLATION .............................................................................................................................15
8. ELECTRICAL CONNECTIONS...............................................................................................................16
8.1. INSTRUCTIONS FOR ELECTRICAL CONNECTIONS .......................................................................16
8.2. GROUNDING ..............................................................................................................................16
8.2.1. GENERATING SET WITHOUT EARTH FAULT RELAY DEVICE.................................................16
9. START-UP INSTRUCTIONS .................................................................................................................17
9.1. GENERAL INDICATIONS FOR START-UP......................................................................................17
9.2. NECESSARY CHECKS AND OPERATIONS TO BE CARRIED OUT BEFORE START-UP.....................17
9.3 GENERATOR STARTING ...............................................................................................................18
9.4 TURNING OFF.............................................................................................................................. 18
10. GENERATING SET MAINTENANCE AND INSPECTION......................................................................18
10.1 GENERAL INSTRUCTIONS FOR MAINTENANCE AND INSPECTION ............................................18
10.2 ORDINARY MAINTENANCE........................................................................................................19
10.3 CONTROL PANEL FAULTS ..........................................................................................................19
11. STORAGE INSTRUCTIONS ................................................................................................................19
11.1 ALTERNATOR............................................................................................................................. 19
11.2 ELECTRICAL PARTS ....................................................................................................................19
12. INSTRUCTIONS FOR DECOMMISSIONING.......................................................................................19
13. WARRANTY TERMS .........................................................................................................................20
14. ELECTRICAL SCHEMATICS................................................................................................................ 22

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1. INTRODUCTION TO THE MANUAL
Thank you for having chosen a AgriQuip generating set manufactured by Green Power Systems SRL in Italy.
We advise you to read carefully this manual, observing safety standards for proper use and maintenance of the generating set.
The manual defines the purposes for which the generating set have been conceived and contain all the information that you
need to use it in a proper and safe way.
The constant observance of the indications guaranties the safety of the man, of the gen set, the right use and a long duration of
it.
The present manual, together with other documents delivered with the generating set are all part of the gen set as per
2006/42/CE standard.
The manual’s objective is to supply information and essential instructions for the right use of the gen set.
The manual and its attached documentation is to be consulted and always accessible to all people involved in the life cycle
of the unit.
Compliance to all safety standards is the client’s responsibility.
WARNING:
The generating set is a machine that should be installed and used by qualified technicians only;
Faults in the installation or use of the generating set can cause serious damages to the unit, installation
and people involved.
Do not let children or animals approach the generator when it is working.
Do not touch the generator with wet hands. It could provoke electric shocks if it used in the wrong way.
All operations must be carried out in accordance with all safety standards.
It is imperative to respect the laws in force in the country of installation: in case the standards differ, the more stringent
standards are to be respected.
Agriquip Limited declines all liability for damages to persons or objects due to improper use of the genset, incorrect
or unreasonable or failure to respect current accident prevention regulations.

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2. DESCRIPTION OF THE GENERATING SET
2.1 IDENTIFICATION OF THE GENERATING SET
Please look at Fig.1.
1. Machine type
2. Machine code
3. Serial number
4. Year of manufacturing
5. Weight
6. Continuous power
7. Power factor
8. Declared frequency
9. Rated voltage
10. Rated current
11. Performance class
Fig. 1
The serial number, the year of construction, the code of the machine has to be always mentioned while asking for information,
spare parts etc.
2.2 GENERAL FEATURES
Main components
1 Alternator
2 Electric panel
3 Gearbox
4 Frame
5 Leg
6 Canopy
7 Alternator mountings
8 Identification label
9 Attachment points of the tractor
10 Ground terminal
1
2
3
4
5
6
8
9
10
7
Fig. 2
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2.3 TECHNICAL FEATURES
1500 RPM
EQUIPMENT SPECIFICATION
MODEL
(ISO8528/1) 50 Hz
GP33 TR/S
GP55 TR/S GP77 TR/S GP95 TR/SF GP115 TR/SF
Prime power at power factor 0.8 30 kVA 50 kVA 75 kVA 87.5 kVA 100 kVA
Prime power at power factor 0.8
24 kW
40 kW
60 kW
70 kW
80 kW
Voltage available to the terminals 400/230 V 400/230 V 400/230 V 400/230 V 400/230 V
Dimensions (mm) 1140x750x1055 1140x750x1065 1140x750x1065 1140x750x1210 1140x750x1210
Weight (Kg)
2
395
454
506
572
GEARBOX
R.P.M. output
1500
1500
1500
1500
1500
R.P.M. input 430 430 430 840 840
Ratio 1:3.5 1:3.5 1:3.5 1:1.8 1:1.8
Recommended Tractor
Horsepower 60-80 80-100 110-130 130-150 140-180
ALTERNATOR
Brand and model
MECC ALTE
ECP28-VL/4 (*)
MECC ALTE
ECP32-1M/4 (*)
MECC ALTE
ECP32-3L/4 (*)
MECC ALTE
ECP34-1S/4 (*)
MECC ALTE
ECP34-2S/4 (*)
Synchronous with compound
governor voltage
± 1% ± 1% ± 1% ± 1% ± 1%
Pole 4 4 4 4 4
Stator/rotator insulation
H
H
H
H
H
Protection level IP23 IP23 IP23 IP23 IP23
Continuous power
30 kVA
50 kVA
75 kVA
85 kVA
105 kVA
ELECTRICAL PANEL
Magnetothermic circuit breaker YES YES YES YES YES
Single phase socket – NZ
standard 3-pin 1 1 1 1 1
63A cee form 5-Pin Socket 1 - - - -
125A cee form 5-Pin Socket
-
1
1
1
1
Analogue gauges (voltage,
frequency, amp meter) YES YES YES YES YES
Power terminal board NO NO NO NO YES
(*) = or similar brand
In line with our manufacturers policy of continuous development
2.4 ALTERNATOR
The alternator is the rotating electrical machine that transforms the engine’s mechanical energy into electrical energy. All
alternators on AgriQuip gen sets have been purchased by the manufacturer from primary alternator manufacturers and are
therefore able to guarantee the market’s maximum standard.
N.B.: Before carrying out any work on the alternator, carefully read the alternator manual
delivered with the unit.
The alternator generates electrical current that can be dangerous in case of accidental
contact with current sources. However, the alternators used are supplied with suitable
protection according to UNI EN 12601 standard. The danger exists for operations carried out
with terminal board open and the generating set running.
It is important to note that the eventual removal of the hot parts or of rotation parts of the
alternator must be done only by qualified and authorized people. It is necessary to put them
back on before starting up the generating set.
Before carrying out any maintenance operations use the proper safety gear.
2.5 ELECTRIC CONTROL PANEL
The electrical panel is the assembly of all the control instruments of the generating set, and the sockets and the power
terminal board for the total power. Our control panels are mounted in appropriate housings granting a IP42 standard
protection. The electrical design and the electrical schematics are supplied together with this manual.
Before carrying out any work on the electrical panel, carefully read this manual and the
manual of the electrical panel delivered with the unit.
For the utilization of the gen set it is not necessary to open the electrical panel. The
electrical panel while closed has an IP42 protection. The electrical panel has to be locked
and only qualified and authorized staff can open it.

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Before carrying out any maintenance operations block the generator.
We recommend performing any maintenance employing all PPE required.
Every modifications made on the electrical links and/or the electrical instruments even the
substitutions must be made only after our technicians approval. Unauthorized operations will
also result in immediate forfeiture of the warranty.
2.6 GEARBOX
To correct rotary speed of the tractor and that of the alternator which are different from each other, a step-up gearbox is fitted.
The step-up gearbox consists essentially of gears capable of converting the speed of rotation of the input to the correct speed
for the optimal operation of the alternator.
2.7 CANOPY
The canopy is a protection against the atmospheric agents and protects the operator when the generator is running.
When the gen set is operating it is necessary to keep it closed as the canopy is a protection to
personnel.
The opening of the canopy must only be done by qualified and authorized people. Note: the
canopy is not designed for access while the unit is in operation.
4. DANGER ZONES AND SAFETY GEAR
To avoid exposing personnel to potentially dangerous situations, it is advised that maintenance interventions be carried out
with the control panel in block mode, generating set and accessories isolated from the Mains and by
qualified persons.
Reminder: Compliance with all safety measures are the client’s responsibility.
Safety shoes must be worn before carrying out any work on the generating set in order to avoid slipping and
accidental contact with hot or rotating parts on the unit.
Close fitting clothing must be worn before carrying out any work on the generating set in order to avoid
entanglement with any rotating parts.
Safety gloves must be worn before carrying out any work on the generating set in order to avoid contact with
the unit’s hot parts or dangerous liquids.
Safety glasses must be worn before carrying out any work on the generating set: These are necessary to
avoid eye injury caused by expelled fluid or parts.
Hearing protection must be worn before approaching a generating set.

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3.1 DANGER ZONES
Following the analysis of risks during designing phase, the following table briefly shows the danger zones on a unit :
Danger Zone Existing
danger
Severity of
the danger
Exposure
frequency Probability
Possibility
of
avoidance
Preventative measures Notes
Connecting part
zone without
permanent
protection
Cut or
amputation
High Very low Low High
Shielding the part via appropriate
permanent protection.
Training personnel responsible for
genset maintenance through the User
and Maintenance manual and labels. Fig. 1
Fig. 4
Alternator
voltage regulator
live parts without
permanent
protection
Electrocution
High Low Average Average
Shielding the part via appropriate
permanent protection.
Training personnel responsible for
genset maintenance through the User
and Maintenance manual and labels.
Information on the necessity of carrying
out all maintenance operations with all
electrical energy fonts disconnected.
After all maintenance operations,
reconnect any protection removed
and/or close the canopy doors before
restarting the unit.
Fig. 2
Moving the
generator set
Crushed
Severe Low Low High
Maintain a safe distance from the unit;
Use adequate means and measures;
Training personnel responsible for
genset maintenance through the User
and Maintenance manual and label s.Fig. 3
1
1
22
3

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DANGER OF AMPUTATION BY
REMOVING PROTECTIVE
PARTS:
ROTATING PARTS
DANGER OF AMPUTATION
BY REMOVING
PROTECTIVE
PARTS:
ROTATING PARTS
Fig.1 Alternator fan and coupling area
Fig.4 Gearbox
DANGER OF ELECTROCUTION
WHEN PROTECTION
REMOVED: LIVE PARTS
Fig.2 Voltage regulator open
3.2 RESIDUAL RISKS
Residual risk Where to find the symbols Symbols / rules
Cut, amputation, trapping and crashing Engine fan protection Do not remove the protections
Electrocution Electrical parts The parts with this symbol have charge