Hyundai DHY22KSE User manual

Diesel Generator
User Manual

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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.

Safetylabelsinformation
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TRANSPORTWARNING
!Neverliftthegeneratingsetbyattachingtothe
engineoralternatorliftinglugs,insteadusethe
liftingpointsonthebaseframe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.
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MECHANICALWARNING
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!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
jewelersawayfrompulleys,beltsandothermoving
parts.
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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hazardoustohearing.
!Wearprotectiveclothingincludingglovesandhat
whenworkingaroundthegeneratingset.
!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.

CHEMICAL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.
!Neverstoreflammableliquidsneartheengine.
!Donotsmokeorallowsparks,flamesorother
sourcesofignitionaroundfuelorbatteries.Fuel
vaporsareexplosive.Hydrogengasgeneratedby
chargingbatteriesisalsoexplosive.
!Neverstoreflammableliquidsneartheengine.
!Donotsmokeorallowsparks,flamesorother
sourcesofignitionaroundfuelorbatteries.Fuel
vaporsareexplosive.Hydrogengasgeneratedby
chargingbatteriesisalsoexplosive.
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ELECTRICALWARNING
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!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.
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!Makesureconnectgeneratorsettoearth.
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!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.
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!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.

Table of Contents
1 General Introduction
1.1 Brief Introduction……………………………………1
1.2 Generator Set Main Parts Specifications…………1
1.4 Alternator ……………………………………………1
1.3 Diesel Engine ………………………………………1
1.4 Alternator …………………… …………………… 1
1.5 Cooling System ……………………………………2
1.6 Electrical System …………………………………2
1.7 Coupling ……………………………………………2
1.8 Fuel Tank and Base Frame ………………………2
1.9 Control Panel ………………………………………2
1.10 Optional for Canopy Generator Set ……………2
1.11 Others ……………………………………………3
2 Installation
2.1 General Outline ……………………………………4
2.2 Transportation ……………………………………4
2.3 Design for Foundation ……………………………4
2.4 Design for Generator 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 control panel ………………………………16
4 Maintenance
4.1 General outline……………………………………18
4.2 Engine ……………………………………………18
4.3 Alternator …………………………………………19
4.4 Control panel ……………………………………19
4.5 Start battery ………………………………………19
4.6 Maintenance record ……………………………19
5 Check for Malfunction
5.1 General outline……………………………………20
5.2 Malfunction checklist ……………………………21
APPENDIX

User manual
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1GeneralIntroduction
1.1BriefIntroduction
HYUNDAIseriesdieselenginegeneratorsetsisthe
coreproductsofHYUNDAIPowerEquipment
ManufacturingCo.,Ltd.Thankstotheirgood
performance,thegeneratorsetsarewidelyusedin
thefieldsofconstruction,communication,banking
business,mining,leasingindustryandotherspecial
sites.Aswhatyouareexpecting,HYUNDAIgenerator
setsendeavortomeetyourneedsfortheconceptof
individualdesignthroughtheexcellentfeaturesof
moresafe,morereliableandmoreclean.The
generatorsetsprovidedbyHYUNDAIPoweris
reliableandprofessional.Theadvantageoflownoise
level,energyconservation,andstableperformance
hasmadeacredibleassuranceformanyenterprises.
Ourgeneratorsetssupplythefollowingpower
service:
Continuousservice
Usedasmainpowersupplytogenerateelectricityfor
severalpurposes:motionforce,lighting,heatingetc.
Thegeneratorsetscancontinuerunningandallow10%
overloadfor1hourper12hoursundervariableload,
whichisusedforremotearea.
Standbyservice
Usedasstandby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maycauseseriousproblemsto
people,physicaland/orfinancialdamageortoface
consumptionpeaks.Thegeneratorsetcanstartin
shortordertoprovidesteadyelectricpowerforthe
loadswhenthemainssupplyhappenabnormity,and
switchtostopafterthemainssupplybecomes
normal.Generallythegeneratorsetcontinues
workingforseveralhours.
1.2GeneratorSetMainPartsSpecifications
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NONAME
1 CONTROLPANEL
2 BUSBARPANEL
3 LIFTINGLUG
4 BASEFRAMEFUELTANK
5 ENGINE
6 BATTERY
7 RADIATOR
8 ALTERNATOR
9 FUELDRAINOUTLET
10 FUEL LEVEL SENSOR\
11 ABSORBER
1.3DieselEngine
Accordingtodifferentoutputpowerofthegenerator
sets,andcombinewiththeadvantageofeachmodel
ofdieselengineinaspecificrangeofpoweroutput,
HYUNDAIPowerchoosestheengineswithfirstclass
performanceandhighreliability.Andfurthermore,
HYUNDAIPowerpayspecialattentiontothe

User manual
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technicaladvantageofenginesintheaspectsof
reducingexhaustgas,decreasefuelconsumption
rateandgoodnoiselevelcontrol.
1.4Alternator
AllofthealternatorschosenbyHYUNDAIPowerare
singlebearingself‐excitationbrushlessalternators
withtheattributesofinternationaltopbrand.By
citingStamfordalternatorasanexample,wecan
illustratethefeaturesofouralternatorsasfollows:
◆Fourpolarbrushlessself‐excitation,singlebearing,
insulationclassisHandprotectionlevelisIP22.
◆Statorsarewoundto2/3pitch,whichcaneffectively
eliminatestripleandcurbswaveformdeformationof
outputvoltage.Wheninparallelwiththemainsor
othergeneratorsets,thistypeofwindingcan
effectivelyavoidexcessiveneutralcurrentsand
reducesinductiveheat.
◆Beforebeingassembled,rotorsneedtopassdynamic
balancetesting.Theimproveddamperreduces
voltagedeviationandheatunderunstableload.
◆Theexciterrotoroutputisfedtothemainrotor
throughathreephasefullwavebridgerectifier,the
rectifierisprotectedbyasurgesuppressoragainst
surgescausedbyshortcircuitorout‐of‐phase
paralleling.
◆Automaticvoltageregulatorhasthefeatureof
automaticloadcurtailmentwhichisusedtoprotect
theengine,andmakeitpossibletoaddfullloadto
thealternatoratonetime.Steadystatevoltage
adjustingratecanreach±1%(undercertain
requirements,steadystatevoltageadjustingratecan
meet±0.5%).IfPMGsystemischosen,themotor
willhavehighstartingcapacityandtheabilityof
interferencerejectionforthedeformedvoltage
waveformfedbythemainstatorgeneratedby
non‐linearload(suchassiliconcontrolDCelectric
motor,UPSetc).

◆TelephoneinfluencefactorTIF<50,telephone
harmonicwavefactorTHF<2%
， thebrushlessstyle
andhighqualityAVRensureslowinterferencewith
Radio.
1.5CoolingSystem
Theenginecoolingsystemiswatercooled.Thewater
cooledsystemiscomprisedofaradiator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.Othertypesofbatteriesmaybe
fittediftheywerespecified.

1.7Coupling
Engineandalternatorarefirmlyjoinedbyacoupling
conethatguaranteestheproperassemblycoaxiality
Single‐supportmachinesarealsousedaspecial
flexiblediskisusedinplaceofaflexiblecoupling.
1.8FuelTankandBaseFrame
Theengineandalternatorarecoupledtogetherand
mountedonaheavydutysteelbaseframe.Thisbase
frameincludesafueltankwithcapacityof
approximately8hoursoperationundervariableloads.
Thetankiscompletewithfillingcapandfuellevel
gaugeandisconnectedbyflexiblejointstotheintake
pipingandtotheoverflowpipingcontainingfuel
fromtheinjectordrain.Bigcapacitygenerator'sfuel
tankisseparatefromgeneratorset.
1.9ControlPanel
AllmodelsofHYUNDAIPowergeneratorsetsuse
highgradecontrolpanel.Thecoreofcontrolpanelis
animporteddigitaldieselenginecontrolmodule,
whichhasbeenfacilitatedwithmorecomplex
functionssuchasfurthermonitors,demonstration,
people‐moduledialogue,distancecommunication
andprotectionetc.
HYUNDAIPowergeneratorsetcontrolpaneluse
steelplatestructure,whichensuressecurityand
reliability,andthesurfaceofithasbeentreatedwith
staticpowderpainting.Theoutsideappearanceis
beautiful.Speciallockhasbeenusedtofixit.Ithas
beendesignedforeasymaintenance.


1.10OptionalforCanopyGeneratorSet
1.10.1Externalantifreezeaddinghole
Ourgeneratorsetshasbeenfacilitatedwithexternal
antifreezefillinghole.Whenuserintendstoadd
antifreeze,Heonlyneedstoopentheantifreeze
fillingholeontheroofofcanopyandtheradiator’s
pressurevalvecaptodirectlyaddantifreezetothe
hole,andeasilywatchtheanti‐freezelevel.




1.10.2 Lubr
connectto

Ourgene
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Ourcanop
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Ourgenera
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toensuret
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atorsets
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designfea
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oved
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and


User manual
4
2Installation
2.1GeneralOutline
Correctinstallationofgeneratorsetisthe
preconditionwhichensurethenormalworkingstatus
ofthegeneratorset.Theworkingroomforgenerator
setshallbedesignedspecificallytomeetthe
expectedfunctionsandmaintenanceoperations,and
atthesametimethedesignofgeneratorsetworking
roomshallconformtolocalgovernment’slawsand
regulationsonarchitecture,fireprotectionlawsand
otherapplicableregulations.
2.2Transportation
Duringtheperiodofshipment,protectionshallbe
madeforthegeneratorset.Inaddition,the
generatorsetshallbetightlysecuredintheloading
trucksothattoavoidanyvibrationduringshipment
whichwillcausethegeneratorset’scomponents
loosenandevendamaged.Duringtheprocessof
shipmentofgeneratorset,nopeopleorother
materialisallowedtoplaceabovethegeneratorset
sothattoavoiddamagetogeneratorsetcausedby
weight.
Whenloadingorunloadingthegeneratorsettothe
truck,forkliftorhoistingdeviceshallbeusedtoavoid
thegeneratorsetbecometiltedorfelltotheground,
whichcausesdamage.
Liftingholeshavebeendesignedonthecommon
baseframeofourgeneratorsets.Someofthe
specificallydesignedgeneratorsetshasbeen
facilitatedwithliftingholesontheroofandforklift
openingsonthebaseframeetc.Userscantransport
thegeneratorsetaccordingtotheguidancespecified
onthespecificlabelsstickedonthegeneratorset.
Pleasedonotusetheliftinglugsontheengineoron
thealternatortohoistthewholegeneratorset.
2.3DesignforFoundation
Thefoundationwhichusedtoinstallandfixthediesel
generatorsetisveryimportant,itmustconformto
thefollowingrequirement:
◆Haveenoughhardnessandstability,sothattoavoid
deformation,whichwillaffecttheconcentricityof
dieselengineandalternatorandotheraccessory
parts.
◆Tosupporttheweightofthewholegeneratorsetand
toabsorbthedynamicimpactcausedbyunbalanced
forceandvibrationduringengine’srunningperiod.
◆Generatorset’sfoundationisnotallowedtoconnect
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concretefoundation,
pleasemakesurethesurfaceofconcreteisflat,and
noscratchisallowed.Gradienterorsimilar
instrumentsneedtobeusedduringinstallationof
generatorsetanditsexhaustsystem.
Thedesignoffoundationcanrefertofollowing
calculationformula:(belowisthediagramfordiesel
generatorsetfoundation)
1.Generatordimensionlength×width:L1×W1
2.Foundationdimensionlength×width:L2×W2
L2=L1+400(mm)
W2=W1+400(mm)
3.B=2×M/(L2×W2×D)
B:Thicknessoffoundation
M:Generatorsetweight
L2:Lengthoffoundation
W2:Widthoffoundation
D:DensityofConcrete(referto2322kg/m3)
(FoundationdrawingRefertoAPPENDIXA)

2.4DesignforGeneratorSetWorkingRoom
Theinstallationofgeneratorsetshallbedesigned,so
thattomeetthedemandofplannedoperationand
maintenance.Thecompleteinstallationshallconform
tolocalarchitecturelaws,fireprotectionlawsand
otherapplicableregulations.Excepttheabove
matters,thereareothermattersneedsyour
attentionasfollows:
◆Ensuredieselenginegeneratorsetworkingroomis
furnishedwithrainproof,sunscreen,andwindproof.
◆Ensuredieselenginegeneratorsetworkingroomhas
goodventilationandgoodexhaustsystem,andthe
areaforventilationissufficient,andatthesametime
usepipestoletoutthehotairgeneratedfromthe
radiatorandpreventthehotairfromreturning.
◆Ensurethewastegasgeneratedduringgeneratorset
runningperiodcanbedischargedtooutsidetimely,
andtryyourbesttoreducetheadverseeffectcaused
toenvironment.Thesilencerandexhaustpipeshall
besupportedbytheroof,thesupportershallallow
theexhaustpipetoexpand.Itisnotpermittedto
installtheexhaustsystemdirectlyonthegenerator
set.
◆Enoughspaceshallbereservedforthediesel
generatorsetforconvenienceofcooling,operation
andmaintenanceetc.Generallyspeaking,noforeign
materialisallowedtobeplacedwithintheareaof