d.g Set Foundation

27
We can achieve excellent performance from a Silent DG set, if proper care is taken during its installation. (The following suggestions shall help you to achieve optimum performance from the D.G. Set.) JAKSON & CO. Note: 1. Please always sign the report made by our Service Engineer. 2. Warranty is applicable for two years subject to use of Kirloskar K- Oil, Kirloskar genuine filters, K cool super plus and services sourced through KOEL authorized Service Dealer.

Transcript of d.g Set Foundation

Page 1: d.g Set Foundation

We can achieve excellent performance from a Silent DG set, if proper care is taken during its installation. (The following suggestions shall help you to achieve optimum performance from the D.G. Set.)

JAKSON & CO.

Note: 1. Please always sign the report made by our Service Engineer. 2. Warranty is applicable for two years subject to use of Kirloskar K-

Oil, Kirloskar genuine filters, K cool super plus and services sourced through KOEL authorized Service Dealer.

Page 2: d.g Set Foundation

Proper space should be there for placement and opening of doors of the

Silent DG set.

There should be atleast 1.5 meter free space around the DG set for

proper operation and maintenance.

SELECTION OF SITE

1

There should be cross ventilation of air to ensure proper cooling of DG

set. Exhaust gases and hot air discharge should not re-circulate inside

the acoustic enclosure (canopy).

There should be no restriction for fresh air suction and hot air discharge.

If 2 DG sets are installed at the site, ensure that hot air outlet of the one

DG set does not become the fresh air intake of the 2nd DG set.

A low height shelter for the Silent DG Set should be avoided. It should

not obstruct the hot air outlet.

It is preferable to install the DG set in an open area. No shade (roof) is

required over it. However, if the AMF Panel is outside the Acoustic

Enclosure, then a shelter is recommended for the Panel.

For Roof Top Installation, ensure that the civil structure is capable to

bear the static and dynamic load of DG set. The load of the Silent DG set

should be borne by Columns and Beams of the building.

Proper space should be there for Earthing.

If there are no space constraints, the DG set should be placed near the

distribution panel.

The DG set should be located away from polluted surroundings such as

corrosive fumes, cement dust, fibres, cotton and toxic chemicals to

avoid overheating of the D.G. Set.

JAKSON & CO.

Page 3: d.g Set Foundation

2

FOUNDATION DETAILS AND GUIDELINES

A. Ground base Foundation (RCC/PCC)

The Foundation should be water leveled and atleast 3” above the

Ground Level.

The Length and width of the Foundation should be atleast 200mm to

400 mm more than that of the DG set size.

Please refer to the foundation drawing attached herewith.

A rigid foundation ensures the least vibration. Sand Filling should be

there around the foundation. Rubber matting can also be used over the

foundation to minimize the vibration effect and noise leakage.

Please refer to the dimension of DG set for deciding the foundation

length, width and depth.

Note: Please ensure that the foundation should not be made over any

basement, water tank or Sewer Line.

B. Roof Top Foundation

The weight of Silent DG set should be on Column and Beam through

proper foundation.

The RCC foundation should be on the Beam or supported on two

Beams.

ISMC Channel or MS “I” Section may also be used to cater the load of the

DG set with the canopy. Load of ISMC Channel or MS “I” Section should

be on the column of the building.

M.S. Sheet is to be provided at the bottom of the base frame of the Silent

DG set for roof top installation.

JAKSON & CO.

Page 4: d.g Set Foundation

JAKSON & CO.

NO

T TO

SC

ALE

IF IN

DO

UB

T A

SK

LEN

GTH

OF

DG

SET

+30

0 M

M

50

50

DG

SET

WIDTH OF DG SET + 300 MM

TAB

LE F

OR

BA

R' S

SIZ

ETO

P VI

EW

BARS

@

150

C/C

BO

TH W

AY. (

PL. R

EFER

TAB

LE)

200

FFL

THER

MO

CO

L45

0 S

AN

D

RC

C 1

:2:4

PCC

FR

ON

T VI

EW

DIM

ENS

ION

MA

RKE

D A

S (

) T

O B

E D

ECID

ED B

Y S

TRU

CTU

RA

L C

ON

SU

LTA

NT/

CLI

ENT.

*TH

IS IS

ON

LY A

REF

EREN

CE

DR

AW

ING

. KIN

DLY

CO

NS

ULT

YO

UR

CIV

IL E

NG

R /

CO

NS

ULT

AN

T FO

R M

AK

ING

FO

UN

DA

TIO

N

S.N

OR

ATI

NG

OF

SLE

NT

DG

SET

SIZ

E O

F B

AR

1U

P TO

82.

5 KV

A10

MM

DIA

210

0 KV

A T

O 2

00 K

VA12

MM

DIA

3 250 K

VA

TO

600K

VA

16

MM

DIA

SO

LD&

SER

VIC

EDC

-268

,267

,IND

, AR

EA,P

HA

SE-

2,M

AYA

PUR

I, -N

EW D

ELH

I -64

JAKS

ON &

CO.

TITL

EFO

UN

DA

TIO

N D

RA

WIN

G O

F S

OU

ND

PR

OO

F G

EN

SET

PART

NA

ME

FOU

ND

ATI

ON

DR

AW

ING

DRA

WN

BY

DR

G. N

O.

RF-

7-06

CH

ECKE

D B

YD

ATE

7/0

2/0

6

APP

RO

VED

BY

KIRL

OSK

AR E

NG

INE

3

Page 5: d.g Set Foundation

4

EARTHING SYSTEM

An Earthing system is required for the protection of equipment and human

being, as per Indian electricity Rules 1956.

Separate earth should be used for body and neutral earthing.

4 Nos. earthing pits are required for 3 phase DG set, 2 each for neutral &

body.

2 Nos. earthing pits are required for single phase DG set, 1 each for

neutral & body.

The min. distance between 2 earthing pits should be 2.0 meters.

An earth pit cover should be provided.

A watering pipe of 19mm with a funnel should be provided for each pit,

wherever depth of the earthing pit is not at water level.

Earthing system should be checked with meagre and maximum 1.0

om resistance should be ensured.

The earthing plate/pipe and strip size should be selected as per the rating of

the DG set.

Description Unit 15 KVA - 125 KVA

Copper Strip 25x3 mm

GI Strip 25x6 mm

Description Unit 140 KVA - 625 KVA

Copper Strip 25x6 mm

GI Strip 50x6 mm

JAKSON & CO.

Page 6: d.g Set Foundation

5

EXHAUST PIPING

The exhaust system must be designed to keep the resistance to hot gases (back pressure) as low as possible and load of the extended exhaust pipe/silencer should not be on the engine manifold.

The Following may please be noted.

There should not be any load or stress on the exhaust bellow.

A uniform gap has to be maintained between bellow flange and exhaust pipe

flange.

There should be proper support for the exhaust pipe.

Pipes should be extended through proper flanges only.

Short bends should be avoided.

Always use proper size M.S. pipes (G.I pipe and bend should not be used in

exhaust piping).

Air cooled

Description Unit 15 KVA-35 KVA

40 KVA­62.5 KVA

75 KVA

Exhaust Pipe Dia

mm 63 76 100

Water cooled R-Series

Description Unit 15 KVA 35 KVA

40 KVA 62.5 KVA

75 KVA­82.5 KVA

100 KVA ­125 KVA-

Exhaust Pipe Dia mm 63 76 100 125

SL Series

Description Unit 140 KVA 250 KVA

Exhaust Pipe Dia mm 125

K Series

Description Unit 275 KVA 320 KVA 400 KVA - 625 KVA

Exhaust Pipe Dia mm 125 150 2 x 150

JAKSON & CO.

Page 7: d.g Set Foundation

6

FUEL PIPING

A supply and return fuel pipe is required in each DG set .

SDGs upto 200 KVA are provided with fuel tanks inside the acoustic

enclosure.

Above 200 KVA, the fuel tank is outside the acoustic enclosure.

�For fuel tank inside the enclosure, fuel piping is done by the

manufacturer/supplier.

However, for Fuel Tank outside the enclosure, fuel piping is to be done

by the customer.

Size of the fuel piping should be 12mm upto 250 KVA DG set.

�B/C Class M.S. pipe (19 mm - 25mm I.D.) is recommended For fuel

piping above 250 KVA DG sets.

MS pipe should be used with proper welded joints.

Stop valve and flange should be used at supply line to engine near fuel

tank (for Fuel Tank mounted outside).

PRECAUTIONS TO BE TAKEN FOR FUEL PIPING AND FUEL SYSTEM.

Never use GI pipes in fuel piping of DG set.

Joints should be welded and never threaded.

Pipe should be above ground level with proper MS support.

All joints should be tested for any seepage or leakage.

For 320 KVA and above DG sets, Fuel Tank height should be such that

lowest level of Fuel Tank is above Diesel pre-filter height.

JAKSON & CO.

Page 8: d.g Set Foundation

CABLING It has been our experience that most electrical failures are caused by overheating due

to loose thimbling or undersize cables.

Please use cable of correct size to carry full load current and thimble of correct size for

cable termination.

At no time, loose wires should be tightened on to terminal/busher with bolts.

Crimping should be done with proper crimping tool.

CABLE SIZE

For 3 Phase KVA 15 20/30 35/45 50 62.5 82.5 100 125

Al. Cable Size

3.5 core sq. mm

1x16

1x6.0

mm2

1x25

1x10

mm2

1x25

1x16

mm2

1x35

1x25

mm2

1x50

1x25

mm2

1x70

1x35

mm2

1x95

1x50

mm2

1x120

1x70

mm2

Copper Cable Size

3.5 core sq. mm

KVA 140 160 180 250 320 400 500 600

Al. Cable Size

3.5 core sq. mm

1x150

70

mm2

185

95

mm2

240

120

mm2

300

150

mm2

2x185

240

mm2

2x300

or

3x185

300

mm2

3x300

or

4x240

2x185

mm2

3x300

or

2x400

400

mm2

Copper Cable Size

3.5 core sq. mm

For 1 Phase KVA 15 20 30-35 40 50 62.5 70

Al. Cable Size

2 core sq. mm

25

25

50

70

95

or

2x50

120

or

2x70

150

KVA 15 20 30-35 40 50 62.5 70

Copper Cable Size

2 core sq. mm

16

16

25

35

50

70

70

Note : -

a. Correct size cable Glands should always be used for holding the cable.

b. Control wiring should always be done with 2.5 sq.mm copper cable.

c. Form 320 KVA to 600 KVA bus bar terminal box will be provided by customer.

Page 9: d.g Set Foundation

8

BATTERY CHARGING PROCEDURE

a. Battery charging procedure

If dry battery is supplied along with the DG set then initial charging of the

battery is required.

� from an authorized service Please get initial charging of the battery done

dealer of the battery manufacturer.

The initial charging process is of 72 hours.

Specific gravity of acid inside the battery should be 1.23 to 1.28 kg/ltr.

b. Method to use charged battery

If charged battery has been provided along with the DG set, and the DG set is

not in use then ensure that at positive terminal battery lead is not

connected. It should be connected at the time of the commissioning of the DG

set.

Charged battery may be used for commissioning of DG set within 15-20 days,

else re-charging of charged battery is required.

Always connect the battery with the proper battery charger. The battery

should be connected to the battery charger, which is connected with 230V

AC supply.

The Battery charger is provided with an AMF Panel (Auto Mains Failure

Panel) under the standard scope of supply. 230V AC supply is essential for

battery charger operation.

Note: Battery charger is not supplied with a std. manual Panel. So, it is suggested

that the DG set must run once a day for 15-20 minutes so that battery is charged by

engine dynamo/charging alternator.

c. Precaution to be taken during handling of battery

Do not charge the battery at a wet a place.

Flame, Candle and matchbox should not be used near charged battery.

Use hand gloves while handling the charged battery.

Electrolyte level should be below the neck ?

Always switch off the charger first before disconnecting the battery from the

DG set.

Never put tools etc. on the battery.

JAKSON & CO.

Page 10: d.g Set Foundation

SUMP CAPACITY (LITRES)

AIR COOLED

Engine Model HA294 HA394 HA494 HA494TC HA694 HA694TC Rating

Lts. 4.5 9 11 11 13.5 13.5

Engine Model RV2 Rating

Lts. 5.4 8.5 8.5 9.5 11 13 15 15

RV3 2R 1040 3R1040 4R/4R1040T 4R1040TA 6R1080T 6R1080TA

Engine Model SL90TA SL1500TA TA TA TA TA TA Rating

Lts. 22.5 22.5 22.5 23 28 35 40

SL8800 6K12 8K15 10K18 12K22

Note:

�First, after 50 Hours �After that, every 250 hours

Recommended lube oil / filters change interval

9

JAKSON & CO.

Page 11: d.g Set Foundation

10

CHECK UP BEFORE STARTING THE DG SET

SttsauS.N. Dsrpin o ct e oi

1. Air cleaner mounting Fitted/Not fitted

2. Air cleaner cleanliness Clean/dirty/replaced(Dry or oil)

3. Air cleaner clamps 7 Hoses Cracked/normal/not clamped

4. Grade & specs of oil used ........ as per manufacture's recommendation

5. Lub oil level & positioning of oil filter OK/Not OK

6. Check lub oil safety OK/Not OK

7. All Nuts & Bolts Proper/Tightened

8. Battery condition Charged/Discharged

9. Battery Terminal/Leans Proper/damaged/replaced

10. Electrolyte level High/Medium/Low

11. Fuel Filter Proper/to be replaced

12. V Belt for charging alternator Proper/Tightened/notProper

13. V Belt tension Proper/adjusted

14. Water level in the Radiator OK/filled

15. Check water temp. sefety OK/not OK

16. Wiring (Engine/Panel) OK/not OK

17. Check all wires tightening OK/not OK

18. Alternator back cover Fitted/removed

19. Cable termination Proper/loose/Tightened

20. Canopy door alignment proper/adjusted/not proper

21. Canopy door hinge operation OK/not OK/Adjusted

JAKSON & CO.

Page 12: d.g Set Foundation

11

PRE-COMMISSIONING CHECK

Whenever you want to call a Service Engineer for commissioning, kindly

ensure that -­

Installation work has been completed (i.e. exhaust pipe job has been

completed with proper supports, if extended beyond the canopy)

Fuel pipe line job is completed, if Fuel Tank is outside the canopy.

Power cable laying, fitting and connection jobs are completed with

proper glanding.

If panel is out side canopy, Power Cable Control cable laying, fitting &

connection jobs have been completed.

�Most important - Battery is charged.

If the DG set is with AMF Panel, then 230 V AC supply is provided at the

AMF Panel to check its operation and for Battery Charger.

Diesel is available in the Diesel Tank.

Engine is duly filled with Lube Oil.

Load is available.

Note: It is mandatory to get your Diesel Generating Sets commissioned on load

and kindly do sign the commissioning report made by our Service Engineer.

JAKSON & CO.

Page 13: d.g Set Foundation

ROUTINE CHECK POINTS

12

Check Fuel Level

Drain water from fuel Tank (Especially during winter Season.)

Check coolant Level.

Check Water level in the Radiator

Check for any leakage

Check for any loose connections

Check Battery condition

Check Lube oil level and quality (lube oil should not be very

thick with visible carbon and metal particles).

JAKSON & CO.

Page 14: d.g Set Foundation

13

DO'S & DON'T'S

DO'S :

Check Fuel Level

Check Lube Oil Level and quality, lube oil should not be very thick with

visible carbon and metal particles

Check coolant Level.

Check for any leakage.

Check for any loose connections

Check Electrolyte Level in Battery.

Check the Battery terminals.

Check Fan Belt Tension.

Check Battery Charger working.

Drain the water from the fuel tank, weekly during winters.

Please check all the Nuts, Bolts, Engine/alternator foundation bolts and

loose cable connections tightening at the time of commissioning and then

monthly.

Always use K-oil to avail two year warranty.

Purchase all spare parts from authorized Kirloskar Service Dealer.

Refer Engine Maintenance Manual for routine and daily maintenance check.

DONTS :

If the DG set is with AMF panel please do not touch live wire as mains also flow

from AMF panel even if DG SET IS OFF.

Do not check coolant level, while DG is running.

Do not change any wiring or modify wiring it may attract void of `

warranty

Please do not get the DG set repaired and serviced by any unauthorized

person. It may attract void of warranty. It should be done by the

manufacturer or Kirloskar authorized Service Dealer.

Contd.

JAKSON & CO.

Page 15: d.g Set Foundation

14

FOR DG SET WITH CANOPY :

Cable entry holes, if not in use, should be properly closed.

�Don't Unneccearly open the locked doors which can lead to damage

inside the lock.

Exhaust pipe installation for Silent DG set should be very-very precise.

The load of the Exhaust pipe should not come on the bellow and it should

also not touch the roof body.

Note : Please note that normally DG sets are dispatched with dry batteries. So

please make sure that batteries are properly charged by authorized dealer, as

per the manufacturers recomendations, if batteries are not charged, as per the

recommendations, life of the Battery is reduced drastically and it could be

difficult for us to entertain warranty for that.

Silent DG and Genset with Radiator, Should be installed at a place

where opening for hot air escape and intake of fresh air is available.

JAKSON & CO.

Page 16: d.g Set Foundation

15

TROUBLE SHOOTING - ENGINE

Trouble Cause Redress

Engine dose not start No fuel in tank. Fill in fuel, vent fuel system.

Air in fuel system. Vent fuel system.

In sufficient speed of starter Charge batteries.

Engine does not start at See above or the ready to start Of above , or change lamp.

temperatures below 0 C signal lamp does not light.

Defect of series resistor solenoid Consult authorised

valve, or flame heater plug workshop.

Paraffin precipitation of fuel Heat up fuel Pipings, change

Filter

Engine starts up but stops Fuel tank cock closed. Open cock

after brief time

Dirt in primary fuel cleaner or Clean or change filter

in fuel filter. cartridge respectively.

No fuel in tank, no conveyance Fill in fuel , vent fuel system.

of fuel. inspect correct operation of

fuel pump, replace if

necessary, and check safe

venting of tank.

Water or dirt in fuel system. Clean fuel tank, fill in clean

fuel replace filter, and vent

fuel system.

No power and misfiring of Interruption of air supply or Inspect, replace if necessary

engine heavy jamming of air filter. or clean.

Air in fuel system Vent fuel system

Fuel filter jammed. Change filter

Starts of fuel supply missed. Reset start of fuel supply.

Defect of exhaust brake. Inspect and repair

Engine emits white or Retorted and start of fuel Set correct start of

bluish fumes, supply fuel supply.

JAKSON & CO.

Page 17: d.g Set Foundation

Trouble Cause Redress

Engine is still cold. Permit engine to heat up in operation

Mis setting of fuel injection Check start of fuel supply system. inspect injectors.

Engine emits black fumes. Engine is overloaded. Reset fuel injection system.

consult workshop.

Air filter jammed. Change air filter element.

Fuel injection piping loose or Tighten fuel injection piping

broken. or replace it, respectively.

Heavy knocking of engine. Starts of fuel supply too early Set correct start of fuel

supply.

Mis-setting of valve air gaps Adjust & correct valve air

gaps.

Mechanical defects of engine Consult authorised

workshop.

Engine grows excessively hot. Slipping of V-Belts. Tighten or Replace V-belts.

V-belts broken. Replace V-belts.

Defect of temperature Emergency operation; forced

governor. opening of valve plate.

Defect of temperature Perform electrical check of

Controller temperature controller.

Lack of coolant. Fill in coolant.

Radiator is dirty. Clean radiator.

Mis-setting of fuel supply. Set correct engine in fuel

supply

Intake or exhaust system Redress cause of trouble.

jammed.

Heavy dirt accumulation on Consult workshop.

cylinder elements.

16

JAKSON & CO.

Page 18: d.g Set Foundation

Irregular speed of engine. Defect of speed governor. Inspect fuel injection pump

and governor.

Excessively high fuel Mis-setting of fuel injection Check, fuel injection system.

consumption system

Injection of excessively great Have fuel injection pump

fuel quantity engine emits adjusted by specialised

black fumes workshop.

Leakage of solenoid valve of Replace solenoid valve.

cold starting device.

Jammed air filter. Replace air filter.

Engine is worn. Consult authorised workshop

Defective exhaust brake. Consult workshop.

Very low oil Pressure. Jammed paper filter cartridge. Replace paper filter cartridge.

Deficient oil level. Check and add oil.

Pressure gauge or pressure Inspect and replace or

gauge tube loose or defective. tighten.

Leakage in oil system. Check.

Improper lube oil (viscosity). Check brand of oil.

Defect of control valve for Replace valve.

cooling of pistons.

Heavy wears of bearings. Consult authorised

workshop.

Increase in lube oil Leakage in oil system. Inspect pipings, filters, and

consumption ducts for tightness.

Excessively high oil level. Defect of air filter system, and

cooling of pistons, consult

authorised workshop.

Trouble Cause Redress

17

JAKSON & CO.

Page 19: d.g Set Foundation

No dirt deposits centrifugal Rotor jams. Inspect rotor bearings,

filter. inspect oil supply to rotor.

Heavy blowing from Excessively high oil level, Adjust oil level, consult

venting hose of engine. damages of cylinder elements. authorised workshop.

No air supply from piston Defect of cylinder element or Consult authorised

or compressor. of valve plate. workshop.

Battery charging signal Defective insulation in fanned Consult authorised

lamp alight while ignition cable workshop.

is switched off.

Battery charging signal Defect of signal lamp. Replace signal lamp.

Interruption of D* governor and Plug in connector.

generator

Battery discharged Change battery.

Battery charging signal Broken V-belt. Replace V-belt.

lamp alight during normal

operation Defective alternator. Inspect or consult workshop.

Heavy boiling of battery. Defective governor, excessive Consult authorised

contact resistance of negative workshop.

polarity across brush holder

and end shield bearing of

generator.

Starter does not run. Battery discharged. Charge battery.

Deficient speed of starter Starter terminal voltage too low. Check battery cells,

recharge battery.

Oxidized or loose terminal Clean and fasten terminals.

connections.

Carbon brushes jam or Clean or replace brushes.

are worn.

lamp does not light up

when ignition is switched

on

Trouble Cause Redress

18

JAKSON & CO.

Page 20: d.g Set Foundation

19

TROUBLE SHOOTING CHART : ALTERNATOR

Fault Cause Rectification

No voltage build - up 1) Insufficient residual 1) Excite the rotor using a

voltage. battery.

2) Improper connection 2) Correct the connection

3) Low speed 3) Reset the speed to the

nominal.

4) Faulty Winding 4) Check the winding

resistance and rewind if

required.

5) Rotating rectifier failure 5) Replace the rotating

required.

6) Faulty AVR 6) Replace the AVR

Low no-load voltage 1) Low Speed 1) Reset the speed to the

nominal

2) Faulty Rotating rectifier 2) Replace the rotating

rectifier.

3) Faulty Winding 3) Check the winding

resistance

and rewind if required.

Low voltage on load 1) Low speed at full load 1) Set the rated speed of the

prime mover.

2) AVR faulty 2) Change AVR

3) Faulty rotor winding 3) Check the rotor winding

resistance and if faulty,

rewind it.

4) Over load on alternator 4) Operate on specified load.

High voltage on load 1) Capacitors on the load 1) Disconnect the PF

side improvement capacitors

2) Faulty AVR setting or 2) Correct the setting/Replace

AVR is faulty AVR

Too high 1) Excessive speed 1) Adjust the revolving speed

no-load voltage 2) Correct the setting Correct the setting

Replace AVR Replace AVR

JAKSON & CO.

Page 21: d.g Set Foundation

20

Fault Cause Rectification

Voltage oscillations 1) Incorrect AVR Setting 1) Set the AVR stability pot

2) Thyristor load more that 2) Reduce the Thyristor load

specified limits

3) Insufficient engine

flywheel

Unbalance Voltage 1) Unbalance load 1) Correct the load

2) Loose connections 2) Tighten the loose

connections

3) Stator winding faulty 3) Check winding resistance

& rewind if required.

Generator does not Prime mover speed droop Set prime mover speed

share properly.

(2 Generators in

Parallel Operation

KW load proportionately Improperly set Droop (Governor)

characteristic of engines.

Generator does not Quadrature droop Interchange CT secondary

share

KVAr load Incorrect Correctly by QDC Pot in AVR.

proportionately

QDC-CT polarity reversed Interchange CT secondary

QDC-CT are not in Check and rectify

W-phase

Excessive overheating 1) Set misalignment 1) Align the set properly

of one or both bearings 2) Bearing loose in end 2) Replace the faulty End

(temp. of bearings over shield housing Shield

80ºC)(with or without

noise)

JAKSON & CO.

Page 22: d.g Set Foundation

21

Fault Cause Rectification

Excessive overheating 1) Air flow (inlet-outlet) 1) Check air inlet - outlets of

of alternator frame partially clogged or hot the alternator

air is being circulated

either from alternator

or prime mover

2) Alternator operating 2) Set the voltage to rated

at high Voltage at load value

3) Alternator overloaded 3) Operate at specified load

4) Load PF less then 4) Correct the load power

0.8 lag. factor

Excessive Vibrations Defective mounting or Replace the coupling & check

play inthe coupling the alignment Reset the speed

to the nominal

Loose mounting Bolts

Excessive vibration and 1) Three phase alternator 1) Check and correct the load

humming noise coming is single phase loaded in

from the alternator excess of acceptable

limits

2) Start up with no-load:if 2) Rewind stator

humming persists-faulty

alternator stator

winding

Smokes, spark or Short circuit in the external Stop the gen-set

flames coming from the circuit (including wiring immediately

alternator between alternator

and control board)

Object fallen into the

machine short circuit or

flash in the stator winding

JAKSON & CO.

Page 23: d.g Set Foundation

22

Fault Cause Rectification

Alternator damaged by Short circuit in external Stop the gen-set immediately

as significant impact circuit faulty parallel

which is followed by connection (out of phase)

humming and vibration Break or deterioration in

the coupling Break or twist

in shaft extension shifting

or circuit of main field

winding Bursting or

unlocking of the fan Diode

burnt, rectifier bridge

damaged.

JAKSON & CO.

Page 24: d.g Set Foundation

23

TROUBLE SHOOTING GUIDE FOR MANUAL PANEL

Engine does not start by turning the starting key provided on panel.

Check the DC supply control MCBs No. 5. This should be in ON position.

Check the battery voltage at terminal 1 and 2 in the panel. It should be at or above 24/12V.

Check all control wires at control terminals in the Panel.

If there is rattling sound that the self starter of engine is engaged, but it slips or

cranks slowly.

The battery connection may be loose or corroded. Check and correct the problem.

Check if the battery voltage is at 24V/12V or above. If not, get the battery charged

before making further attempts as the battery may be weak.

The engine cranks but will not fire.

Check the fuel supply line.

May be connection of fuel pipe at fuel tank is open.

JAKSON & CO.

Page 25: d.g Set Foundation

24

TROUBLE SHOOTING GUIDE FOR AMF PANEL

Engine does not start from the AMF panel in any mode.

Check the DC supply control MCBs F10 and F11 for 3 phase Supply. These

should be in ON position.

Check the battery voltage at terminal 1 and 2 in the AMF Panel. It should be at or

above 24V/12V.

Check all control wires at control terminals in AMF Panel.

Check Battery terminals. They should be properly tightened and should not be

corroded.

Check LLOP signal at AMF Panel control terminal No. 8, up to 125 KVA It should

be properly connected on engine terminal.

It there is rattling should that the starter is engaged but it slips or cranks slowly.

The battery connection may be loose or corroded. Check and correct te

problem.

check if the battery voltage is at 24V/12V or above. If not get the battery charged

before making further attempts as the battery is weak. If the main supply is

available, set the battery charger to boost and wait till the battery voltage is as

stated above.

The engine cranks but will not fire.

Check the fuel supply line.

JAKSON & CO.

Page 26: d.g Set Foundation

25

Engine starts but there is no Voltage from the control Panel

Check that the HRC fuses/MCB below the alternator contactor are O. K.

Check that the setting at the Alt Voltage Monitor is not too high, set it to 360 V

and try.

Check the overload Relay if it is tripped and press the reset lever.

The Main supply is restored, but the load does not transfer.

Check the control MCBs at F4, F6. It should be in 'ON' position.

Check if all three phases (RY, YB and BR) of Mains supply are available.

These can be checked through selector switch and voltmeter provided on AMF

Panel. All three phases should be available and voltage should be more that

the setting of mains voltage monitor or AMF Relay.

If required, lower the voltage setting of mains voltage monitor and differential

setting or setting in AMF relays. Increase the voltage setting gradually if Mains

Voltage is not acceptable on load equipment.

JAKSON & CO.

Page 27: d.g Set Foundation

26

All Office Addresses, E-mail Addresses, Phone Nos. are on the Back Cover Page

JAKSON & CO.