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DIESEL GENERATOR GROUP

OPERATING & MAINTENANCE


MANUAL

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

DEAR THE USER OF EMSA GENERATOR;


First of all thank you for choosing Emsa generator.
This operating and maintenance manual is prepared and developed to introduce you Emsa generator system.
This manual gives general information about installation, operation and maintenance of the generator.
Moreover general information, tables and schemas related the generator you have purchased are provided here.
Never operate, maintain and repair your generator unless you take safety measures.

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

TABLE OF CONTENTS
1. INTRODUCTION .........................................................................1
2. SAFETY ....................................................................................2
2.1 General .........................................................................2
2.2 Installation, carrying and towing ..........................................2
2.3 Fire and explosion ............................................................2
2.4 Mechanics .....................................................................3
2.5 Chemical ........................................................................3
2.6 Noise .............................................................................3
2.7 Electrical ........................................................................4
2.8 First aid in case of electric shock .........................................4
3. GENERAL DESCRIPTION .............................................................6
3.1 Definition and description of the generator ............................6
3.2 Diesel Motor ...................................................................6
3.3 Motor electrical system ......................................................6
3.4 Cooling system.................................................................6
3.5 Alternator ........................................................................6
3.6 Fuel tank and frame...........................................................6
3.7 Vibration isolators ............................................................6
3.8 Silencer and exhaust system ...............................................6
3.9 Control system..................................................................6
4. INSTALLATION, REMOVING AND STORAGE ................................8
4.1 General .........................................................................8
4.2 Cabin............................................................................8
4.3 Moving of the generator ....................................................8
4.4 Selection of generator place ..............................................8
4.5 Installation of vibration isolation ..........................................9

4.6 Combustion ventilation .......................................................9


4.7 Cooling and ventilation......................................................9
4.8 Exhaust ........................................................................10
4.8.1 Dimensions of generator room ..................................11
4.9 Fuel system ..................................................................13
4.9.1 Daily fuel tank ......................................................13
4.9.2 Main fuel tank ......................................................14
4.9.3 Fuel road ............................................................14
4.10 The oil used at the generator and antifreeze ......................16
4.10.1 Viscosity and temperature diagram..........................16
4.11 Batteries .....................................................................17
4.11. 1 Well-kept type batteries .......................................17
4.11.1. Filling battery with the first acidic water ..................17
4.11. 1.2 Battery care ............................................17
4.11. 1.3 Testing of battery ......................................17
4.11. 1.4 Hydrometer Test .......................................18
4.11.2 Neglectred type batteries ......................................18
4.12 Electrical connections ....................................................18
4.12.1 Wiring ..............................................................18
4.12.2 Protection ...........................................................18
4.12.3 Loading ............................................................18
4.12.4 Power factor ......................................................19
4.12.5 Grounding/grounding conditions ..........................19
4.12.6 Parallel operation.................................................19
4.12.7 Isolation test .......................................................19
4.13 Sound silencer .............................................................21

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


9.1.3 AMF 4.0 Automatic Transfer Device ..........................24
10. LOCATION AND REPLACEMENT OF POWER BOARD ................26
11. FAILURES OF ALTERNATOR AND RECOVERY ............................27
12.FAILURES OF DIESEL MOTOR AND RECOVERY...........................28
13.PERIODIC MAINTENANCE INSTRUCTION ..................................30

4.13.1 Exhaust silencers .................................................21


4.13.2 cabins ..............................................................21
4.13.3 other sound silencers ............................................21
4.14 Towing of the generator with trailer ..................................21
4.14.1 Preparation for towing ..........................................21
4.14.2 Towing .............................................................21
4.14.3 Parking .............................................................21
4.15 Storage.......................................................................21
4.15.1 Storage of motor .................................................21
4.15.2 Storage of alternator............................................21
4.15.3 Storage of battery ...............................................21
4.16 Motor Block water heater ...............................................21
5. GENERATOR CARE ...................................................................22
6. CONTROLS AND PROCESSES TO BE CARRIED OUT BEFORE
THE STARTING OF THE GENERATOR.........................................22
7. GENERATOR CONTROL SYSTEMS ..............................................22
8. OPERATION OF THE GENERATOR.............................................23
8.1 Operation instruction of automatic generator .......................23
8.1.1 Operation with DKG 307 Control Panel ...................23
8.1.2 Operation with EOAM 210FD-FL Control panel...........23
8.1.3 Operation with AMF 4.0 Control Panel .....................23
8.2 Operation instruction of manuel generator ..........................23
8.3 Points to be noted while starting up ...................................23
9. INTRODUCTION AND OPERATION INSTRUCTION OF AUTOMATIC
TRANSFER DEVICE ........................................................................24
9.1
DKG 307 Automatic Transfer Device.............................24
9.1.1Digital indications ...................................................24
9.1.2 EOAM 210 FD-FL Automatic Transfer Device: .............24

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


1. INTRODUCTION
Emsa Generator is designed to be applied to the circuit immediately
wherever it is taken as long as cooling water and its antifreeze, fuel,
lubricating oil and charged battery are provided.
EMSA manufactures efficient, reliable and high-quality generators by
means of experience of long years.
This operation and maintenance manual is prepared to help the user
about using and performing maintenance of the generator easily. In
the event of following recommendations and instructions in this manual,
maximum performance and effect can be obtained.

In order to ensure regular operation of generator in dirty and dusty


environment, it should be noted to maintain more frequently.
Settings and repairs should always be performed by authorized and
qualified personnel. Every generator, frame has the model and series
numbers shown on the label. Moreover, manufacture date, current,
voltage, power term of kVa, frequency, power factor and its weight
are indicated on this label.
This information on the label is necessary for ordering spare parts,
processing o guarantee or providing service.

Gen - Set Type

Gen - Set Serial No

Engine Type

Engene Serial No

Alternator Type

Alternator Serial No

Power (kVA)

Voltage (V)

Frequency (Hz.)

Current (A)

Speed (rpm)

Cos

Phase (kg)

Production Year

Nominal Voltage

Weight (kg)

Max. Height

Max Temp.( C)

Performance class
EMSA Elektromotor Alternatr San. Tic. A..
Meclis Mah. Teraziler Cad. No:37 Sargazi/stanbul Tel: +90 216 420 00 03 (pbx) Fax: +90 216 364 45 00
e-mail: info@emsa-jenerator.com.tr www.emsa-jenerator.com.tr

Figure 1.1 EMSA Generator Label

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


2.SAFETY

(-) pole of battery.

2.1. GENERAL
The generator is designed to be safe completely provided to be
operated correctly. In addition to this, safety responsibility belongs
to the ones who install, operate and maintain the generator. If the
safety precautions indicated are applied, the possibility of accident
is very low. Ensuring the necessary safety before any technical
operations or processes is dependent on the one who performs that
operation or process. The generator can only be operated by
authorized and qualified personnel.

Generator must be installed and operated by authorised service


personnel in accordance with the standards.
2.2 INSTALLATION, CARRYING AND TOWING
Section 4 covers installation, lifting and storage of generator. Read
this section before carrying, installing or towing the generator with
trailer. Please note the safety precaution stated below.
WARNINGS

WARNINGS
Perform the electrical connections as per the relevant standards.
Grounding and grounding failures are included in these standards.

Please read and understand all warnings in this manual before


operating or maintaining the generator.

Please make sure that fuel storage systems for generators are
mounted in accordance with relevant codes, standards and other
requirements.

In the event of not following procedure, instruction and safety


precautions in this book, accident and injuring are likely to increase.
Do not operate the generator in the event of known unsafe condition.

Motor exhaust gases are dangerous for personnel. Exhaust gases


of all generators indoors must be disposed with
proper, leak proof, black pipes as per the relevant
standards. Hot exhaust silencer and exhaust pipes
should be protected against being contact with
flammable objects and touching of personnel.
Please ensure disposal of exhaust gases out of

If there is an unsafe condition in the generator, put danger warning


and prevent operation of generator by disconnecting of negative (-)
pole of battery until correction of this negative condition.
Before maintaining and cleaning of generator, disconnect negative
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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


danger.

WARNINGS

Do not lift up the generator , alternator and motor via lifting rings.
In order to lift up the generator use the lifting points on the frame.
(Figure 4.1).

Ventilate the generator room properly.


Keep clean the Generator, generator room and the floor. In the
event of spilling of fuel, oil, battery electrolyte or cooling water
around, clean the spilled area immediately.

Make sure that lifting devices and support structures are durable
and have the capacity of bearing the generator. When the Generator
is lifted all personnel should be kept away the generator. While
towing the generator with trailer, you should note all traffic rules,
standards and other regulations. Necessary hardware and speed
limits expresses explicitly in the regulations are included.

Do not keep flammable liquids near the motor.


Do not allow events to cause the combustion
such as smoking, flame, spark around fuel.
Before performing connection or disconnection
of battery connection, disconnect feeding of battery charger.

Do not allow personnel to travel on the mobile generator. Do not


allow personnel to stand on the towing bar or between mobile
generator and wrecker.

Keep grounded conductive objects away from


areas being exposed to electricity such as terminals, in order to avoid
arc event. Sparkle or arc may inflame the fuel.

Unless designed distinctively, do not install and operate the generator


in an environment characterized as dangerous.

While motor is working, do not fill the fuel tank.


2.3 FIRE AND EXPLOSION
Do not operate the generator if there is fuel
leakage in the fuel system.

Fuel and smoke being parts of generator can flame and explode.
Taking proper precautions during the storage of these materials can
be reduced fire and explosion risks. Class BC and ABC fire extinguishers
must be kept handy. Personnel must know how to use them.

There must be an emergency exit door for


personnel's easy existing in the event of any fires.

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


2.4 MECHANIC

cooling water has cooled. Before opening the


radiator hole completely, loose the hole slowly
for reducing the high steam pressure.

Generator is designed with its housings in order to be protected


against moving parts. Yet, precaution should be taken to protect
personnel and devices against other mechanic hazards while working
in the generator room.

2.5 CHEMICAL
Oils, cooling water and battery electrolyte used in the Generator are
industrial type. If not used properly, they may harm the personnel.

WARNINGS

WARNINGS

Do not operate the generator in the event of safety housings' are


not in place. Do not attempt to reach near or under of safety housing
for maintaining or another reason while the generator is working.

Do not contact fuel, oil, cooling water and


battery electrolyte with skin and swallow. If
swallowed accidentally, seek medical treatment
immediately. In the event of contacting with skin,
wash contact area with soup and water.

Hand, arm, long hair, jewellery, overhang clothes parts should be


kept away from moving parts of generator.
Caution: Some moving parts are not seen visibly.
Keep closed and locked the Generator room.
Avoid contacting of hot fuel, hot cooling water,
hot exhaust gas smoke, hot surfaces and sharp
corners.

Do not wear clothes contaminated by fuel or


oil. While preparing the battery, wear acid-resistant overall, face
mask and safety goggles. In case of spilling of battery electrolyte on
the skin or clothes, clean the area spilled plenty of pressurized water
immediately.

Use protective clothes and materials while


working at generator site.

2.6 NOISE

Do not open the cell filler hole of radiator until

Loudness level of generators not being equipped with sound isolation


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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


cabin is more than 105 dBA. Long term exposure
to loudness level more than 85 dBA is dangerous
for hearing..

Do not attempt performing load connecting or disconnecting while


standing on wet or watery ground.
Do not contact with conductor, connection cables and electrical
parts on the Generator with any parts of your body or any objects
not being isolated.

WARNINGS
Wear headphone while working in the generator site.

2.7 ELECTRICAL

After performing load connection or disconnecting load, fix the


cover of alternator its place. Unless the cover is not fixed securely,
do not start up the generator.

Efficiently and secure working of electrical devices is provided with


installing, using and maintaining of these devices properly.

Connect the generator to loads and electric systems conforming


to its electrical characteristics and power.

WARNINGS

Keep all electrical equipment clean and dry. Replace the electrical
system where isolation has abraded, cracked and broken. Replace
the terminals having abraded, corroded and faded. Keep clean the
terminals and perform connections tightly.

Attaching of generator with the load should be


performed by authorised and qualified service
personnel in accordance with relevant electric
codes and standards.

Isolate all connections and idle wires.

Before starting up the Generator, (including mobile generators)


make sure that grounding of the generator has been performed.

Use Class BC or ABC fire extinguisher in case of electric fires.

Before connecting or disconnecting load to generator, stop operation


of the Generator and disconnect the negative (-) terminal of battery.

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


2.8 FIRST AID IN CASE OF ELECTRICAL SHOCK CAUTION

via seeing, hearing and feeling.

Do not touch with bare hand to the person being exposed to the
electricity before switching off the electric source.

BLOOD CIRCULATION
Control the survivor's pulse from his neck.

If possible deactivate the electric source. If not, unplug it or move


away the electric cable from the one being exposed to the electricity.

IF HE CAN NOT BREATHE BUT THERE IS PULSE


Close the nose of survivor tightly. Unite your lips
with survivor's lips via taking deep breath.
blow from the mouth observing the rising of thoracic cage. Then
permit thoracic cage to go down completely through stopping
blowing. Give breath for 10 times average per minute to the survivor.
If the survivor is left unattended so as to call for help, come back in
a short time with breathing out for 10 times again and continue the
action of breathing out. After every breathing out,
control the pulse. Position the survivor in recovery
position when he starts breathing.

If they are not possible, stand on dry, non-conducting material,


move away the one being exposed to the electricity via using
preferably dry wood.
If the survivor breaths, position the survivor as the way described
below.
If the person being exposed to electricity has lost his consciousness,
perform the treatment stated below to bring round:

IF HE CAN NOT BREATH AND THERE IS NO


PULSE
Seek medical assistance or call the nearest health
institution. Breath out the survivor for 2 times and
start cardiac massage as described below.

DECONGESTING THE RESPIRATORY TRACT


Hang the head of survivor backward and lift up
his chin. Remove the objects getting into mouth
or throat of the survivor such as false teeth, chewinggum, cigarette.

Position your palm above 2 finger from the junction


of thoracic cage.

BREATHING
Control whether the survivor is breathing or not

Position your other hand locking your fingers.


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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


Holding straight your arms press 4-5 cm down
15 times per minute.
process and 15 times cardiac message until
medical aid comes.
condition of the survivor, continue breathing out
via controlling his pulse. Control his pulse after
every 10 breathing out. As soon as he begins
to breath convert him recovery position.

Emsa Generator is designed as a whole to ensure high quality and


security. Figure 3.1 shows the main parts of a typical generator. But
every generator shows difference as per the configuration and sizes
of main components. This section describes parts of generator group
in short. More detailed information is provided next sections of this
manual. In every generator a label pertaining to that generator is
stuck on the frame. (Figure 1.1) This label contains information
describing the generator and working characteristics of generator.
This information is model number, series number, alternator voltage
and frequency, out power as kVA, weight and manufacture date.
Model and series number only define that generator and they are
necessary in the event of processing of guarantee, demanding service
and spare parts.

RECOVERY POSITION
Lay the survivor sideward. So as to ensure the
respiratory tract's being open keep his head leaning
in such a way that his chin will look towards.
Ensure the survivor not to tumble forward and backwards. Control
his breathing and pulse regularly. If either of them stops, repeat the
actions described above.

3.2 DIESEL MOTOR


Diesel motor (1) driving the generator is chosen since it is manufactured
especially for generator and secure. The motor is four-cycle, industrial
heavy duty type and all accessories for enduring safe energy are
provided on it. Exchangeable dry type air filter, mechanic or electronic
engine speed control governor are some of these accessories.

WARNING
Do not give liquids such as water until the survivor
has gained his consciousness again.
3. GENERAL DEFINITION

3.3 MOTOR ELECTRIC SYSTEM

3.1 DESCRIPTION AND DEFINITION OF GENERATOR

Motor electric system is negative grounded 24 r 12 v D.C. this


system consists of electrical starter motor, battery and battery charge
11

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


alternator.For 12 V electric system one and for 24 V electric system
two uncared type starter battery are provided. If desired, other type
batteries can be provided, too. Batteries are explained in details in
Section 4.

3.7 VIBRATION INSULATOR


Vibration insulators (8) are used for preventing the generator's
conveying vibration to the ground it has been installed via reducing
the vibration of motor. These insulators are placed between motor
and alternator stays and frame. If requested, special insulators can
be used between frame and ground.

3.4 COOLING SYSTEM


Motor cooling system is air cooled or water cooled. An air-cooled
system includes a high fan to cool the motor which gives cool air
inside of the motor. Water- cooled system consists of radiator (3),
fan, recirculation pump and thermostat. There is built-in fan in the
alternator to cool the winding of alternator.

3.8 SILENCER AND EXHAUST SYSTEM


Exhaust silencer is provided with the generator and/or separately
for mounting (2). The silencer and exhaust system reduces the noise
spreading from motor and orients the exhaust gas for a safe output.

3.5 ALTERNATOR
3.9 CONTROL SYSTEM
Output voltage and power of generator is produced by the alternator
(4) which has protected cage IP 21-23 protection Standard (protected
against particular and dripping), is self-warned, self-regulation, and
brushless. Terminal box made of steel plate (5) is mounted on the
alternator.

Manual or automatic control system and panel (9) are mounted on


the generator so as to protect the generator against possible failures,
control the operation and output of the generator. Detailed information
on these systems are provided in Section 7.

3.6 FUEL TANK AND FRAME


Motor and alternator are mounted on a steel frame (6).
There is fuel tank inside of the frame (7) (see Table 4.2 for capacities
of fuel tank).
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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

5
2

Figure 3.1 Typical generator group

1.
2.
3.
4.

Diesel Motor
Exhaust
Radiator

Alternator

5. Terminal Box
6. Frame
7. Fuel Tank (inside the frame)
8. Vibration Insulators
13

9. Control Panel

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


4. INSTALLATION, LIFTING AND STORAGE

4.2 CABIN

4.1 GENERAL

When the Generator is put in a cabin, moving and installation will


be very easier. Cabin protects the generator against using of
unauthorised persons and exterior factors.

After being familiar with dimensions of the Generator, the plan for
installation of generator can be arranged. This section includes
necessary and important factors for safe and efficient installation of
generator.

Figure 4.1 Lifting of generator with crane


14

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


4.3 CARRYING OF GENERATOR

-It should be protected against harmful materials carried from air such
as dust, thread, smoke, oil smoke, steam and motor exhaust smoke
that abrade or provides conductivity .
-Ground of Generator room should be flat and stable.
-It should be protected against of tree or beam that can fall and crash
over.
-There should be at least 1 meter space around the generator and
2 meter space over it so as to perform cooling, service and maintenance
of the generator.
-There should be proper way for carrying the generator to the room.
-Access of unauthorised persons to generator site should be restricted.
If the generator should be placed outside of the building, the generator
should be put in a cabin or a room. Moreover, using of cabin during
the operation of generator indoors or outdoors is beneficial.
Basement floor plan of a typical generator group is shown on Figure
4.4.

Generator frame is designed to make easy the carrying of generator.


Wrong lifting of generator may cause serious damages of parts.
Generator can be lifted via using forklift. In order to avoid damages
which are likely to occur during carrying with forklift, certainly put
wood between frame and forklift. Place forklift blades (brackets) under
the generator frame carefully. Note that both frame brackets will be
on the forklift blades.
WARNINGS
Do not lift up generator via using motor or alternator lifting rings.
Use proper equipment for weight of Generator.
When the generator is lifted up for the purpose of carrying, keep
personnel away from the Generator.
While the generator with cabin or without cabin is being lifted,
use lifting ring bolt holes on the frame.
Take necessary precautions in order not to damage parts that are
contacted with steel rope or chains to be used for lifting up the
generator.

4.5 INSTALLATION OF VIBRATION ISOLATION


Vibration insulators should be used between motor-alternator stays
and frame after generator, motor and coupling of the alternator.
Generator foundation: For generator foundation, there should be
reinforced concrete ground being 15-20 cm high and having at
least dimensions of generator. Reinforced concrete reduces the
vibration enabling hard and durable ground. The ground that
foundation subsides should have the structure that can bear wet
weight of foundation and the generator. If the generator is installed
above the ground, the building structure must have the capacity of

4.4 SELECTION OF GENERATOR PLACE


Following factors should be taken into consideration while selecting
the place where the generator will be put:
-There should be enough ventilation.
-It should be protected against rain, snow, flood water, direct sun
light, perishing cold, excessive temperature.
15

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


enduring the generator, fuel tank and other accessories. If Generator
room is sometimes wet, ground of generator must be elevated. So
abrasiveness of frame will have been reduced.
4.6 COMBUSTION VENTILATION
Motor combustion air must be clean and cold as much as possible.
Combustion air is drawn from the environment where the generator
is via air fitler mounted on the motor. But sometimes air around the
generator may not be suitable because of dust, dirt and temperature
conditions. Under these circumstances, air inlet channel can be
provided. This channel ensures clean air for the air filter on the motor
from outside or another room.

Figure 4.2 orienting of air ejecting from radiator with deflection


channels
A sharp corner between radiator hot air ejecting channel or funnel
should be avoided. (Figure 4.3). to circulate the air ejected outside,
directing arrangement should be done. (Figure 4.2).

4.7 COOLING AND VENTILATION


Motor and alternator release heat and cause increasing of ambient
temperature. Increasing of temperature affects negatively working of
the generator. For this reason, enough ventilation should be provided
so as to keep cool motor and alternator. Air flow should be as seen
on Figure 4.4. air must enter the generator room by alternator, exist
from the room by means of flexible bellows canvas made of tent
canvas passing over the motor and through radiator. If a canvas is
not used for ejecting hot air out of the room, fan reduces the efficiency
of cooling via expanding hot air in the generator room.

Figure 4.3 poor ventilation assembly


Air inlet and output Windows should be large enough for being easy
of air inlet to the room and output from the room. Air inlet and output
Windows should be larger 1.5 times than radiator area on the basis
of a rough estimate. In order not to affect generator by bad weather
16

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


4.8 EXHAUST
The aim of motor exhaust system is to eject exhaust fumes outside the
room in order not to cause danger and discomfort and reduce the
noise. So as to reduce loudness level of motor a proper exhaust
silencer should be fixed to the exhaust pipe.
WARNINGS
It is dangerous to inhale motor exhaust gas. Gases of all generator
in the closed area must be ejected with leak proof
pipes in accordance with standards.
Keep away hot exhaust silencer and exhaust
pipe from flammable materials and ensure them
to be protected for the safety of personnel.
It is noted when designing the exhaust system
that back pressure shall not exceed the pressure
values instructed by the motor manufacture. Excessive back pressure
causes motor to be damaged. In order to reduce back pressure,
exhaust pipes must be short and flat as much as possible.
Every necessary elbow must have arc at least 1.5 times radius more
than inner diameter of pipe. It will be good to use 1 inch larger pipe
diameter at every 6 meters or 3 elbows for reducing exhaust back
pressure.
In order to prevent conveying of motor vibration to exhaust pipe
system and building, and due to the expansion resulting from heating,
a flexible connection between exhaust manifold and exhaust pipe
system.
Weight of exhaust pipe should be supported by surrounding
structure for not being weight for motor manifold. Weight of exhaust

conditions, inlet and output Windows must be louvered Windows.


These louver may be fixed, but it is preferred that they should be
moving for cold climates. Louvers can be closed while generator is
not operated. So hot air facilitiating first starting up and providing
to the load stays in the room. Louvers can be moved automatically
if they are moving in a generator room having automatic control
system. By this means, louver can be opened immediately after motor
starts to operate and closed immediately after the motor stops.

Figure 4.4 Basement floor plan of typical Generator group


17

Table 4.1 Emsa open type diesel generator sizes, room sizes, sizes of air inlet
and output Windows and measures of exhaust diameter.
Figure 4.5 please see the letters provided at generator room.
Note: Please consult your dealer about groups with Remote radiators.

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

18

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


4.9 FUEL SYSTEM

system should be given to the building. Tensile element can be used


for this.
Generator room should be isolated for loudness level of exhaust
parts and heat released. Silencer and exhaust pipes should be placed
away from flammable materials.
Opposite weights flap type rain covers can be used for preventing
rain inlet to exposed exhaust outputs with different applications.
Every generator must have its own exhaust system. Exhaust outputs
of generators can not be connect using only one exhaust pipe.
Exhaust material should be of metal pipe.

Generator fuel system should continuously clean fuel for the motor.
The fuel system consists of daily fuel tank, fuel hoses and main fuel
tank.
WARNINGS
Fuel storage systems of Generators must conform
to standards.
Do not allow events being likely to cause fires
such as flame, sparkle or smoking around the fuel.

4.8.1 DIMENSIONS OF GENERATOR ROOM


4.9.1 Daily fuel tank:
Daily fuel tank keeps the daily fuel that generator needs ready to
use. For this reason, daily fuel tank should be at generator room.
Steel frame of generator is manufactured as tank-frame to store daily
fuel tank. (up to 880 kVA).
Note: For larger force please consult your authorised sales representative
(Table 4.2).
4.9.2 Main fuel tank:
The main fuel tank can be installed in addition to daily fuel tank for
providing operation of Generator longer.
Main fuel tank should be placed somewhere outside the room so
as to perform filling and maintenance easily. But since at cold

Figure 4.5 Generator room


19

Table 4.2 Fuel tank capacities pertaining to Generator groups and fuel
consumption at full load.

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

20

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


WARNINGS

atmospheres fuel flow is restricted with increasing of viscosity, main


fuel tank should not be left at excessive cold atmosphere. In order
to reduce vaporization, expansion or air pressure occurring during
the fuel filling to the tank, vent output should be mounted on the tank.
This vent output prevents vacuum forming in the tank during fuel
consumption. Bottom of fuel tank should have slope. So it prevents
fuel tank to damage via ensuring accumulating of water and hoses
at one point.
A drain valve should be placed the lowest point of fuel tank to
discharge water and deposit.

Do not use galvanized pipe for fuel system.


Do not fill fuel tank completely. Leave a gap as 6% of fuel tank
capacity for allowing expansion of fuel at high ambient temperature.
There should not be natural flow from fuel pipes to motor because
of gravity when the motor stops.
Fuel temperature is a critical factor for proper motor operation.
Since fuel heat more than 71C decreases heat content per volume
because of expansion, motor output power decreases.

4.9.3 Fuel channel:


Materials conforming with fuel such as Black, steel pipes or flexible
hoses can be used for fuel piping. In order to avoid leakage and
damages caused by motor vibration, flexible fuel hoses must be
secured between motor and fuel tank. Fuel feeder line should take
the fuel at least 50 mm above from the bottom of fuel tank and from
a point far away from fuel return line.

Connection pipe from main fuel tank to daily fuel tank should be
bigger than or equal to daily tank feeder pipe.
Using water separator pre-filter in fuel system line will protect
injections and fuel pump.

FUEL PIPE RECOMMENDATIONS


Generator Stand

Maximum

Maximum

Maximum

Recommended

By Power

Length of fuel

vertical height

number of pipe

pipe diameter
(inch)

(kVA)

pipe (m)

(m)

Fittings Elements

0-800

0,9

1"

800-1500

0,9

1 1/2"

1500-2200

0,9

2"

Main fuel tank can be higher or lower than daily fuel tank.
For fuel tank applications to be mounted as per Standby generator
groups, it is necessary to apply positive static fuel pressure to fuel
pump inlet.

Table. 3 Table of recommended pipe diameter of fuel installation


21

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

Figure 4.6 Typical general fuel piping mounting of fuel from main fuel tank to daily fuel tank
1. Filling Cabin
2. Filling line to main fuel tank
3. Ventilation shaft
4. Main fuel tank level indication
5. Main fuel tank
6. Drain valve
7. Fuel-liquid accumulation tank
8. Output valve
9. Feeder line leading to daily fuel tank
10. Electrical fuel transfer pump

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
22

Electrical fuel shutoff valve


Fuel-liquid accumulation tank
Daily fuel tank (in the frame)
Fuel level control switches
Manual filling and for air
Fuel level indication
Drain valve
Fuel leakage alarm
Motor fuel filter
Motor fuel pump

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

Figure 4.7 Typical fuel diagram placed below the fuel tank motor
Check valves should be used in case of the fuel tank is 2 m above
from crankshaft center. Maximum fuel level cannot exceed 2 m above
crankshaft center and minimum fuel level should be above 15 m from
fuel injection pump. If fuel level exceeds 2 m. The motor can be
damaged. If fuel level is below 15 cm. proper fuel pressure can not
be provided at fuel pump inlet. In another way, tank fuel level should
not be above the injection and below more than 80 cm from fuel
pump. Figure 4.7)
If fuel tank is raised above about 1.5 m height from
Injections, (Figure 4.8) it is placed for protecting motor against
hydraulic locking as the same with 2 pieces check valve. The
protection capacity of these valves is from 0 to 1.5 m height. If fuel
tank is to be above more than 1.5 m float m float tank should be
placed. Tank mounted far away and at a higher point is shown.
(Figure 4.9) under motor level fuel tank placed far is shown, also
(Figure 4.10).

Figure 4.8 Fuel tank and check valve connection put about 1500
mm above from fuel return

Figure 4.9 Float tank used with elevated fuel tank


23

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


While adding water to your radiator,
minimum 35% antifreeze should be added. Using antifreeze water
in your motor during summer and winter is very important for motor
life and water channels.

Figure 4.10 Fuel tank placed below 1500 mm


4.10. OIL AND ANTIFREEZE USED IN GENERATOR
Lubrication system of diesel motors is one of the most important parts
of the motor. Exact motor care (oil replacement period, filter replacement
period and noting sufficiently for oil type used) prolongs motor life
and reduces usage cost of motor.

4.11 BATTERIES
4.11.1 WELL-KEPT TYPE BATTERIES:
WARNINGS
Do not allow events to cause combustion such as flame, sparkle,
smoking around the batteries. While preparing battery wear an
overall resistant to acid, face mask and safety goggles. In case of
spilling of battery electrolyte on skin or clothes, clean the spilled area
with plenty of pressurized water immediately. Take off jewellery
objects in your hand and wrist such as chain, ring before using

Recommended oil;
15W40 Turbo Diesel, Antifreeze Super 4 season.
4.10.1. Viscosity -temperature diagram:
You can control the conformity of oil you use with temperature in your
area by means of following chart.
The antifreeze is not placed in radiator of your set as factory- exit.
24

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


4.11.1.2 Battery care
Maintain clean on the battery and terminals. Coat battery terminals
and connections with Vaseline carefully. Tight the terminals very well.
Control electrolyte level regularly. Electrolyte level must always be
over 10 mm from plates.
Control whether there is abrasion at v-belt of charging alternator or
not and tightness of v-belt regularly. Note that battery does not remain
without charging.

conductive tools.
While performing battery connection, negative terminal should be
connected at last, while disconnecting battery negative terminal
should be disconnected from battery at first.
Pouring water to battery and battery maintenance should be performed
under open air.
Batteries should be place as near as possible to the generator. If
batteries are placed far away from generator, it causes voltage drop.
This reduces starter capacities of motor.

4.11.1.3 Testing of battery


Visual check should be done before testing the battery. As time
passes, oxidation occurs at lead terminal of battery and connection
point. Oxidation abrades battery lead terminals and prevents charging.
Disconnect and clean the oxidation with boiling water. Then perform
connection again and coat with Vaseline. Do not allow loose
connection.

4.11.1.1 Filling of first acidic water of battery


Remove the protective cover on the battery cap.
Dismantle air throw cups.
Fill the battery until 15 mm above from the top point of plates with
clean battery acid whose specific gravity is 1280, at 20 C. Battery
and acid heat should be above 10 C.
Wait the battery for about 15 minutes. Then heating will begin at
battery eyes (pouches) and gas bubbles will rise out from the surface
of electrolyte. Fit air throw caps in place.
Control the battery with a hydrometer after waiting for minimum 15
minutes.
Minimum charging time is 6 hours. Control charging current and
electrolyte level with 1 hour internal. If there are no any changes for
1 hour, it has charged. Control electrolyte level after 2 hours, later
charging and if necessary add pure water in such a way that it will
be above 10 mm from plates.

4.11.1.4 Hydrometer Test


Specific gravity and charging status of sulphuric acid within the
battery can be measured using hydrometer.
If water level of battery has decreased, do not add distilled water.
Only use pure water. Keeping vertical barrel part of hydrometer draw
sufficient electrolyte upward. There should be free floating within
tube. Reading should be done at eye level. The evaluation is as the
following;
1.270
25

1.280 full charged with specific gravity

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


1.2201 230 half charged with specific gravity
1.150 1.220 specific gravity discharged.

Since it is not possible to produce harmonics and predict the quantity


in advance during planning stage of installations, neutral conductors
should either be dimensioned as high values or cross-section of neutral
conductor should be at leas as phase conductor cross-section.
Another point that needs to be noted about selection of cable is
whether there is load with demurrage (such as electric motor) and
distance between load and generator. At low voltage network, it the
distance is very long since current drop will increase very much during
demurrage voltage may drop undesired levels. To prevent this, load
table with more suitable cross-section can be chosen by means of
the formula below.

4.11.2 Uncared type batteries:


Make sure that electrical connections are correct and batteries have
charge. Except from it, these batteries do not require any maintenance.
4.12 ELECTRICAL CONNECTIONS:
Electrical connections and their maintenance must be performed by
qualified and experienced authorised service personnel.
WARNING
Perform electric connections in accordance with relevant electric
codes and standards.

u = 3 x L x I ( R Cos + X Sin )
u = absolute voltage drop (Volt)
L= Length of line (m)
I= line current (A)
R= resistance of cable (ohm/m)
X= resistance of cable (ohm/m)
If the distance is short at low voltage
Networks;

4.12.1 Wiring:
Electrical connections must be carried out with flexible cables due
to the vibration on the Generator. Cables should be located in cable
channels and generator should be in accordance with output voltage
and current. While deciding about cable cut, tolerances for ambient
temperature, installation method, adjacency to other cables will be
given. Moreover, cables should be chosen as per TSE or VDE
standards. Correctness of all cables must be controlled carefully.
Cable cross-sections as per current capacities and generator powers
are stated below. ( table 4.5, table 4.6)

If current is known, =
the formula

1,73.L.I.Cos

k.u
L.P

with

you can
If power is known, =
k.u
choose load cable withproper crosssectionwith this formula.
26

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


A= cross-section of line (mm2 )
L= length of line(m)
I= line current (A)
u=% voltage drop (For force line it should not exceed 3%.)
k= conductivity (for copper k=56).
P = power (W)
U = voltage between network phases (V)

drawn from the generator increases. If compensation panels performed


for correcting power factor are not configured as per the desired
technical features, it causes to damage AVR card of the generator.
Because of this reason, compensation panel must be deactivated
when generator is connected to the load.
4.12.5 Grounding/grounding conditions:
Failures, damages being likely to occur in isolation of electrical
devices cause metal parts not being related with energy system
except main current circuit of devices to be under voltage. Sometimes,
isolation is pierced through reaching excessive values of voltage level
and being exposed to piercing voltage and it causes these nonconducting parts to be under voltage. Grounding must be performed
both for protecting human life and devices.
Expected from a good grounding:
It should be continuously and constantly
It should have capacity of bearing failure currents
It should have enough low impedance to keep voltage drop in a
limited level.
Being low value of ground spread resistance
It can restricted as being low of specific resistance of ground.

4.12.2 Protection:
Distribution system and cables connected to generator are protected
with circuit-breaker switch which isolates connection automatically
in case of overloading and short circuit.
4.12.3 Loading:
It is very important to provide giving balanced load to generator
while planning of electric distribution panel. If load on a phase is
more than another phase, this causes overheating of alternator
windings, being imbalanced of output voltage between phases and
damages sensitive three phase devices connected to the system. No
phase currents should exceed nominal current of generator. Existing
distribution system can be arranged again so as to carry out these
loading conditions.

There are different grounding forms as network varieties of electric


companies. For this reason, electric companies in different regions
in the world choose transmission and distribution power systems, TT,
TN and IT systems which are suitable for them.

4.12.4 Power factor:


Our generators are configured as per 0,8 power factor. Therefore,
the power indicated on the label value can be taken into consideration
for this power coefficient. If power factor of load is below 0,8 current
27

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


TN type Networks are the most widespread used network kind
nowadays. The star point of this kind of network is grounded. Housing
and metal parts of devices are secured to protection conductor PE.
PE is also connected with grounded part in its star point. In the event
of contact between phase-ground, voltages against ground of PE or
PEN protection lines and connected devices increase. Keeping lower
than 2 ohm this value of these voltages RB resistance, desired value,
namely, a value which is under the allowed contact voltage can be
obtained.

Electrode type to be used in the grounding is established.


Short circuit current of installations and opening time of protection
elements to be connected to the system are determined.
Spread resistance is calculated.
Grounding conductor cross section calculation is carried out.
The accuracy of selection and calculation is examined.
The conformity of system in question is searched via calculating
step and contact voltage. Before commissioning, all conductors and
connection points are controlled visually.
Grounding resistance should be Rt < 4 ohm. If this value can not
obtained, processes stated above should be repeated and ground
resistance value should be made proper.
The most important subject while grounding in the generator system
is that the distance between network grounding area and generator
grounding area should be at least 20 m. This distance is for preventing
affecting of grounding system each other.
Distance between stick most used for grounding and the stick used
for performed grounding and their length are important.
In grounding systems performed with more than one stick grounding
the distance of sticks' penetrating should be at least distance of two
sticks. In a grounding used 1,5 m long stick
The other stick should be penetrated at least 3 m distance forward
than the first penetrated stick.

Figure 4.11 TN Type network


In projecting of grounding installations:
The place of grounding installations is determined.
Measurement processes are performed for determining of ground
specific resistance.
28

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


operated. In the event of waiting of generator for prolonged time
without operated, test insulation resistance of windings. Meanwhile,
all connections with the aim o control and automatic voltage regulator
connection (AVR) should be isolated. Rotating diode should be shorted
or disconnected. Megger of 500 V or a similar measurement tool
can be used. Connect Megger between output terminal and ground
(frame). Insulation resistance should be 1 M more than the ground.
In case of insulation resistance is less than 1 M, alternator windings
should be dried.
CROSS SECTION

mm2
The housing of generator should specially be grounded. In order to
prevent breakage to occur due to the vibration, the ground connection
should be flexible. Grounding cables should meet the standards and
have the capacity at least bearing full load current.
4.12.6 Parallel operation:
Extra fittings should be secured for operating a Standard generator
with other generators or network in parallel way.

4.12.7 Insulation test:


Insulation test should be carried out in the event that generators
purchased from our company waits for prolonged time without
29

CURRENT CAPACITY

GROUND

AIR

4
4
4
4
4
3
3
3
3
3

x
x
x
x
x
x
x
x
x
x

2.5
4
6
10
16
25/16
35/16
50/25
70/35
95/50

36
46
58
77
100
130
155
185
230
275

25
34
44
60
80
105
130
160
200
245

3
3
3
3

x
x
x
x

120/70
150/70
185/70
240/120

315
355
400
465

285
325
370
435

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


Table 4.5 Cable cross sections of proper cables as per current
bearing capacity and in accordance with
PVC isolated YVV (NYY) 0.6/1 KV VDE norms and TSE

in case of conditions such a loose nut, spun metal, crack, abrasion,


excessive tear.
Please control the conditions of all tires. Control working of all flash
lights and headlights.

4.13 SOUND SILENCER


Today controlling noise of generator is getting more and more
important. To control the sound level of generator, there are many
equipments.

4.14.2 Towing:
Do not forget that while towing generator with trailer, weight of trailer
may affect the manoeuvre and stopping distance.
WARNINGS
While towing the generator with trailer all traffic rules, standards
and other regulations
should be observed. Necessary hardware and speed limits expresses
explicitly in the regulations
are included. Do not allow personnel to travel on the mobile generator.
Do not allow personnel to stand on the towing bar or between
mobile generator and wrecker.
Avoid barriers such as slopped and soft land and hole, stone, etc.
Make sure that ground behind the mobile generator and under it
are clean while manoeuvring backwards.

WARNINGS
While working at generator site, please wear headphone.
4.13.1 Exhaust silencer:
Exhaust silencer reduces the sound level coming from the motor
(section 4.8).
4.13.2 Cabins:
Sound isolation cabins reduce loudness level of generator.
4.13.3 other sound silencer:
Other equipment such as Sound louvers, fan silencer, sound absorbing
walls can be used indoors. They reduce the loudness level of generator.

4.14.3 Parking:
Park generator with trailer on a dry ground to be able to bear the
weight of generator. If it is parked on a slopped ground, park as
crossed to the slope to prevent its being towards downward. Do not
park on a ground that exceeds 15.

4.14 TOWING OF GENERATOR WITH TRAILER


4.14.1 Preparation for towing:
All connection elements on wrecker and generator should be checked
30

Table 4.6 Cable selection table as per the Generator power

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

31

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


4.15 STORAGE
Long term storage of Motor and alternator may have harmful effects.
These effects can be reduced minimum via preparing and storing
generator in proper way.

5. MAINTENANCE OF GENERATOR
A good maintenance program extends service life of generator.
When and which maintenance should be performed on the generator
is indicated on periodic maintenance chart. Periodic maintenance
chart is provided with every generator. Maintenance and repairs
should be performed only by authorised and qualified service
personnel. Results of maintenance and repairs having performed
should be recorded on Periodic maintenance chart. Generally the
generator must always be kept clean. Do not allow materials such
as water, fuel and oil to accumulate in and on the generator. Always
keep clean ground of Generator.

4.15.1 Storage of Motor:


A motor protection procedure including cleaning motor and protective
liquids can be applied.
4.15.2 Storage of Alternator:
During Alternator storage, moisture occurs in the windings. In order
to reduce this moisture, store the generator in a dry place. To dry
the windings, if it is possible heat air. Alternator which has not been
used for prolonged time, must have insulation test.( section 4.12.8).

6. CONTROLS AND PROCESSES TO BE CARRIED OUT BEFORE THE


STARTING OF THE GENERATOR

4.15.3 Storage of battery:


The battery must be controlled every 8 week while storing, if necessary
it must be charged completely.

Examine motor and generator visually as general. Ensure easy air


suction to the generator site somewhere determined.
Look at the water level via opening radiator cap. If it is missing,
add some water. Water level should not ve 30 mm below water
filling gland.
Antifreeze must be available in cooling water of motor even as
per the coldest weather conditions of the region. Mixing of 50%
antifreeze and 50% water will ensure proper protection in every
region.
Please check the air filter indication. If need change to air filter
element.Keep opened window louvers of radiator.

4.16 MOTOR BLOCK WATER HEATING


For staring up the motor and taking the load on it, heater of block
(roundabout) water is used. The heater warms roundabout water
while generator is not working. For this reason, the heater must be
activated in every season. There are block water heater in generators
activating automatically. It is optional in manual generators.

32

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


If there is, remove foreign objects such as keys, tools, rag, paper,
etc. On he motor and alternator.
Check the fuel level in the daily fuel tank. If it is not enough, add
some fuel. Check the oil level of motor with the oil dipstick. If it is
insufficient add the proper oil. The oil must be close maximum specified
line.
Check if there are breaks, crack, torn, leakage, looseness. If there
is a failure, do not operate the generator until you remove the failure.
Make sure that circuit breaker output switch is on deactivated (OFF)
position.
Make sure that emergency stop button is not pressed.
If you use well-kept type battery, check the water level on the eye
via opening the battery cap. Fill the missing ones in such a way that
pure water will be 1 meter above from the separator. Never add
tap water, acidic water or acid to eyes.
Check the battery connection cables. Tighten the loose battery
post with wrench and keep clean the posts.
Check the shroud of radiator air output , if it is obstructed, unclog
it and move anything obstructing air flow.

Control panel enables operation of generator, stopping it, monitoring


of working condition and output voltage. Moreover it stops generator
automatically in case of low oil pressure, high motor temperature
and other failure conditions.
8.OPERATION OF THE GENERATORS
8.1. Operation instruction of automatic generator
8.1.1 Operation with DKG 307 Control panel:
1. Turn the automatic transfer device (DKG 307) located on the front
panel of generator to AUTO(automatic).
2. While network voltage is within normal limits, generator is in standby mode. If one of the network phases are cut or network voltage
drops excessively, the generator will step in and start feeding the
installation. In the event of turning of network voltage or entering the
usual limits, the system begin to feed from the network in two minutes.
The motor of generator Works for two minutes for its own cooling
and stops.

7.GENERATOR CONTROL SYSTEMS


8.1.2 Operation with EOAM 210FD-FL Control panel:
1. Turn the automatic transfer device (EOAM 210 FD-FL) located on
the front panel of generator to AUTO(automatic).
2. While network voltage is within normal limits, generator is in standby mode. If one of the network phases are cut or network voltage
drops excessively, the generator will step in and start feeding the

For controlling and monitoring of operation of generator, electronic


control systems are used. One of the Standard control systems can
be used as per the requirement of Generator. They are M 30 and
M 40 Model Manual Start control system and P 500 Model or P
2020 Model and P 2010 Full Automatic Start and control Systems.
33

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


8.2. Operation instruction of manuel generator

installation in 7-8 seconds. In the event of turning of network voltage


or entering the usual limits, the system begin to feed from the network
in two minutes. The motor of generator Works for two minutes for its
own cooling and stops.

1. Turn contact switch from '0' position to '1' position. (Figure 8.1)
2. Meanwhile, oil pressure failure and charge warning light will go
on.
3. Then turn starter switch to 'START' position (like starting up a car).
Motor of Generator will start working. After starting of motor, let
starter switch.
4. Check whether warning lights on the panel go on and values on
the indications are normal or not.
5. Operate the generator in idling status for about 1 minute. During
this period the motor will get heated.
6. Meanwhile, receivers (loads) on the installation must be turned
off. ,
7. Turn main switch to '1' position.
8. Turn inverter switch from NETWORK position to 'GENERATOR'
position.
9. Engage receivers one by one.
10. Check amperage and voltage on the phases via using amper
meter and voltmeter commutator.
11. Turn inverter switch to NETWORK when the network returns.
12. Operate generator at idle position for 1 minute to cool. Then
turn starter switch to 0 position.

8.1.3 Operation with AMF 4.0 Control panel:


1. Turn the automatic transfer device (AMF 4.0) located on the front
panel of generator to AUTO(automatic).
2. While network voltage is within normal limits, generator is in standby mode. If one of the network phases are cut or network voltage
drops excessively, the generator will step in and start feeding the
installation in 7-8 seconds. In the event of turning of network voltage
or entering the usual limits, the system begin to feed from
the network in a minute. The motor of generator Works for one minute
for its own cooling and stops.

8.3 Points to be noted while starting up:


It is important that load distribution on phases is balanced for both
manual and automatic remote control generator so as to ensure
Figure 8.1

34

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


operation of generator without problems. It is the user's responsibility
that load distribution among phases will remain between -/+ 15%
tolerance values. Failures resulting from insufficient and/or deficient
maintenance are not within the scope of guarantee.

The following are read on these indications :


- Measured parameters,
- Service counters,
- Statistical counters,
- Program parameters.

9. INTRODUCTION AND OPERATING INSTRUCTIONS OF


AUTOMATIC TRANSFER DEVICES:
9.1 DKG 307 Automatic Transfer Device:
The device is control and protection panel to be designed for used
in the generators. It shows values that it has measured on the screen.
Programmed parameters are stored on a nondeletable memory in
such a way that they will not be affected by power cut.
MEASURED PARAMETERS
Voltages between Network Phase-Neutral (R-N,S-N,T-N)
Voltages between Network Phase-Phase (R-S,R-T,S-T)
Voltages between Generator Phase-Neutral (U-N,V-N,W-N)
Voltages between Generator Phase-Phase (U-V,W-V,U-W)
Generator phase currents (I)
Generator phase voltage (V)
Generator phase power (W)
Generator frequency (Hz)
Generator total active power (kW)
Generator power coefficient (Cos )
battery voltage
Temperature of cooling water
Oil pressure
Introduction:
There are 3 pieces, 7 segment LED type indications on the device.

Figure 9.1
35

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

9.1.1.1 Digital Indications:

Value of Program parameter is read o this indication during program


position.

(1) VOLTAGE INDICATION:


Following values can be read on this indication:

(4)ALARM MUTE:
Alarm silencing.

- During operation from Network, (R) phase voltage


- During operation from Generator,(U) phase voltage

(5) MENU:
Browsing of measured values of indications can be done pressing
MENU key. If MENU key is held pressing for one second, service
counters are accessed.

By pressing MENU button, following values can be read separately:


- Voltages between (R-S-T) network phase-neutral
- Voltages between (U-V-W) generator phase-neutral
- Voltages between (RS-ST-TR) network phase -phase
- Voltages between (UV-VW-WU) generator phase-phase
If service counters are read, the name of counter is read on this
indication.
At programming location, (PGM) is read.

(6) LAMP TEST:


Lamp test.
(7) AUTO:
When pressed Auto key, the generator changes to automatic operation
mode and LED on the upper side lights. When this key is pressed,
generator operates automatically when network electricity is cut and
when it returns, it stops.

(2) CURRENT INDICATION:


Measured over current transformer phase currents can be read on
this indication. Current
transformers between 10/5A and 9000/5A can be used by means
of programming. Program number is read here during program
position.

(8) OFF:
It is used for switching off generator whose switch off key is in
operation. While this key is pressed, generator does not step in
automatically.

(3) MULTI FUNCTIONAL INDICATION:


Following values can be read on this indication pressing MENU key.
- Generator frequency (Hz)
- Generator cos
- Generator active power (KW)
- oil pressure (bar)
- Temperature of cooling liquid (C)
- battery voltage (V DC)

(9) TEST:
Test key is for operating generator for the purpose of test when there
is network electricity. When Generator is operated with this key,
automatic control unit does not command connectors. When pressed
this key, LED on the upper side lights.
36

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


(10) LOAD TEST:
Load test is adjusted by authorised service dependent on the request.

STOPPING ERROR LED:


If motor does not stop at the end of adjusted stop period, it occurs.

(11) ALARM LEDs:


Alarms Works as per the first coming principle; according to this;
- If there is any alarm, next coming alarms and warnings are not
included in the process.
- If there is any warning, next coming warnings are not considered.

OVERLOAD LED:
It occurs exceeding programmed limits of one of the generator phase
current or active power of generator.
VOLTAGE LED:
It occurs in the event of exceeding limits of at least one of U-V-W
phase voltages.

Alarms can be of locking or non locking type as per the programming.


For locking alarms, alarm lights remains lighting even if the reason
of alarm has been eliminated and they prevent generator's working.
To delete alarms, any of working patterns is pressed (AUTO-OFFTEST-LOAD TEST)

LEVEL LED:
It is available with some models.
BATTERY LED:
It occurs when battery voltages exceeds programmed levels or
decreases below them. During the starter, this error is not controlled.

OIL LED:
It goes on when motor oil pressure goes down a dangerous level.
If this LED goes on while the generator is not working, oil pressure
switch may be defective.

CHARGE LED:
It lights up in case of failure of charge alternator or belt breaking.

HEAT LED:
It occurs when a signal comes from excessive temperature contact
or when measure value at temperature switch exceeds the adjusted
limit.

RECTIFIER FAILURE LED:


It occurs when signal comes from rectifier failure inlet.
EMERGENCY STOP LED:
It occurs when he signal comes from emergency stop contact.

FREQUENCY LED:
It occurs resulting from exceeding programmed limits of Generator
circuit. (over speed /under speed)

SPARE LED:
It occurs when the signal comes from any of spare failure contacts.

STARTER FAILURE LED:


If generator does not operate at the end of programmed starter
number, this alarm occurs.

SERVICE TIME LED:


This LED is used for helping to perform periodic service of generator
regularly. Periodic service is carried out when a certain motor time
37

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


has completed.

Generator power factor (pF)

LED indications: There are 29 LEDs within 4 group on the device.


- Group 1: Working way: It shows function of the Generator.
- Group 2:Mimic diagram: it shows status of Network and generator
voltages and connectors.
- Group 3: Warnings and alarms: It shows abnormal conditions
experienced during working.
- Group 4: unit: It indicates the unit of value shown on the lower
indication.

Engine RPM
Real Time
Error mesages
Battery voltage
Coolant temperature
Oil pressure

9.1.2 EOAM 210 FD-FL Automatic Transfer Device:


The device is a control and protection panel designed to be used
in automatic generators. It show values that it has measured on the
display. Programmed parameters are stored on a nondeletable
memory in such a way that they will not be affected by power cut.
MEASURED PARAMETERS
Voltages between Network Phase-Neutral (R-N,S-N,T-N)
Voltages between Network Phase-Phase (R-S,R-T,S-T)
Voltages between Generator Phase-Neutral (U-N,V-N,W-N)
Voltages between Generator Phase-Phase (U-V,W-V,U-W)
Generator phase currents (I)
Generator phase voltages (V)
Generator phase power (W)
Generator frequency (Hz)
Generator kVAh
Generator Kwh
Generator kVAr
Charge generator voltage

EOAM 210 FD
Figure 9.2
38

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


Introduction:
(1) The red LED indicates that Mains voltage is displayed.

(14) The red LED shows that the unit is in the MANUEL mode.

(2) The red LED indicates that Generator voltage is displayed.

(15) This button indicates that Mains or Generator voltage is displayed


voltages.

(3) The green LED indicates that Mains voltage and frequency is
within limits and is ready to take over the load.

(16) This button selects either Phase-Neutral or Phase-Phase voltages.

(4) The LED shows that the load is connected to the mains. It's colour
is green.

(17) This button closes the mains contactor, only operative when
manuel mode is selected.

(5) The LED shows that the load is supplied from the generator. It's
colour is green.

(18) This button opens the mains contactor, only operative when
manuel mode is selected.

(6) The green LED indicates that Generator voltage are within limits
and is ready to take over the load.

(19) This button closes the generator contactor, only operative when
manuel mode is selected.

(7) The green LED indicates that the engine has started and is running.

(20) This button opens the generator contactor, only operative when
manuel mode is selected.

(8) In the MAN, AUTO and TEST modes, this LED indicates that the
engine has starting up or is running.

(21) The START button is used for starting the engine when the unit
is in manuel mode.

(9) In the MAN, AUTO and TEST modes, this LED indicates that the
engine has stopping or stopped.

(22) The STOP button is used for stopping the engine when the unit
is in the manuel mode.

(10) The red LED illuminates only when the unit in the programming
mode.

(23) When this button is pressed, the unit goes into its programming
mode.

(11) The red LED shows that the unit is in the OFF mode.
(12) The red LED shows that the unit is in the AUTO mode.

(27) The LAMP TEST button illuminates all LED indicators and display
segments.

(13) The red LED shows that the unit is in the TEST mode.

(28) This button will silence the alarm horn after a failure has been
39

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


detected.

MEASURED PARAMETERS

(29) This button will reset the controller after a failure has been
detected.

(32) The TEST button is used for changing operating mode of the
unit to the TEST mode.

Voltages between Network Phase-Neutral (R-N,S-N,T-N)


Voltages between Network Phase-Phase (R-S,R-T,S-T)
Voltages between generator Phase-Neutral (U-N,V-N,W-N)
Voltages between Generator Phase-Phase (U-V,W-V,U-W)
Generator phase currents)
Generator phase voltages(V)
Generator phase power (W)
Generator frequency (Hz)
battery voltage
temperature of cooling water
oil pressure

(33) The MANUEL button is used for changing operating mode of


the unit to the MANUEL mode.

Introduction:

(35-36-37) The display shows LOAD Amp.

(1)pre-heating:

(38) The display shows Mains or Generator voltages.

When motor is not starting under cold weather conditions, it is tried


to start motor via performing pre-heating.

(30) The OFF button is used for changing operating mode of the unit
to the OFF mode.
(31) The AUTO button is used for changing operating mode of the
unit to the AUTO mode.

(39) Failure indicators.

It operates when only in manual mode and motor is stopping.

9.1.3 AMF 4.0 Automatic Transfer Device:

(START) Starting button:


It is used for providing starting for motor. It operates only in manual
mode and when motor stops. Str is written on the screen during
the starting time of panel.

It a microprocessor-controlled device that monitors one or three-phase


network voltage, transfers load between network and generator and
controls of failure. When holding pressed of Menu key for 3 sn, 98
parameters related with the operation of the device are adjusted
digitally and stored in the memory separately.

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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

(3) Network contactor:


It controls the contactor that enables the load to be fed by the network.
If LED is going on it means that contactor is off and load is feeding
from network.
NOTE: Generator contactor is locked electrically with network
contactor. Both of these contactors can not be turned off at the same
time.
(4) Generator Status LED:
When it goes off it means that generator is stable.
When it goes on it means that generator is working. If LED is flashing,
it means that generator is in the period of cooling and stopping.
(5) Network Status LED. :
When it does not go on, it means that network voltage has exceeded
the limits indicated with parameters. When it goes on it means that
network is within normal values.
If LED is flashing, it means delay times when network passes from
normal statutes to network failure or from failure to normal status.

Figure 9.3
(STOP) Stopping button:
It is used for the purpose of stopping Motor. It is not matter in which
mode is used, when it is pressed, it takes generator to manual mode
and begins to cooling if generator has taken load before of if the
load has not been taken it starts stopping process. During cooling,
if stop key is pressed done more generator will stop.

(6) Failure LEDs:


Detailed information about these failures are provided in the following
sections.
(7) Analog oil pressure and over heating indications:
In this part, values read by indication points of oil pressure and
overheating switches are printed on the screen as bar graphics in
such a way that the user can easily see.For overheating, the dial
starts from 50 C to 100 C, for oil pressure the dial can go the highest
value that the switch can be read from starting low oil pressure failure
level adjusted in parameters.

(2) Generator Contactor:


It provides transferring of produced energy to the load after Generator
has began to work. The status of contactor is indicated via LED on
it. If LED is going on, contactor is off and it means that load is feeding
from generator. To be turned off contactor of network needs to be
on.
41

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


(8) Measurement mode selection button:
It selects if frequency and voltage values shown on 2 screens will
belong to generator or network. It indicates that whether measurement
values shown via LEDs next to it belongs to network 'MANS' or
generator 'GEN'.

selection mode will start flashing when these keys are pressed for
the first time. When it is pressed for the second time the value of
indication is changed. To change th indication in the selection mode,
menu key should be pressed while LED next to the indication is
flashing. After switching one of the parameters on the parameter
menu via pressing ENTER key to adjustment mode, every order of
Parameter value can be adjusted the desired number with the help
of up/down keys.

Esc Key:
This button has many functions.
In the event of failure, horn is silenced at the first pressing. At the
second pressing failure is deleted. It is used for exiting from parameter
menu.
For this process, it needs to be held pressed for 3 seconds.
If the value entered during changing of any parameter in parameter
menu, it is cancelled via this key.

(9) Selection of working mode button:


The system can be operated as manual (hand symbol), automatic
(letter A) or test mode via three keys located at the right of Panel. The
mode of system can be seen via LED next to it.
FAILURE AND WARNINGS:

(ENTER) Menu Key:


This button has many functions.
It provides selection of values to be shown on the indications at the
left side of panel. Under normal operating status, when menu key
is pressed for the first time LED next to the indication in the selection
mode will start flashing. Then value to be shown on this indication
will be changed via down/up keys. It provides entering parameter
menu.
It is used for changing any values on the parameter menu.

Low High speed failure: This failure occurs when


alternator goes out of limits of frequency of electricity
that it has produced.
Low High speed Voltage failure: This failure occurs
when electricity produced by the alternator goes out
of the voltage values.
Overheating Failure:

(+,-) Up, Down keys:


Under normal operating condition, LED next to the indication in the
42

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


Over current Failure:
Periodic service time warning: This warning is provided
when adjusted after resetting of service time periodic
service time has passed. Resetting process is done
by the service.
Stop working Failure: It means that when this failure
occurs generator has not been starts up or stopped.
During the starting up generator, if oil pressure, charge
or alternator voltage are perceived, oil pressure,
charge or low high voltage LED go on together with
stop working failure LED. So, the user can understand
generator does not work due to the signals.

Active functions in the system is emergency stop inlet and water level
failure inlet. In the event that emergency stop button is pressed A3
is written on the indication and AUX failure LED goes on. In case
of a failure in radiator water level, the indication writes A4 and AUX
LED goes on.

Low oil pressure Failure:

(23) Working hour: It shows how many hours your set has worked.

Charge Failure: This failure occurs in the event that


voltage in the end f charge failure of charge alternator
drops.

(24) emergency Stop Button: It provides your set to be stopped


immediately in case of emergency. It should not be used except
emergency. After performing stopping via pressing the button, getting
back should be provided via turning slightly right.

Devices of control panel:

(22) Charge warning lamp: When lamp turns on it means that


battery charge alternator charges less than
normal and there is a problem.

NOTE: The button is located on the cabin at sets with cabin.

Battery Voltage low high Failure: It occurs when


battery voltage goes down or up adjusted limits.
Spare failure LED: If functions of spare inlet are
selected as yellow or red, this failure occurs
when the inlet is active.

43

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


10. LOCATION AND INSTALLATION OF FORCE PANEL
The points to be noted during the installation ot force panel (transfer
switch) are stated below.
1. Mount the force panel as close as main distribution panel.
2. The panel should be located in place which is clean, dry, wellventilating and far away from excessive heat.
3. there should be enough working space around the panel. Covers
of panel must be easily opened and panel should be easily interfered.
4. Values of currents drawn from generator should be distributed to
three phases equally as much as possible. Maximum difference
between phases must be 15%.
5. current bearing capacities of force cables to be used for generators
are indicated on table 4.6.
6. In order to function properly, operation connection of generator
must be performed correctly. The pattern of this connection is shown
at Figure 10.1. there are two cable entries to the panel. One of
them is network entry for the control of network and the other one
is the output of generator. Network line from meter output or if any
network line from compensation panel are transmitted to the receiver
over network. Connecting of generator after the meter should be
noted.

Figure 9.4
44

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

11. ALTERNATOR FAILURES AND REPAIR


FAILURE:
Alternator does not produce voltage.
CAUSE:
a)Loss of residual magnetism at Stator windings.
- If alternator warning is without winding, contact the same poles of
dry battery of 9.5 V to + and - poles of connector at the connector
poles numbered 2 and 3 for 5 seconds.
If Alternator warning is of winding, contact the same poles of dry
battery of 9.5 V to + and - poles of connector at the connector poles
numbered 1 and 4 for 5 seconds.
b)There are loose contact at panel and connector connections.
-Opening cover of panel, control whether cable ends have pulled
out or not and in the same manner, control whether connector ends
have pulled out or not.
c)There is disconnection at warning button.
- control all connections especially alternator series connector
connections.
d) There is failures at rotating diode.
-Test diodes one by one with diode parts of AVO meter and replace

Figure 10.1
45

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


damaged diodes.
FAILURE:
3-Voltage is increasing as the Alternator is loaded.

e)Cycle of drive machine is very low.


- Increase the cycle of drive machine to the nominal.

CAUSE:
f)Regulator card is defective.
-change the card that does not perform regulation.

a)There are motors rotating reversely in the circuit.


-Replace the location of Generator output cables.

FAILURE:
FAILURE:
2-Voltage drops as Alternator is being loaded.
4-Voltage of Generator is very high.
CAUSE:

CAUSE:

a)Regulator card is defective.


- Adjust regulator potentiometer and output voltage to 400 V at idling.
After this adjustment, if voltage decreases as loaded, replace the
card.

a)One of ends of regulator experiencing phase is disconnected.


-control connector connections.
b)There is disconnection at Voltage adjustment potentiometer.
-Control the ends of potentiometer.

b) Cycle drop of drive machine is very much.


-Control the power of drive machine.

c)Regulator card is defective.


-Replace the card that does not perform regulation.

c) It is loaded over Alternator power.


-do not load over nominal.
d)Rotating diodes are defective.
-Control diodes with AVO meter. Replace the defective ones.

FAILURE:
5-Voltage is not read from one or two phases.
46

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


a)Regulator card does not perform regulation function.
- Replace the regulator card.

CAUSE
a)There are disconnections at the end of Voltage control commutator.
-Control the ends of commutator.

b)There are short-circuit at windings.


-Control windings with AVO meter via opening connector box. If
there is resistance difference, it means that there is short-circuit.

b)There is disconnection at Stator windings.


- opening cover of connector box, remove the star connection bridge.
Control short-circuit or disconnection among windings.

c)One or more of bridge diodes are defective.

FAILURE:
12. FAILURES OF DIESEL MOTOR AND REPAIRS
6-Windings heat excessively.
Possible motor failures and their causes are stated below.
CAUSE:
Starter motor revolves diesel slowly
Battery has no charge
Contact of battery cables is poor
Starter motor is defective
Viscosity grade of lubricating oil is wrong

a)Generator is loaded over nominal.


-operate at Nominal load.
b)There may be short-circuit among windings.
-Perform short-circuit control among windings at connector box.

Oil pressure is very low


Viscosity grade of oil is wrong
There is not enough oil in the crankcase
Pressure indication is defective
Oil filter is defective

FAILURE:
7-There is undulation at output voltage of Generator.
CAUSE:

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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


Oil pressure indication is defective
Blue or white exhaust fume

Motor does not provide enough power

Viscosity grade of oil is wrong


Heater is defective
Diesel motor is cold
Valve adjustment out of order
Fuel advance adjustment out of order

Diesel motor Works hard or does not work

Starter motor revolves diesel hard.


Fuel tank is empty
Fuel pipe is clogged
Fuel control solenoid is defective
Fuel filter is dirty
Heater does not function
Exhaust pipe is clogged
Third-class fuel
Fuel tank ventilation is clogged
Fuel leading pump is defective
Injections are defective or their adjustment is out of order
Oil sensor connection is defective

Fuel pipe is clogged


Fuel filter is dirty
Air filter is dirty
There is air in Fuel system
Third class fuel
Exhaust pipe is clogged
Fuel leading pipe is defective
Governor is defective
Motor heat is high
Motor heat is low
Injections are defective or their adjustment is out of order
Fuel tank ventilation is clogged
Fuel advance adjustment out of order

Motor functions irregularly

Oil pressure is very high


Viscosity grade of oil is wrong
48

Fuel pipe is clogged


Fuel governor is defective
Fuel filter is dirty
Fuel pump is defective
Air filter is dirty
There is air at fuel system

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

Injections are defective or their adjustment is out of order


Fuel tank ventilation is clogged
Valve adjustment is out of order
Motor heat is very high
Heater system is defective
There is resistance in the action of Fuel governor

Motor heat is very high

Fuel filter is dirty


There is air at fuel system
Fuel pump defective
Motor heat is very low
Valve adjustment is wrong
Injections are defective or their adjustment is out of order
Heater is defective
Oil sensor or its connection is defective

There is knocking in the motor

Exhaust pipe is clogged


Cooling fan is damaged
Radiator core is dirty or pipe is clogged
Cooling system is insufficient
Air filter or pipe is clogged
Injections are defective or their adjustment is out of order
Heater system is defective
The oil level in the crankcase is low
Water to cool level is insufficient

Valve adjustment is out of order


Injector is defective or its adjustment is out of order
There is failure at Fuel pump
Third-class fuel
Motor heat is very low
Heater system is defective

Fuel consumption is very much


Crankcase pressure is high

Crankcase ventilation pipe is clogged


Valve adjustment out of order
Ignition (in case of not working)
Fuel pipe is clogged
49

Air filter is dirty


Fuel is third-class
Exhaust pipe is clogged
Heater system is defective
Valve adjustments are wrong
Motor temperature is very low
Injections are defective or their adjustment is out of order

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


Exhaust fume is black

Air filter is dirty


Motor is overloaded
Fuel is third-class
Exhaust pipe is clogged
Motor heat is very low
Valve adjustment is out of order
Injection is defective or its adjustment is out of order

Vibrating operation

Fan is damaged
Fuel governor has difficulty in its movements
Injection is defective or its adjustment is out of order
Motor heat is very low

Motor stops after functioning

There is air at fuel system


Fuel filter is dirty
Air filter or suction system is clogged
Oil sensor or its connection is defective
Stop solenoid conservative bobbin is defective

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DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


13. PERIODIC MAINTENANCE INSTRUCTION

51

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

DEAR EMSA GENERATOR USER;


PLEASE NOTE FOLLOWING POINTS TO ENSURE THAT YOUR GENERATOR WILL NOT BE VOID OF GUARANTEE BEFORE ITS TIME,
FUNCTION PROPERLY AND BE LONG-LIVED.
1. TRANSACTIONS PERFORMED WHEN GUARANTEE DOCUMENT OR INVOICE ARE NOT PRESENTED WILL NOT BE INCLUDED
WITHIN THE SCOPE OF GUARANTEE.
2. THE WARRANY IS VALID ONLY FOR SPARE PARTS AND THE PERIOD IS FOR 1 YEAR OR 1000 HOURS RUNNING TIME FROM
THE DATE OF DISPATCH. THE WARRANTY IS INVALID IN CASE OF GENERATOR IS INTERFERED BY OTHER PERSON THAN EMSA
AUTHORISED SERVICES FOR ANY REASONS.
3. CHECKS AND MAINTENANCE STATED ON THE PERIODIC MAINTENANCE CHART MUST BE PERFORMED ON TIME AND
COMPLETELY. FAILURES RESULTING FROM NOT HAVING PERFORMED PERIODIC MAINTENANCE ARE NOT WITHIN THE SCOPE
OF GUARANTEE. INSTALLATION OF THE GENERATOR MUST BE PERFORMED AS STATED IN THE MANUAL. IF NOT,
PROBLEMS TO OCCUR WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE.
4. THE CUSTOMER WILL BE RESPONSIBLE FOR FAILURES RESULTING FROM DIRTY AND WATERY FUEL.
5. OIL SELECTION OF MOTOR SHOULD BE IN ACCORDANCE WITH THE ONE STATED IN THE MANUAL. OTHERWISE, FAILURES
TO OCCUR WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE.
6. BATTERIES DO NOT REMAIN UNDER WARRANTY IN CASE OF BREAKING, EXCESSIVE ADDITION OF ACID, HARDENING DUE
TO NOT CHARGING.
7. DO NOT START UP OR STOP DIESEL MOTOR WHEN GENERATOR IS UNDER LOAD IN
MANUAL GENERATORS. STARTING AND STOPPING MUST BE PERFORMED AFTER LEAVING OF LOAD, WHEN GENERATOR
IS IDLED. OTHERWISE, COMPRESSIONS MAY OCCUR IN THE VALVES. THIS CAUSES DAMAGES IN VOLTAGE REGULATOR,
TRANSFORMER AND DIODES. THESE CONDITIONS ARE NOT UNDER WARRANTY.
8. OUR COMPANY IS NOT RESPONSIBLE FOR FAILURES RESULTING FROM OVER CURRENT, LOW AND HIGH VOLTAGE TO
OCCUR IN THE NETWORK CONTACTOR USED IN AUTOMATIC GENERATORS.

52

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

RESPONSIBILITIES OF CUSTOMER
1. The customer of EMSA GENERATOR must not allow unauthorised service or person except services of Emsa Generator to interfere
with his generator under spare part warranty. Such an interference will cause to invalidate of generator spare part guarantee.
2. Commissioning of generators purchased must be performed by Emsa Generator authorised services. If the customer performs start
process himself or gets it performed by another service, this causes invalidation of guarantee. Commissioning process performed via
controlling working conditions of generator (installation, mounting, electrical connections, cable cross sections, ventilation, exhaust
output, fuel channel, etc.) is valid only for the location where commissioning has been performed and point where electrical connections
have been carried out. In case of requesting to change the location where the first start has been carried out, since working conditions
of generator dependent on the environment will change, it must be commissioned by Emsa Generator authorised services via controlling
for continuance of guarantee period and efficient working of generator.
3. Entire maintenance indicated on periodic maintenance chart of all our generators should be performed by Emsa Generator authorised
services within the guarantee period. Maintenance chart and maintenance booklets pertaining to the generator are handed over the
customer with the generator. In the event of losing maintenance manual and chart in question the customer is responsible for obtaining
them again.
4. The customer will cover prices for repairing of all maintenance, failures and problems except manufacturing defect.
5. Maintaining of the generator under proper conditions including failures resulting from negligence, misusing, unloading responsibility
(after the delivery of on the track until commissioning (start) process) will be the responsibility of the customer.
6. For deliveries on the trucks, maintaining of the generator under proper conditions including shipping responsibility, unloading (after
the delivery of on the track until commissioning (start) process) will be the responsibility of the customer.
7. If the generators purchased are not commissioned within 2 months, it can be waited provided that storage conditions related with the
generator in question are ensured. You may obtain information about storage conditions of your generator from Emsa Generator
Authorised services. It is imperative to get Emsa Generator performed the storage processes (conservation) of a generator within the
guarantee period.
8. Overtime pay of a service personnel who furnishes guarantee service if requested by the customer, will be paid by the customer.
9. Prices resulting from entries built for accessing the generator, barriers, walls, parapets, bases, ceilings, decks and structures like these,
53

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL


hired hoists or similars, ramps or similars, wrenches or taking of generator completely or securing of the generator will be met by the
customer.
10. The customer has the right to ask and inquire the authority of the personnel coming for the service. This is at the same time responsibility
of the customer.
12. The customer is obliged to show the guarantee certificate and start form of the generator to the service authorities to obtain guarantee
service. Thus, these documents in question should be maintained in the generator room and in an easy-to reach place.
13. In the event of changing operation place of a generator being under guarantee, to ensure the continuance of the guarantee commissioning
process should be demanded from Emsa Generator authorised services after the installation of generator in the new place. Place
changing and commissioning to be carried out by the unauthorised person cause the generator to be excluded from the guarantee.
The price of second commissioning will be covered by the customer.
14. The customer is responsible for ensuring dimensions of generator room to conform with the norms, sufficient ventilation, and exhaust
output.
15. The damages resulting from not added of chemicals that need to be added so as to prevent pitting in cooling systems, cylinder liner
or block, erosion and deposit will be the responsibility of the customer.
16.Addition hardware and projects except original equipment and Project can not be applied to generators purchased within the spare
part guarantee period. If additional Works planned to perform (synchronous, additional control unit, transfer panel, etc. ) are carried
out without the approval of Emsa Generator, the spare part guarantee will be invalidated.
17. For all our generators under spare part warranty, original spare parts of Emsa Generator should be used. In the event of not using
original parts, all damages will be under the responsibility of the customer.
18. Emsa Generator is not responsible for the failures resulting from excessive current drawing than generator nominal current over the
network contactor selected proper for the power of generator.
19. Failures to occur in the generator resulting from the environmental effects are not under spare part warranty. For example, earthquake,
flood and similar natural disaster.
20. Network low and high limits for our all generators are determined on the basis of values that our generator and plant that the customer
have will function well. In the event of requesting of customer to change Network voltage limits, these changes can be performed
provided that a report will be written that shows failures resulting from these changes will be the responsibity of customer.

54

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

NOTES

55

DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL

NOTES

56

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