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

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5
1~1.5mofdistancefromthegeneratorsetand
1.5~2mabovethegeneratorset.
◆Thegeneratorsetworkingroomshallbefurnished
withfireextinguishhydrantwhichconformtothe
specifiedstandard.
◆Emergencylightingfacilitiesshallbeinstalledinthe
generatorsetworkingroomfortheconvenienceof
operationandmaintenance.
◆Nocombustibleandexplosivematerialsareallowed
tobeplacedinthegeneratorsetworkingroom.
Belowisthelayoutfortheopensystemgeneratorset
workingroom.
(FoundationdrawingRefertoAPPENDIXB)


Note:
Ourcompanycanmakedrawingsanddesign
installationdimensionsforgeneratorsetworking
roomaccordingtocustomer’sspecialrequirements.

Belowisthelayoutforthecanopysystemgenerator
setworkingroom.
(FoundationdrawingRefertoAPPENDIXC)
Note:
Canopiedgeneratorsetcanworkoutdoordirectly.If
userswantstooperatethegeneratorsetindoor,
abovediagramcanbetakenasreference.wecan
designthelayoutofgeneratorsetworkingroomand
installationdimensionaccordingtocustomer’sspecial
requirements.
2.5InstallationofGeneratorSet
2.5.1Locatethepositionofgeneratorset
Vibrationreductionunitshavebeeninstalledonour
generatorsets(exceptafewgeneratorsetsdon’t
havethiskindoffacility).Userscantakereferenceon
theinstallationdiagram,correctlyinstallthe
generatorsetonaflatandhardfoundation,usethe
expansionboltstotightlyfixthegeneratorsettothe
concretefoundationthroughtheinstallationholeson
thebaseframe.Whennospecialrequirementis
needed,wedon’tsuggestcustomerstoinstall
additionalvibrationreductionunits.
Softconnectionisneededtoconnectthepartsofthe
generatorsettooutside.Forexample:corrugated
vibrationreductionpipehasbeenusedtoconnect
exhaustpipes,airexhaustpath,fuelinletpipe,fuel
returnpipeandbusbarcableetc.,alloftheseparts
needtousesoftconnections.Onlyinthiswaywecan
reducetheadverseeffectcausedbythevibrationof
generatorsettotheminimumextent.
2.5.2Ventilation
Whenageneratorsetwithacompletesetofradiator
assemblyhasbeeninstalledintheworkingroom,the
basicprincipleistodischargethehotairinthe
workingroomtooutsideandletinthelow
temperatureairfromoutside,andtryyoubestto
avoidthehotaircomeinfromoutside.
Thediagramintherightsidedemonstratestheideal
positionofageneratorsetintheworkingroom.
Thepurposeofthisarrangementistogetcoldair
fromthelowestpointasmuchaspossible,andforce
themtopassthroughtheradiatorcore,andthenlead
themout.



Userscanusemetalplateorcanvastomakeawind
guidecover,theconnectionbetweenwindguide
coverandtheradiatorshallbesoftconnection,so
thattocutoffthetransmissionofvibrationfromthe
generatorset,andalsoensurethehotairexhaustto
outsidethoroughly.
Theeffectivecirculationsectionalareainsideofthe
windguidecovershallbebiggerthan1.25timesof
thefrontfaceareaoftheradiatorcore.Andthewind
guidecovershallbesmooth,nosharpangleand
cambersothattoreducetheresistancetothewind.
Atthesametime,theeffectivecirculationsectional
areaintheairinletopeningshallalsobebiggerthan
1.25timesofthefrontfaceareaoftheradiatorcore.
Whentheusershaveinstalledmeshcoverorshutters
intheairinlet/outletopeningorthereistoomany
cambersintheairinlet/outletopening,theeffective
aircirculationsectionalareawillbereducedand
resistancewillincrease,andtherefore,it’snecessary
tofurtherincreaseaircirculationarea.

User manual
6

Undernormalconditions,theairvolumegenerated
fromtheradiator’sfanisenoughtomeetthe
requirementoftheworkingroomventilation.
Theairinlettemperatureoftheengineshallbebelow
30degreeCelsius.Iftheairinlettemperaturekeep
risingabove30degreeCelsius,theengine’soutput
powerwillbereduced,andthereforefreshairfrom
outsideshallbeintroducedintothegeneratorset’s
workingroominatimelymanner.
Ifthegeneratorsetisfurnishedwitharemote
radiator,forcedaircirculationforthegeneratorset
workingroomisamust.Theforcedaircirculation
needtwofans,onefanisresponsibleforairintake,
anotherisairexhaust,whichexhaustshotairto
outside.
Whentheengineisfurnishedwithpropelledfan,itis
recommendedthataseparatepipeisneededto
exhaustthegaswhichgeneratedfromthecrankcase
tooutside.Otherwisetheexhaustgasfromthe
crankcasewillaccumulateontheradiator,whichwill
causetheradiatorstuckbydirtymaterial,andasa
result,theheat‐sinkingcapacitywillbereduced.
2.5.3Exhaust
Ourstandardconfigurationdieselgeneratorsets
provideaccessoriessuchasindustryheavysilencer,
softcorrugatedpipeandelbowetc.Userscandesign
theexhaustsystemofgeneratorsetworkingroom
bythemselves.Whendesignandinstalltheexhaust
system,pleaseconsiderthefollowingaspects:
◆Ensurethetotalexhaustbackpressurenohigherthan
themaximumallowedvaluespecifiedbythe
engine(usuallygeneratorset’smaximumexhaust
backpressureisnomorethan5Kpa)Fixtheexhaust
systemtomakesuretheexhaustmanifoldand
turbo‐chargerarenotsubjecttotheverticalpressure
andsidestress.
◆Reservesomespaceforhotshrinkageandcold
expansion.
◆Reservespaceforgeneratorsetvibration.
◆Reduceexhaustnoiselevel.
Overloadofexhaustbackpressurewillcause
followingadverseeffect:
◆Outputpowerloss
◆Fuelefficiencyreduce
◆Exhaustgastemperaturerise


Note:
Whenmorethanonegeneratorsetareinstalled,try
nottodischargeallofthegeneratorsets’gasfrom
oneexhaustpath.Ifnoseparatedexhaustpipeis
allowed,undertheconditionthatthetotal
backpressurewillnotexceedthegeneratorsets’total
backpressureamoveableseparatepanelshallbe
installedinsideofthebranchexhaustpipesothatto
preventthegasfromreturn.


Intheexhaustsystem,softcorrugatedpipeshallbe
usedtoconnecttheexhaustpipewiththe
turbocharger,thispipehasthreefunctionsas
follows:
◆Separatethedieselenginewithvibrationandthe
weightofexhaustpipe.
◆Compensatetheheatexpansionofexhaustpipe.
Ifthedieselgeneratorsetisinstalledonthe
anti‐vibrationbaseframe,thecorrugatedpipecan
compensatesidewaymovementwhenenginestartor
stop.

Note:
1.Seriousdamagewilloccurwhenrainorcondensed
waterenterintoengine’sexhaustsystem.
Therefore,onewaterdischargeopeningshallbe
installedinthelongexhaustpipe,thepositionof
whichshallbeclosetothegeneratorset. 
2.Whenthetopoftheexhaustpipeisabovethe
architecture,lighteningprotectionisneeded
(connecttotheground)
2.5.4Noisereduction
Whendieselgeneratorsetisrunning,normallyitwill
generatenoiselevelof90～110dB,andthemorethe
load,thehigherthenoiselevel.
Inordertomeetthenoiselevelstandardsestablished
bythelocalenvironmentalprotectionbureauandto
preventthenoisepollutioncausedtoambient
environment,whichwillaffectpeople’snormallife,
toreducenoiselevelofdieselgeneratorsetisalso

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veryimportant.
Noisereductionengineeringisacomprehensiveand
professionalengineering.Duringtheprocesswhen
userstrytodesigntheschemefornoisereduction
project,atthesametimepleasefullyconsiderthe
bottomlimitofairinlet/outletvolumeneededby
engine’snormalrunningandthemaximumallowed
valueforexhaustbackpressureetc.Otherwise,the
noisereductionprojectwillseriouslyaffectgenerator
set’soutputpower,andmakegeneratorset’s
temperaturerise,causefrequentmalfunctionofthe
generatorset,andevenitwillshortenthelife
expectancyofgeneratorset.

Note:
HYUNDAIPowercanprovidecustomerswithoverall
soundproofgeneratorset.
2.6Coolingsystem
Ourstandardconfigurationdieselgeneratorsetsare
closedcyclingwaterchillingunitswithfanand
radiatorinstalled.Closedwaterchillingenginedrive
thecoolingpumptogeneratecirculationpower,
whichkeeptheanti‐freezeinthepathsofcylinder
bodyandcovercontinuouscirculationandheat
elimination.Engine’scoolingpump,radiator(orheat
exchanger)formsaclosed,pressurecyclingand
coolingsystem.
Themostcommoncoolingsystemiscoolingfan
directlydrivenbyradiatorandengine,whichcanbe
replacedbyheatexchanger,remoteradiatoror
remotecoolingtoweretc.Iftheinstallationposition
oftheremotecoolingfanisrelativelyhigher,
transmissionradiatorisneededtopreventthe
damageofheatexchangercausedbytoobiginternal
pressure.

Note:
Thedirtymaterialstayintheradiator’scorewill
greatlyaffectradiator’scoolingcapacity.And
thereforeitisnecessarytocleantheradiatoroften.
2.6.1Coolant
Coolingsystemshallusethecoolantwhichcan
protecttheenginefromcontaminationandfreezing.
Coolantshallbeamixtureofpurewaterand
anti‐freezeorpurewaterandanti‐rustfluid.Inthis
mixture,waterPHvalueshallbebetween6～8,
usuallysuggesttousedistilledwater.Thespecific
mixingratioshallbeaccordingtolocalweather,and
thatofthecoolantrecommendedbytheengine
supplier,andreferencetotheoperation(preparation)
manualofthecoolant.Mixtheliquidsinaseparate
containerevenlyandthenaddthemixtureintothe
radiator,ensuretheanti‐freezewillnotfreezeunder
lowtemperature.Intheareawhenthereislow
possibilityoffreezing,thecoolantcanbeamixtureof
waterandanti‐rust,accordingtotheanti‐rustwhich
recommendedbytheenginesupplierandrefertoits
operationmanual,mixtheliquidsinaseparate
containerevenlyandthenaddthemixtureintothe
radiator.Atthefirsttimewhenanti‐rustisadded,the
generatorsetshallbekeptrunninguntilitgettohot
sothattoachievethebesteffectofanti‐corrosion.

Engine’scoolantshallhavethreefunctionslistedas
below:
◆Provideenoughheattransmissioncapacity
◆Preventallmetalmaterialandsealingmaterial
withinthecoolingsystemfromcorrosion(Cave
corrosion)
◆Providesufficientanti‐freezecapacity

Warning:
!Tochoosetheanti‐freezewhichisrecommendedand
approvedbythequalifiedenginesupplieristhe
criticalpointtoensureengine’snormalrunning.
!Donotmixtheanti‐freezeandanti‐rustofanytypes,
thiswillgeneratealargeamountofbubbleand
reducethecoolant’sperformance. 

!Iftheanti‐freezeusedinthegeneratorsetisofbad
qualityandnotapprovedbytheenginesupplier,
whichcausethemalfunctionofthegeneratorset
(waterleakage,contaminationandetc.),this
malfunction(s)doesnotbelongtothescopeof
warranty.
2.6.2Changeofcoolant
Theeffectofanti‐freezeandanti‐rustwilldecreaseby
thetimeperiodofservice.Andthereforeperiodically
changeofanti‐freezeisamust.Themixtureof
anti‐freezeshallbechangedineverytwoyears.The
mixtureofanti‐rustshallbechangedatleastonetime
everyyear.Andiffilterofthecoolantisinstalled,at
leastthisfiltershallbechangedineveryhalfofyear
(pleaserefertotheengineoperationmanualforthe
specificintervalsofthechangesrequired).
Whenitistimetodischargethecoolant,makesure
thegeneratorsethasbeenshutdownandtheengine
hasbeenfullycooleddown,thenopentheradiator’s
liquidaddinghole.Afterthatopenthedischarge
valveinstalledintheradiatorandintheengine
respectivelytodischargethewater.Ifthegenerator
setisfurnishedwithcoolantfilter,itshallbe
detachedfromtheengineandbechanged.
2.6.3Cleaningofcoolingsystem

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Whenchangethecoolant,cleaningisneededforthe
coolingsystem,thecleaningproceduresare
suggestedasfollows:
◆Emptythecoolingsystem
◆Usewatertorinsecoolingsystem
◆Feed15%~20%condensedcoolanttothecooling
system,timelyrunthegeneratorsetforoneortwo
timesthendischargethecoolant
◆Emptythecoolingsystemthenusenormalmixed
liquidtorinse
◆Ifcontaminantstillexists,thenrepeatthecleaning
procedureuntilnocontaminantexistsinthesystem
◆Afterthesystemhasbeenfullyrinsed,feednew
coolantwhichhasbeenmixedaccordingtospecified
proportion

Note:
Ifthecoolingsystemiscleanedperiodically,onlyrinse
itwithsmallamountofadditivesorcleanwateris
enough.
2.6.4Feedingofcoolant
◆Beforeaddingcoolanttothecoolantsystem,please
makesuretheradiator‘sdischargevalveandthe
engine’sdischargevalvearetightlyclosed.
◆Addthecoolanttothesysteminaproperspeedso
thattoavoidaircockbeingformedinthesystem.
◆Airshallbedischargedthroughtheaddingholeor
thedischargevalveintheenginebody.Ifthecooling
systemisfurnishedwithheater,thecontrolvalvefor
theheatershallbeopened.Ensureventilationofthe
unitwhenaddingthecoolant.
Note:
Theairdischargevalveintheenginebodyshallbe
locatedinthetoppointofthewaterpathornearthe
thermostatorwatertemperaturesensor,oryoucan
slightlyloosethewatertemperaturesensorand
re‐tightenitwhenyouseecoolantrunoutfromitso
thattodischargetheair.

◆Whenaddingthecoolant,thesurfaceofliquidshall
reachtothelevelthatis5centimetersbelowthe
radiator’sweldedsurface(orshallreachthelevel
indicatingLine).Besurethatthegeneratorsethas
stoppedandbecomefullycooledbeforeadding
Coolant.Beforethesystemiscapableofventilation
andtheliquidisaddedtotherequiredlevel,please
don’tstartthegeneratorset.Afterthecoolantbeing
fed,pleasestartandpre‐heatthegeneratorset,and
atthesametimechecktheliquidlevelandadd
coolantifneeded.Thecoolantwhichneedstobe
addedtotheradiatorshallbeofthesame
specificationasthatexistingintheradiator.
◆Forsomegeneratorsetsinstalledwithcoolantfilter,
pleaseopenthefilter’svalvebeforeputintouse.
2.7Lubricantsystem
Lubricantsystemiscomposedofoilpan,oilpump,
strainer,oilpipe,oilcoolingunit,oilfilterunit,and
theoilpathinsideoftheengineandallkindsof
lubricantpartswhichareinrelativemotionetc.The
mainpurposeofthelubricantsystemistoprovide
sustainedtemperedoilfilmbetweenthepartswhich
areinmotionsothattoreducefrictionandwear,and
drawsoffpartoftheheatabsorbedbytheparts,
bathmechanicalpart,improvesealingeffectand
preventrustfromeachpart’ssurface.
Userscandeterminethemodeloflubricantaccording
tothespecificworkingenvironmentandconditions.
Forthefirsttimelubricant,normallyusersshall
changeitwithin100hoursuponandfromthetime
whenthegeneratorsetfirststarted.(detailsreferto
enginemaintenancemanual)

Note:
Thecriticalpointistousequalifiedlubricantoilwhich
iswithproperviscosityandconformtotheengine’s
requirement,andperiodicallychangethelubricantoil
andoilfiltersothattoensurethegeneratorset’s
normalworking.Themalfunctionscausedbywrong
modeloflubricantoilwithlowqualityorlongtimeno
changeoflubricantoil,oroilfilterdonotbelongto
thescopeofwarranty. 

WerecommendthathighqualitymultigradeSAE
15W/40highserviceengineoilindieselenginesare
used.Atambienttemperaturesabove‐15degree
Celsiusis15W40.TheminimumAPIoilqualitylevels
recommendedforuseisCH/CI‐4,CHorCI‐4canbe
usedinareaswhereCF4oilisnotyetavailable,but
theoilintervalmustbereducedAPICA,CB,CC,CD,
CE,CG4categoriesnotrecommended,donotuse.



2.8Fuelsystem
Ourgeneratorsetsrequiresthefuel‐dieselshallbe
clean,withoutairandwaterandwithproper
pressure,ofwhichallkindsofparameterssuchas
sulphurcontentetc.shallmeetnationalstandards,
andendusetemperaturegrademeetthe
requirementofcustomer’sworkingenvironment.
Generallygeneratorset’sfuelsystemincludestwo
parts,thatis,engine’sfuelsystemandexternalfuel
system.HYUNDAIisonlyresponsibleforinstallation
oftheexternalfuelsystemwhichincludesfueltank
andconnectingfuelpipesetc.
2.8.1FuelRecommendations

User manual
9
Thefollowingfueloilspecificationistypical.Fora
specificenginerefertomanufacturers’datasheets
forfueloildetails.
FuelRecommendedPhysicalPropertiesFeature
Viscosity
1.3to5.8centistrokes(1.3to5.8mmpersecond)at40°C(104°F)
(ASTMD445)
CetaneNumber
40Minimumabove0°C(32°F)~45Minimumbelow0°C(32°F)
(ASTMD613)
SulphurContent
Nottoexceed0.5masspercent*(ASTMD129or1552)
ActiveSulfurCopperStripCorrosion
NottoexceedNo.2ratingafterthreehoursat50°C(122°F)
(ASTMD130)
WaterandSediment
Nottoexceed.05volumepercent(ASTMD1796)
CarbonResidue
Nottoexceed0.35masspercenton10volumepercent
residuum(ASTMD524orD189)
Density
42to30°APIgravityat60°F(0.816to0.876g/ccat15°C).
(ASTMD287)
CloudPoint
6°C(10°F)belowlowestambienttemperatureatwhichthefuel
isexpectedtooperate(ASTMD97)
Ash
Nottoexceed0.02masspercent(0.05masspercentwith
lubricatingoilblending)(ASTMD482)
Distillation
Thedistillationcurvemustbesmoothandcontinuous(ASTM
D86)
AcidNumber
Nottoexceed0.1MgKOHper100ML(ASTMD664)
Lubricity
3100gramsorgreaterscuffingBOCLEtestorWearScar
Diameter(WSD)lessthan.45mmat60°C(WSDlessthan.38mm
at25°C)asmeasuredwiththeHFRRmethod.

DieselFuelPropertyDefinition
Ash‐Mineralresidueinfuel.Highashcontentleads
toexcessiveoxidebuildupinthecylinderand/or
injector.
CetaneNumber‐Ignitabilityoffuel.Thelowerthe
cetannumber,theharderitistostartandrunthe
engine.Lowcetanefuelsignitelaterandburnslower.
Thiscouldleadtoexplosivedetonationbyhaving
excessivefuelinthechamberatthetimeofignition.
Incoldweatherorwithprolongedlowloads,ahigher
cetanenumberisdesirable.
Sulphur‐Amountofsulphurresidueinthefuel.The
sulphurcombineswiththemoistureformedduring
combustiontoformsulphuricacid.
Viscosity‐Influencesthesizeoftheatomized
dropletsduringinjection.Improperviscositywilllead
todetonation,powerlossandexcessivesmoke.Fuels
thatmeettherequirementsofASTMor2.0diesel
fuelsaresatisfactorywithfuelsystems.


2.8.2Fueltank
Ourgeneratorsetsprovidebaseframestylefueltank
forcustomer.Thebaseframestylefueltankis
installedwithfueltank,fuelpipesandfuellevel
indicator.Thisfuelsupplysystemdoesnotneed
customertomakeotherinstallations.Customersonly
needtoaddfueltothebaseframe.
Userswhointendtoselfmanufacturethefueltank
shallusestainlesssteelorsteelplatetomakethe
backuptank,donotmakepaintingorgalvanization
insideofthefueltanksothattoavoidthepossible
chemicalreactionbetweenthesekindofmaterials
anddiesel,whichmaygeneratethematerialharmful
tothegeneratorsetanddecreasethequality,Merit
Ratingandcombustionefficiencyofdiesel.In
addition,theconfigurationoffueltankassemblyshall
beasfollows:
◆Airventilationpipeabovefueltanksurface
◆Manholeonthetopsurfaceoffueltank
◆Watchwindowforfuellevel
◆Dischargevalveatthebottomoffueltank
◆Groundcablebetweenfueladdingholeandfueltank
◆Separatepanelwithholesbetweenfuelsupplyarea
andfuelreturnarea,sothattoreduceheatexchange
◆Theendoffuelsupplypipeshallbe50mmabovethe
bottomofbaseframesothattoavoidthedeposit
andwateratthebottomoffueltankbeingsucked
intofuelsupplypipe.
◆Partofthegeneratorsets’fuellevelshallbehigher
thanthepositionoffuelinjector,sothattoavoidfuel
returnfromfuelinjector,whichcausestartdifficulty.

2.7.2Installationoffueltank
◆Thepositionofthefueltankshallensurethe
maximumsuctionfuelheadisnolessthan2meters.
Suctionfuelheadofthefueltransferpumpshallbe
calculatedfromthebottomofthefueltank.
◆Thepositionofthefueltankshallensuremaximum
returnfuelheadnolessthan1.5meters.Returnfuel
headshallbecalculatedfromthetopofthebase
frame.
◆Thearrangementofthefuelpipeshallavoidthefuel
beingaffectedfromtheheateliminationfrom
generatorsettoomuch.
◆Themaximumtemperatureofthefuelbeforefuel
pumpshallbelowerthan60degreeCelsius.
◆Noleakageoffuelandairisallowedinthefuelinlet
andfuelreturnpipe.Thisisveryimportant.
◆Hoseneedtobeusedtoconnectgeneratorsetwith
fueltransferpipe.Ifthegeneratorsetusesoft
connection(throughvibrationreductionunit),hose
shallbeused.
◆Whenengine’sfuelinletpipeisabove6metersand

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below10meters,thisfuelinletpipe’sinsidediameter
shallbeatleast20%biggerthanthatofthehose
installedinthisengine.Fuelreturnpipeshallbe
connectedtothetopoffueltank.Don’tdirectly
connectittofuelinletpipe.



2.7.3Fuelconsumption
Thecontentofdieselplaysaverycriticalroleindiesel
engine’sperformance,lifeexpectancyandthe
contentofdischargedmaterial.Inordertoachieve
theratedpower,fueleconomyandspecified
emissionstandard,onlythefuelwhichreferto
internationalstandardornationalstandardcanbe
used.
Theparametersofdieselfuelincludelow
temperaturefeature,sulphurcontent,specificgravity,
watercontentandforeignmaterialcontentshallbe
thefirstprioritywhenuserneedtochoosethequality
ofthefuel.Differentqualityoffuelwilldirectlyaffect
dieselgeneratorset’sstart,lubricating,outputpower,
discharge,andfuelfilterchangecycleetc.
Specificrequirementforfuelpleaserefertoengine
operationmanualwhichattachedwiththegenerator
set.

Warning:
!Whenyouintendtoaddfuelintothefueltank,
pleasemakesurethegeneratorsethasbeenstopped.
Onlyaftertheaddedfuelbecomestaticforsome
time,thisgeneratorsetcanbestartedagain.This
waytoavoidtheforeignmaterialinthedieselfuel
beingsuckedtofuelsupplyhose,whichwillcause
fuelfilterstuckandfailtosupplyenginewith
sufficientfuel,andinturndecreasetheoutput
power.
!Themalfunctioncausedbybadqualityoffueldoes
notbelongtothescopeofwarranty.

2.8Controlsystem
Ourdieselgeneratorsetshasbeenfurnishedwith
controlpanel.Allofthecontrolpanelschoose
importeddigitalmeterasthecoreofcontrolsystem
forthegeneratorsets.
◆Digitalcontrolpanel:thegeneratorsetcanbe
controlledlocallybymanual,andalsocanbestarted
orstoppedbyremotecontrol(controlledbyexternal
signalline)usersarerequiredtocorrectlyconnectthe
signallinetothiscontrolpanel.(detailsseethe
controlpaneloperationmanual)
◆Automatictransferpanel(optional):istheautomatic
transferswitchfortransferbetweengeneratorset
andmains.(detailsrefertocontrolpaneloperation
manual)

2.9Battery
Ourgeneratorsetstandardconfigurationprovides
startbatteryasaccessoryparts.Accordingtouser’s
differentrequirements,ourcompanycanprovide
twotypesofbatteries,thatishighefficientplumbous
acidbatteryandmaintenancefreebattery.
Ifmaintenancefreebatteryisused,usersonlyneed
toconnectcablesforthebattery.
Ifplumbousacidbatteryisused,beforebeingused,
usersneedtousestandardbatterytoelectrolyze
primaryliquid.Untightenthebatterycover,slowly
pourelectrolyteintothebatteryuntiltheelectrolyte
levelreachtheindicatinglineintheinternalpolar
plates(notallowtoexceedthisline),thentakeoffthe
lablefromthebatterycover’sairholeandclosethe
cover.Aftertheelectrolytebeingadded,pleasedon’t
useitimmediately,keepthebatteryinstaticstatus
forthirtytosixtyminutes.Inlowtemperature
environment,thistimeperiodneedtobeextended
(usebatterychargertochargebatterywhen
necessary)
Userscanusethestandardconnectingcable
attachedwiththegeneratorset,theredcolorshall
beconnectedtopositivepolar,black(orblue)to
negativepolar,correctlyconnecttothegenerator
set’sstartmotor.Mostofthedieselgeneratorsets’
cableshavebeenconnectedtotheenginesbefore
shipment.

Theenergystoragecapacityofthestartbatterywill
determineifthedieselenginegeneratorsetcan
smoothlystartinaspecifiedperiod.Duringthe
processofgeneratorsetsrunning,thecharging
alternatorinstalledintheenginewillcontinuously
chargebatterytostartbattery.
Warning:
!Pleaseensuretheconnectionforpositiveand
negativepolariscorrect.Wrongconnectionwill
causemalfunction!(Wrongconnectionwillsurely
causedamagetothechargingalternator)
!Whengeneratorsetisrunning,batterycablesarenot
allowedtobecutdown!

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


2.10ElectricalConnection
Onlyfullqualifiedandexperiencedelectrical
techniciansshouldcarryoutelectricalinstallation,
serviceandrepairwork.

Warning:
!Makeelectricalconnectionsincompliancewith
relevantelectricalcodes,standardsorother
requirements.

2.10.1Cabling
Duetomovementofgeneratingsetsontheir
vibrationmounts,theelectricalconnectiontotheset
shouldbemadewithflexiblecable.Thecablemust
besuitablefortheoutputvoltageofthegenerating
setandtheratedcurrentoftheset.Indetermining
thesize,allowancesshouldbemadeforambient
temperature.Methodofinstallation,proximityof
othercables,etc.Allconnectionsshouldbecarefully
checkedforintegrity.
Currentcarryingcapacityofpowercablesthatwillbe
giveninAPPENDIXA.Ontheotherhand,thereisa
onemoreimportantpointwhilecablecrosssections
arebeingselected.Ifthedistancebetweenloadand
generatoristoolength,voltagefallingattheload
sidecanbetoomuchatthetransientcurrent
duration.Thevoltagedropacrossacablecanbe
determinedasfollows:

1000
)XsinRcosIL3
ΔU
 

ΔUVoltagedrop(V)
LLengthofconductors(m)
IRatedcurrent(A)
RResistance(Ω/kmtoVDE0102)
XReactance(Ω/kmtoVDE0102)

RefertoAPPENDIXECableCurrentloadstandard.
2.10.2Grounding/EarthingRequirements
Theframeofthegeneratingsetmustbeconnected
toanearthground.Sincethesetismountedon
vibrationisolators,thegroundconnectionmustbe
flexibletoavoidpossiblebreakageduetovibration.
Groundconnectioncablesorstrapsshouldhaveat
leastfullloadcurrentcarryingcapacityandmeet
applicableregulations.

2.10.3InsulationTest
Beforestartingthegeneratingsetafterinstallation,
testtheinsulationresistanceofthewindings.The
AutomaticVoltageRegulator(AVR)shouldbe
disconnectedandtherotatingdiodeseithershorted
outwithtemporarylinksordisconnected.Any
controlwiringmustalsobedisconnected.
A500VMeggerorsimilarinstrumentshouldbeused.
Disconnectanyearthingconductorconnected
betweenneutralandearthandmeggeranoutput
terminaltoearth.
Theinsulationresistanceshouldbeinexcessof1MΩ
toearth.Shouldtheinsulationresistancebelessthan
1MΩwindingmustbedriedout.
2.11Powerdistributionsystem
Ourdieselenginegeneratorsetusethreephasefive
linesystemforpowerdistribution.Thatis,three
phaselivewires,oneneutralline,onegroundline.
Theneutrallineandthegroundlinearenot
connected.Userscanchoosethreephasefourlines
forpowerdistributionaccordingtorequirementthat
istoconnecttheneutrallinetotheground(base
frame),sothattosolvetheproblemoffeintthatthe
neutrallinesometimesiselectriferous.

Note:
HYUNDAIPowerseriesdieselenginegeneratorsets
requireuserstosafelyconnectgeneratorsetsand
baseframestotheground,pleaserefertotheground
labelforconnectingpoint.

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3Operation
3.1InspectBeforeOperation
Afterfinishedinstallation,ourdieselengine
generatorsetcanbeputintouse.Eachtimebefore
startingthegeneratorset,followingitemsshallbe
checkedwithoutfail:
◆Ifthereisforeignmaterialexistsinthesurfaceof
generatorsetorintheambientenvironmentwhich
mayhamperthegeneratorset’soperation.
◆Iftheairinletandventilationpathinthegenerator
setworkingroomisexpedite.
◆Iftheanti‐freezelevelisnormal.
◆Iftheairfilterindicatorworkswell
◆Ifthelubricantleveliswithinthespecifiedrange
◆Ifthefuelvalveisopen,ifthefuelhasbeensupplied
totheenginenormally.
◆Ifthecablehasbeenconnectedtothebatteryina
correctway.
◆Checkiftheloadequipmenthasbeenwellprepared.
Whenthegeneratorsetdirectlyconnectstotheload,
theairswitchshallbecutoffbeforestart.
Warning:
Operatorsshallestablishgoodoperation
(maintenance)procedure,thisisthepreconditionfor
generatorset’ssmoothrunninginlongtimeperiod.
3.2Generatorset’srunning
3.2.1Pre‐heat
Forthegeneratorsetwhichisinstalledwith
pre‐heater,operatorsneedtodecideifpre‐heatingis
neededbeforestartthegeneratorsetaccordingto
environmenttemperature.Thecontrolpanelwhichis
installedwithpre‐heatswitchcaninstructtheengine
tostartthepre‐heatersothattoachievethepurpose
ofpre‐heating.
3.2.2Connecttopower
Turntheairswitchinthecontrolpanelfrom“OFF”to
“ON”,watchthepaneluntilthebackgroundlight
turnon,thatmeansthecontrolpanelhasbeen
successfullyconnectedtothepower.Atthesame
timemakesurethefuelpipesareopen,andthe
speedgovernororthecontrolunitintheelectronic
fuelinjectiongeneratorsetisunderworkingstatus.



3.2.3Start
Partofthegeneratorsetcontrolpanelhasbeen
furnishedwithidlespeed/fullspeedtransferswitch,
userscanchooseiftheengineneedtobestartedin
idlespeedorinonetimefullspeed.Usuallythetime
periodforidlespeedshallnotexceedfiveminutes.
Donotrunthegeneratorsetinidlespeedinalong
timeperiod.
Pressonthestartbutton,thedurationshallnot
exceed30seconds,enginewillbestartedbythestart
motor.Assoonastheenginebestartedsuccessfully,
youcanreleasethestartbuttonandthegenerator
setwillenterintorunningstatus.

Suggestion: 
Inordertoextendthelifeexpectancyofstartbattery
andstartmotor,thedurationforonetimestartshall
becontrolledwithin5to10seconds.Ifonetimestart
fails,stopforsometimeandbeginthesecondtime
startprocedure.

Forthecontrolpanelswhichareinstalledwith
self‐start(orcommunication)instrument,the
generatorsetpre‐heating,start‐upperiodand
startingtimeshavebeencontrolledbytheprogram
(thisprogramcanbesetandmodifiedbyuser).
Operationprocedurepleasereferstooperation
manual.
Whenthegeneratorsetcontrolpanelhas
malfunction(s),timelyoverhaulingisneededbefore
Re‐startthecontrolpanel.
Warning:
Foranystartupwhichismadethroughforce,notby
controlpanel,themalfunctioncausedbyitdonot
belongtothescopeofwarranty.

3.2.4Running
Whenthegeneratorsetbeginsfullspeedrunning,
andthealternator’svoltageandfrequencybecomes
normalandstable,operatorscanputthegenerator
setintonormalrunning.
Duringthegeneratorset’srunningperiod,operators
shalloftenwatchandchecktheparameterssuchasif
thegeneratorsetisrunningnormally,ifthecontrol
panelinstrumentisindicatingtherightposition,ifthe
controlpanelhaspre‐warningindication,andthefuel
levelinthebaseframeetc,andmakerecordforthe
parameters.(seeattachfile)
3.2.5Emergencystop
Incasethegeneratorsetwasfoundtohavesevere

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13
malfunctionorpowerdistributionmalfunction.
Pleasepressdowntheemergencystoponthe
controlpanel,sothattoimmediatelyshutdownthe
generatorset.Undernormalcondition,pleasedonot
useemergencystoptostopthegeneratorset.
3.2.6Normalstopthegeneratorset
Beforestopthegeneratorsetundernormal
condition,firstseparatetheloadfromthisgenerator
set,thenrunthegeneratorsetwithnoloadfora
certainperiodoftime(3to5minutes),sothatto
makesurethegeneratorsetbecomefullycooled,
afterthatthegeneratorsetcanbestopped.(Please
donotmakecoolingrunningunderidlespeed)
Forsomegeneratorsetswhichhavebeeninstalled
withstopsolenoid,itisimpossibletostopthe
generatorsetbycuttingoffthekeyswitchonthe
controlpanel.Correctoperationis:topressthestop
buttonwhenthepowerofthecontrolpanelbeing
resumed,onlyinthiswayyoucanstopthegenerator
set.(pressthestopbuttonuntilthegeneratorset
fullystoprunning)
3.3AfterRunning
Afterthegeneratorsetstoprunning,itisnecessary
tocarryonfollowingjobs:
◆Tocheckifthegeneratorsethas“threeleakage”
(lubricant,fuel,anti‐freezeleakage)
◆Shutdownfuelvalve
◆Shutdownairinletandairexhaustfacilityinthe
generatorset’sworkingroom(whennecessary)
◆Shutdownthegeneratorset’soutputairswitch
◆Shutdownthepowerkeyswitchonthecontrolpanel,
takeoutthekeyandkeepitingoodcondition(when
necessary)
Whenthegeneratorsetneedtobeshutdownfora
longtimeorisundermaintenance,pleasedis‐connect
thestartbattery’snegativepolarcable,andfully
dischargethefuelandanti‐freezeliquidwhen
necessary.
Fortheself‐startgeneratorset,someoftheabove
termsarenotapplicable.Aftertheself‐start
generatorsetstops,pleasekeepitinthesamestatus
asthatofpre‐start(readytostart),sothatitcanstart
atanytimeunderemergencycases.
3.4Recordforrunning
Foreachrunningoperation,usershallmakerecord.
Runningrecordhasvariousforms.Thebasiccontent
shallcover:thetimeperiodforthisrunning,
accumulatedrunningtimeforthisgeneratorset,
valueofengine’soilpressuregauge,temperature
meter,outputvoltage,frequency,maximum
power(current)etc.andtherunningsituation,andif
thereisanymalfunctionwarning/generatorsetshut
downetc.

Onlywhenthecorrectandcompleterecordfor
running(maintenance)hasbeenkeptverywell,the
usercangetcorrectandexcellentaftersales
(warranty)service.
3.5Mattersneedattention
Warning:
!Whenengine’stemperatureisverylow,thetime
periodforidlespeedshallbeproperlyextended.
However,whenthegeneratorsetbecomewarm,itis
notallowedtorunthegeneratorsetwithidlespeed
foralongtime,itisnotallowedtocontinuouslyrun
thegeneratorsetunderemptyorsmallload.Such
kindofoperationwillcauseservercarbondeposition
andoilleakageinengine’sturbo‐chargerand
exhaustsystem.
!Itisnotallowedtorunthegeneratorsetwith
overloadinlongtimeperiod,otherwisemalfunction
willoccur,whichwilldecreasethegeneratorset’slife
expectancy.
!Itisforbiddentodetachorchangethecomponents
ofthegeneratorsetwhenitisrunning.
!Thecoolantwhichisgoingtobeaddedneedtobe
thesamespecificationasthatoftheoriginalcooling
system.Whenopenthecoverofwateraddinghole,
pleasepayattentiontothetemperatureandavoid
thesteamorhightemperaturecoolantburstforthto
hurtpeople. 
!Whendischargethehightemperaturelubricantoil,
pleaseavoidbeingburnt. 
!Thefuelbeingusedshallbeconformtonational
standard,otherwiseitwillcausemalfunctionofthe
engine’sfuelpumporfuelinjector.
!Fortheenginesinstalledwithturbo‐charger,itis
suggestednottoadd50%oraboveinstantloadto
thegeneratorset.Otherwisethiswillcauserelatively
bigstalltothegeneratorset.
!Forthelargeelectricityconsumptionequipment,itis
suggestedthattheusersneedtousemethodssuch
asvoltagedecreaseandfrequencychangeetc.to
controlthestart,sothattoreducebigimpactonthe
generatorsetwhenthefacilitystart.
!Backupgeneratorsetsorthegeneratorsetswhich
haven’tbeenrunforalongtime,itissuggestedthat
thesekindsofgeneratorsetsshallberuntoworking
temperatureatleastonetimeamonth.Thesekinds
ofgeneratorsetsneedtobecontinuouslyrunwith
fullloadfor4hoursatleastonetimeperyear.
!Forthegeneratorsetswhichareconnectedin
parallelandcontrolledbymanual,operatorsmust
makesuretheyarerunningsynchronously(same
frequency,samephase‐sequence,samephase,and
samevoltage)beforeswitchon,andmustswitchoff
beforetryingtostopthegeneratorsetsgroup.

User manual
14
Duringthegeneratorsetsgrouprunning,pleasekeep
watchingtoavoidthegeneratorsetsgroupstop
runningbecauseofindividualgeneratorset’s
malfunction. 
3.6Operationforcontrolsystem
3.6.1Generatorcontrolpaneloperation
Ourgeneratorsetstandardsupplytwodifferent
controlmodule:oneissinglegeneratorwithremote
startfunction,theotherissinglegeneratorwith
AutomaticMainsFailture(withATSpanel).
Start‐upgenerator
1)Seteverycircuitbreakerandswitchofloadsto
“OFF”position.
2)TurntheGeneratorsetMainCircuitBreakerand
othercircuitbreakerstothe“OFF”position.
3)Connecttheenginebatterycablewithbattery.
4)Turnonthepanelpowerswitch1S1(Ref. Appendix
Dcircuitdiagram)tothestartposition.
5)Pressthemodulestartbutton.
6)Ifgeneratorsetassemblepre‐heater(airintakeor
waterpre‐heater).ThePre‐heatenginewill
illuminateonmoduleLCD.Preheatingtimevaries
bycoolanttemperature.Usuallywaterpre‐heater
completesinabout60seconds,airintake
pre‐heatercompletes10seconds.Afterpreheating
theLCDputsoutandtheenginebeginstostart.It
willattempttostartagainabout5secondslaterif
theenginefailstostart.
7)Aftertheenginestartssuccessfully,allowthe
enginetowarmupforabout5minutes.Ifthe
enginecouldnotfireduringthepre‐setnumberof
attemptstostart(startattemptsnumber:3times),
theAlarmLCDwouldflash.Ifyouneedtorestart,
waitatleast30secondsbeforetheretry.
8)CheckthereadingofVoltageMeterandFrequency
MeterbyoperatingtheVoltmeterChange‐Over
Switch.Oncethegeneratorsetisrunningatthe
correctvoltageandfrequency,TurntheGenerator
setmaincircuitbreakerto“ON”.
9)Turnoneveryswitchorcircuitbreakerofloads
(fromheavytolightloadinsequence),sendpower
totheloadside.
Controlpanelintroduction


NOModel
1startpanelpowerswitch
2batterychargerswitch
3fuse
4batterycharger
5controlmodule
6electricgovernor

3.6.2Generatingsetcontrolsystem
Tocontrolandmonitorthegeneratingset,an
electroniccontrolsystemhasbeenused.P10/16
modelcontrolsystemisfittedfrom10kVAto2000
KVAsinglegeneratorsetrunningsystem.P20/25
controlsystemisfittedfrom10kVAto2000kVA
transferwithmainspower.Controlpanelprovidesa
meansofstartingandstoppingthegeneratingset,
monitoringitsoperationandoutputand
automaticallyshuttingdownthesetintheeventof
criticalconditionarisingsuchaslowoilpressureor
highenginetemperature.(DSEControlsystemplease
readtheDSEuser’smanual)
P20/25controlsystemmoduleintroduction

MainfunctionofP20/25
Thecontrolsystemofdieselgeneratorsetis
developedthroughtheuseofmodelAMF20/25
module,aspecialdieselcontroller,madebyCzech
COMAPCompany.Thismoduleismainlyusedfor
auto/manualstart‐up,protectivestopand
manual/autoswitchoverthegeneratorsetpowerand
mainspower.Itcanalsoremote