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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
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
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.
WARNINGS
Perform the electrical connections as per the relevant standards.
Grounding and grounding failures are included in these standards.
Please make sure that fuel storage systems for generators are
mounted in accordance with relevant codes, standards and other
requirements.
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).
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.
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.
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
2.6 NOISE
WARNINGS
Wear headphone while working in the generator site.
2.7 ELECTRICAL
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.
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.
BREATHING
Control whether the survivor is breathing or not
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.
WARNING
Do not give liquids such as water until the survivor
has gained his consciousness again.
3. GENERAL DEFINITION
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.
5
2
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
4.2 CABIN
4.1 GENERAL
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.
-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.
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.
18
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.
Table 4.2 Fuel tank capacities pertaining to Generator groups and fuel
consumption at full load.
20
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.
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.
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
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
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
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.
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
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.
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.
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
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.
31
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.
32
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.
34
Figure 9.1
35
(4)ALARM MUTE:
Alarm silencing.
(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.
(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.
(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
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.
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.
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.
Engine RPM
Real Time
Error mesages
Battery voltage
Coolant temperature
Oil pressure
EOAM 210 FD
Figure 9.2
38
(14) The red LED shows that the unit is in the MANUEL mode.
(3) The green LED indicates that Mains voltage and frequency is
within limits and is ready to take over the load.
(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
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.
Introduction:
(1)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.
40
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.
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.
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.
(23) Working hour: It shows how many hours your set has worked.
43
Figure 9.4
44
Figure 10.1
45
CAUSE:
f)Regulator card is defective.
-change the card that does not perform regulation.
FAILURE:
FAILURE:
2-Voltage drops as Alternator is being loaded.
4-Voltage of Generator is very high.
CAUSE:
CAUSE:
FAILURE:
5-Voltage is not read from one or two phases.
46
CAUSE
a)There are disconnections at the end of Voltage control commutator.
-Control the ends of commutator.
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
FAILURE:
7-There is undulation at output voltage of Generator.
CAUSE:
47
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
50
51
52
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
54
NOTES
55
NOTES
56