INSTALLATION RECOMMENDATIONS

&
OPERATION MANUAL
OF DIESEL GENERATING SETS

Dear Aksa Generating Set Operator

First of all, we would like to thank you for your choice of Aksa Power
Generator.
This operating and maintenance manual is designed and developed to
make you familiar with the generator system.
This manual gives general information about mounting, operation and
maintenance of the generating set. Tables and diagrams are also available
outlining your generating set.
Never operate, maintain or repair your generating set without taking
general safety precautions.

CONTENTS
1. INTRODUCTION.........................................................................................

2. SAFETY .......................................................................................................
2.1
General ...........................................................................................
2.2
Installation, Handling and Towing .........................................................
2.3
Fire and Explosion ..................................................................................
2.4
Mechanical ..........................................................................................
2.5
Chemical ................................................................................................
2.6
Noise .....................................................................................................
2.7
Electrical ................................................................................................
2.8
First aid For Electric Shock ...................................................................................

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3. GENERAL DESCRIPTION.....................................................................................
3.1
Generating Set Description and Identification......................................
3.2
Diesel Engine .........................................................................................
3.3
Engine Electrical System .......................................................................
3.4
Cooling System ......................................................................................
3.5
Alternator ..........................................................................................
3.6
Fuel Tank and Baseframe ......................................................................
3.7
Vibration Isolation .................................................................................
3.8
Silencer and Exhaust System ...........................................................
3.9
Control System ..................................................................................

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4. INSTALLATION, HANDLING AND STORAGE...........................................

4.1
General .................................................................................................
4.2
Canopies ......................................................................................
4.3
Location ................................................................................................
4.4
Moving the Generating Set ................................................................
4.5
Foundations Vibration Isolation ...................................................
4.6
Combustion Air Inlet ...........................................................................
4.7
Cooling and Ventilation ......................................................................
4.8
Exhaust ..................................................................................................
4.9
Fuel System ..........................................................................................
4.9.1 Day Tank ....................................................................................
4.9.2 Bulk Storage Tank .......................................................................
4.9.3 Fuel Lines ..........................................................................................
4.10
Lubrication Oil ...................................................................................
4.10.1 Oil Performance Properties .......................................................
4.10.2 Lubrication Recommendations for Cummins Engines.............
4.10.3 Recommended Oil Properties for Perkins Diesel Engines........
4.10.4 Lubrication Oil Recommendations by Lister Petter
4.10.5 Lubrication Oil Recommendations by Deutz ...........................................
4.10.6 Lubrication Oil Recommendations by Volvo Penta .........................
4.10.7 Lubrication Oil Recommendations by MTU ..................................
4.11
Batteries ..............................................................................................................
4.11.1 Maintenance Batteries ..........................................................................
4.11.1.1 First Filling of Acid Water to The Battery ....................................
4.11.1.2 Battery Maintenance .....................................................................
4.11.1.3 Testing the Battery.............................................................................................
4.11.1.4 Hydrometer Test ........................................................................................
4.11.2 Maintenance Free Batteries..........................................................................
4.12
Electrical Connection .......................................................................................
4.12.1 Cabling ...................................................................................................
4.12.2 Protection ......................................................................................................
4.12.3 Loading ................................................................................................................
4.12.4 Power Factor .......................................................................................................
4.12.5 Grounding / Earthing Requirements ............................................
4.12.6 Alternator Reconnection ...... .............................................................
4.12.7 Parallel Running .....................................................................................
4.12.8 Insulation Test ........................................................................................
4.13
Acoustic Silencing................................................................................
4.13.1 Exhausts Silencers .....................................................................
4.13.2 Canopies ..........................................................................................................
4.13.3 Other Sound Attenuation...................................................................
4.14
Engine Jacket Water Heater.........................................................

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Towing (Mobile Generating Sets)..........................................

4.15.1 Preparing to Low ........................................................................
4.15.2 Towing ....................................................................................
4.15.3 Parking .....................................................................................
Storage.....................................................................................
4.16.1 Engine Storage .........................................................................
4.16.2 Alternator Storage ...................................................................
4.16.3 Battery Storage ...................................................................

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5. GENERATING SET MAINTENANCE ...............................................................

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6. GENERAL PRECATIONS AND CONTROLS WHICH MUST BE DONE

BEFORE STARTING UP THE GENERATING SET ........................................

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7. GENERATING SET CONTROL SYSTEMS .............................................................

7.1 Starting with ME 40 Manual Control Panel ...................................................................
7.2
Starting with P 500 Automatic Control Panel ..........................................................
7.2.1 Manual Operation .......................................................................................................
7.2.2 Automatic Mode of Operation.........................................................................
7.3
Starting With P 2010 Autostart Control Panel ....................................................
7.3.1 Manual Operation .......................................................................................................
7.3.2 Automatic Mode of Operation .........................................................................
7.4
Starting with P 2020 Automatic Control Panel .....................................................
7.4.1 Manual Operation ..........................................................................................
7.4.2 Automatic Mode of Operation .....................................................................
7.4.3 Test Operation ............................................................................................................
8. GENERAL PRECATIONS AND CONTROL WHICH MUST BE DONE
AFTER STARTING UP THE GENSET ...........................................................................
9. STOPPING THE GENERATING SETS .......................................................................
9.1 At Manual Models ........................................................................................
9.2 At Automatic Models ..................................................................................................
10. GENERATING SET CONTROL SYSTEMS ...............................................
10.1 Control Panels ..................................................................................................
10.1.1 Manual Control System ME40................................................................
10.1.1.1 DSE 701 Module Features ...............................................................
10.1.1.2 DSE 701 Module Emergency Leds ...............................................................
10.2.1 Automatic Control System P 500 ................................................................
10.2.1.1 DSE 704 Module Features ................................................................
10.2.1.2 Status and Fault Conditions Displayed by LED illumination
10.3.1 Automatic Control System P 2020 Panel Specification .................
10.3.1.1 DSE 5220 Module Features ................................................................
10.4.1 Autostart Control System P 2010 Panel Specification .................
10.4.1.1 DSE 5210 Module Features ..............................................................................
10.5. Panel Equipments .....................................................................................
10.5.1 AC Voltmeter ......................................................................................................
10.5.2 Voltmeter Selector Switch .....................................................................................
10.5.3 AC Ampermeter ......................................................................................................
10.5.4 Frequencymeter ......................................................................................................
10.5.5 Hoursrunmeter ......................................................................................................
10.5.6 Water Temperature Gauge ....................................................................
10.5.7 Oil Pressure Gauge .................................................................................................
10.5.8 Emergency Stop Pushbutton .............................................................................
10.5.9 Alternator Protection ............................................................................................
11. THE PLACEMENT AND INSTULATION OF TRANSFER SWITCH .....
12. DSE 530 MODEL FULL AUTOMATIC TRANSFER SWITCH CONTROL
SYSTEM ....................................................................................................................
12.1 Automatic Mode of Operation ..........................................................
12.2 Manual Restore Mode of Operation ..........................................................
12.3 Manual Operation...................................................................................................
12.4 Indications ....................................................................................................................
13. ALTERNATOR TROUBLESHOOTING................................................................
14. ENGINE TROBLESHOOTING...........................................................................

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4.15

4.16

II

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1. INTRODUCTION
Care should be taken to perform more
frequent maintenance in dirty and dusty
environments in order to keep the generating
set in good working condition.
Necessary adjustments and repairs should
be made only by authorized and qualified
persons.
Each generating set has a model and a serial
number indicated on a label on the base
frame. This plate also indicates the
manufacturing date, voltage, current, power
in kVA and kW, frequency, power factor
and weight of the generating set. These datas
are necessary in spare part orders, for
warranty validity and for service calls.

Aksa Generating set is designed to be

commissioned, when delivered, as soon as
the necessary cooling water, antifreeze, fuel,
lubrication oil and fully charged battery are
provided.
With its long years of experience, Aksa
manufactures efficient, reliable and quality
generating set.
This operating and maintenance manual is
prepared to assist the operator in operation
and maintenance of the generating set.
Observing the advices and rules in this manual
will ensure that the generating set operates
in maximum performance and efficiency for
a long time.

Figure 1.1 AKSA Generating set label

2. SAFETY

2.1 GENERAL
The generating set is designed to be safe
when used in the correct manner. However
responsibility for safety rests with the
personnel who install, use and maintain the
set. If the following safety precautions are
followed, the possibility of accidents will be
minimized. Before performing any procedure
or operating technique, it is up to the user
to ensure that it is safe. The generating set
should only be operated by personnel who
are authorized and trained.

! Engine exhaust emissions are hazardous to

personnel. The engine exhaust for all indoor

generating sets must be piped outdoors via
leak-free piping in compliance with relevant
Codes, Standards and other requirements.
Ensure that hot exhaust silencers and piping
are clear of combustible material and are
guarded for personnel protection per safety
requirements. Ensure that fumes
from the exhaust outlet will not
be a hazard.
! Never lift the generating set by
attaching to the engine or
alternator lifting lugs, instead use
the lifting points on the
baseframe or canopy.
! Ensure that the lifting rigging and supporting
structure is in good condition and has a
capacity suitable for the load.
! Keep all personnel away from the generating
set when it is suspended.

WARNING

! Read and understand all safety precautions and

!
!
!

!
!

warnings before operating or performing

maintenance on the generating set.
Failure to follow the instructions, procedures,
and safety precautions in this manual may
increase the possibity of accidents and injuries.
Do not attempt to operate the generating set
with a known unsafe condition.
If the generating set is unsafe, put danger notices
and disconnect the battery negative (-) lead so
that it cannot be started until the condition is
corrected.
Disconnect the battery negative (-) lead prior
to attempting any repairs or cleaning inside the
enclosure.
Install and operate this generating set only in
full compliance with relevant National, Local,
or Federal Codes, Standards or other
requirements.

2.3 FIRE AND EXPLOSION

Fuel and fumes associated with generating
sets can be flammable and potentially
explosive. Proper care in handling these
materials can dramatically limit the risk of
fire or explosion. However, safety dictates
that fully charged BC and ABC fire
extinguishers are kept on hand. Personnel
must know how to operate them.
WARNING

2.2 INSTALLATION,
HANDLING AND TOWING

! Ensure that the generating set room is

properly ventilated.

! Keep the room, the floor and the

Chapter 4 of this manuel covers procedures

for installation, handling, and towing of
generating sets. That chapter should be read
before installing, moving and lifting the
generating set or towing a mobile set. The
following safety precautions should be noted:

generating set clean. When spills of fuel,

oil, battery electrolyte or coolant occur,
they should be cleaned up immediately.
! Never store flammable liquids near the
engine.
! Do not smoke or allow
sparks, flames or other
sources of ignition around
fuel or batteries. Fuel
vapours are explosive.
Hydrogen gas generated by charging
batteries is also explosive.

WARNING

! Make electrical connections in compliance

with relevant Electrical Codes, Standards or

other requirements. This includes
requirements for grounding and ground/earth
faults.
! For stationary generating sets with remote
fuel storage systems, make sure such systems
are installed in compliance with relevant
Codes, Standards or other requirements.

2.5 CHEMICAL

! Turn off or disconnect the power to the

battery chargen before making or breaking

connections with the battery.
! To avoiding arcing keep grounded conductive
objects (such as tools) away from exposed
live electrical parts (such as terminals). Sparks
and arcing might ignite fuel or vapours.
! Avoid refiling the fuel tank while the engine
is running.
! Do not attempt to
operate the generating
set with any known leaks
in the fuel system.

Fuels, oils, coolants, lubricants and battery

electrolyte used in this generating set are
typical of the industry. However, they can
be hazardous to personnel if not treated
properly.

WARNING

! Do not swallow or allow skin contact with

fuel, oil, coolant, lubricants or battery

electrolyte. If swallowed, seek medical
treatment immediately. Do not induce
vomiting if fuel is swallowed. For skin contact,
wash with soap and
water.
! Do not wear clothing
that
has
been
contaminated by fuel or
lube oil.
! Wear an acid resistant
apron and face shield or goggles when
servicing the battery. If electrolyte is spilled
on skin or clothing, flush immediately with
large quantities of water.

2.4 MECHANICAL
The generating set is designed with guards
for protection from moving parts. Care must
still be taken to protect personnel and
equipment from other mechanical hazards
when working around the generating set.
!

WARNING
Do not attempt to operate the generating
set with the safety guards removed. While
the generating set is running do not attempt
to reach under or around the guards to do
maintenance or for any other reason.
Keep hands, arms, long hair, loose clothing
and jewellery away
from pulleys, belts
and other moving
parts.
Attention: Some
moving parts can not
be seen clearly when the set is running.
If equipped keep
access doors on
enclosures closed
and locked when not
required to be open.
Avoid contact with
hot oil, hot coolant, hot exhaust gases, hot
surfaces and sharp edges and corners.
Wear protective clothing including gloves
and hat when
working around the
generating set.
Do not remove the
radiator filler cap
until the coolant has
cooled. Then loosen the cap slowly to relieve
any excess pressure before removing the
cap completely.

2.6 NOISE
Generating sets that are not equipped with
sound attenuating enclosures can produce
noise levels in excess of 105 dBA. Prolonged
exposure to noise levels above 85 dBA is
hazardous to hearing.
!

WARNING
Ear protection must be
worn when operating or
working around an
operating generating set

2.6 ELECTRICAL
Safe and efficient operation of electrical
equipment can be achieved only if the
equipment is correctly installed, operated
and maintained.

WARNING

! The generating set must be connected to

the load only by trained and qualified

electricians who are authorized to do so,
and in compliance with relevant Electrical
Codes, Standards and other requlations.
! Ensure that the generating set, including a
mobile set is effectively grounded/earthed
in accordance with all relevant regulations
priorts operation.

OPEN THE AIRWAY

! The generating set should be shutdown with

!
!

!
!

the battery negative (-) terminal disconnected

prior to attempting to connect or disconnect
load connections.
Do not attempt to connect or disconnect
load connections while standing in water or
on wet or soggy ground.
Do not touch electrically
energized parts of the
generating set and/or
interconnecting cables
or conductors with any
part of the body or with
any non insulated conductive object.
Replace the generating set terminal box
cover as soon as connection or disconnection
of the load cables is complete. Do not
operate the generating set without the cover
securely in place.
Connect the generating set only to loads
and/or electrical systems that are compatible
with its electrical characteristics and that
are within its rated capacity.
Keep all electrical equipment clean and dry.
Replace any wiring where the insulation is
cracked, cut, abraded or otherwise degraded.
Replace terminals that are worn, discolored
or corroded. Keep terminals clean and tight.
Insulate all connections and disconnected
wires.
Use only Class BC or Class ABC
extinguishers on electrical fires.

Tilt the victims head

back and lift the chin
upwards.
Remove objects from
the mouth or throat
(including false teeth,
tobacco, or chewing
gum).

BREATHING
Check that the victim is breathing by looking,
listening and feeling for
the breath.

CIRCULATION
Check for pulse in the
victims neck.

1
2

2.8 FIRST AID FOR ELECTRIC SHOCK

!

!
!

WARNING
Do not touch the victims skin with bare
hands until the source of electricity has been
turned off.
Switch off power if possible other wise pull
the plug or the cable away from the viation.
If this is not possible, stand on dry insulating
material and pull the victim clear of the
conductor, preferably using insulated material
such as dry wood.
If victim is breathing, turn thi victim clear of
the conductor, preferably using insulated
material such as dry wood.
If victim is breathing, turn the victim into
the recovery position described below.
If victim is unconscious, perform resuscitation
as required:

IF NO BREATHING BUT
PULSE IS PRESENT
Pinch the victims nose
firmly.
Take a deep breath and
seal your lips around the
victims lips.
Blow slowly into the
mouth watching for the
chest to rise. Let the chest fall completely.
Give breaths at a rate of 10 per minute.
If the victim must be left to get help, give 10
breaths first and then return quickly and
continue.
Check for pulse after every 10 breaths.
When breathing restarts, place the victim
into the recovery position described later
in this section.

IF NO BREATHING AND NO PULSE

RECOVERY POSITION

Call or telephone for

medical help.
Give two breaths and
start chest compresion
as follows:
Place heel of hand 2
fingers breadth above ribcage/breastbone
junction.
Place other hand on top
and interlock fingers.
Keeping arms straight,
press down 4-5 cm (1.52 inch) at a rate of 15 times per minute.
Repeat cycle (2 breaths
and 15 compressions)
until medical help takes
over.
If condition improves,
confirm pulse and
continue with breaths. Check for pulse after
every 10 breaths.
When breathing restarts, place the victim
into the recovery position described below.

Turn the victim onto the

side.
Keep the head tilted
with the jaw forward to
maintain the open
airway.
Make sure the victim cannot roll forwards
or backwards.
Check for breathing and pulse regularly. If
either stops, proceed as above.

WARNING

! Do not give liquids until victim is conscious.

3. GENERAL DESCRIPTION
3.1. GENERATING SET DESCRIPTION
AND IDENTIFICATION

3.4. COOLING SYSTEM

The engine cooling system is either air cooled
or water cooled. The air cooled system
consists of a high capacity fan to pull cool
air across the engine to cool it. The water
cooled system is comprised of a radiator
(item 6), a pusher fan and a thermostat. The
alternator has its own internal fan to cool
the alternator components.

Aksa Generating Set has been designed as

a complete package to provide superior
performance and reliability.
Figure 3.1 identifies the major components.
This figure is of a typical generating set.
However, every set will be slightly different
due to the size and configuration of the
major components. This section briefly
describes the parts of the generating set.
Further information is provided in later
sections of thi manual.
Each generating set is provided with a Rating
Label (item 1) generally fixed to the base
frame. This label contains the information
needed to identify the generating set and its
operating characteristics. This information
includes the model number, serial number,
output characteristics such as voltage and
frequency, output rating in kVA and kW,
product date and weight.
The model and serial numbers uniquely
identify the generating set and are needed
when ordering spare parts or obtaining
service or warranty work for the set.

3.5. ALTERNATOR
The output electrical power is normally
produced by a screen protected and
drip-proof, self-exciting, self-regulating,
brushless alternator (item 7) fine tuned to
the output of this generating set. Mounted
on top of the alternator is a sheet steel
terminal box (item 8)

3.6. FUEL TANK AND BASEFRAME

The engine and alternator are coupled
together and mounted on a heavy duty steel
bareframe (item 9). This baseframe includes
a fuel tank (item 10) with a capacity of
approximately 8 hours operation at full load.

3.7. VIBRATION ISOLATION

3.2. DIESEL ENGINE

The generating set is fitted with vibration

isolators (item 11) which are designed to
reduce engine vibration being transmitted
to the foundation on which the generating
set is mounted. These isolators are fitted
between the engine/alternator feet and the
baseframe.

The diesel engine powering the generating

set (Item 2) has been chosen for its reliability
and the fact that it has been specifically
designed for powering generating sets. The
engine is of the heavy duty industrial type
with 4 stroke compression ignition and is
fitted with all accessories to provide a reliable
power supply. These accessories include,
among others, a cartridge type dry air filter
(item 3) and a mechanical or an electronic
engine speed governor.

3.8 SILENCER AND EXHAUST SYSTEM

An exhaust silencer is provided loose for
installation with the generating set. The
silencer and exhaust system reduce the noise
emission from the engine and can direct
exhaust gases to safe outlets.

3.3. ENGINE ELECTRICAL SYSTEM

The engine, electrica system is 12 volts or
24 volts DC, negative ground/earth. This
system includes an electric engine starter,
a battery (item 4) and a battery charging
alternator (item 5). For 12 volts electrical
system one battery is given. For 24 volt
system two lead-acid batteries are given.
Other types of batteries may be fitted if they
were specified.

3.9 CONTROL SYSTEM

One of several types of control systems and
panels (item 12) may be fitted to control
the operation and output of the set and to
protect the set from possible malfunctions.
Section 7 of this manual provides detailed
information on these systems and will aid in
identification of the control system fitted on
the generating set.

Figure 3.1 Typical generating set configuration

No. Description

No. Description

No. Description

1 Aksa generating set rating label

5 Battery charging alternator

9 Baseframe

2 Diesel engine

6 Radiator

10 Fuel tank (inside the baseframe)

3 Air filter

7 Alternator

11 Vibration isolators

4 Battery

8 Terminal box

12 Control panel

4. INSTALLATION, HANDLING AND

STORAGE

4.1 GENERAL

Once the size of the generating set and any

associated control systems or switchgear
have been established, plans for installation
can be prepared. This section discusses
factors important in the effective and safe
installation of the generating set.

4.2 CANOPIES
Installation and handling is greatly simplified
when the generating set has been equipped
with a canopy. The canopy also gives
protection from the elements and protection
from unauthorized access.

Figure 4.1 Lifting generating set by using a winch

4.3 MOVING THE GENERATING SET

4.4 LOCATION

The generating set baseframe is specifically

designed for ease of moving the set. Improper
handling can seriously damage components.
Using a forklift, the generating set can be
lifted or carefully pushed/pulled by the
baseframe. If pushing, do not push the
baseframe directly with fork. Always use
wood between forks and the baseframe to
spread the load and prevent damage.

Selecting a location for the generating set

can be the most important part of any
installation procedure. The following factors
are important in determining the location:
Adequate ventilation.
Protection from the elements such as rain,

snow, sleet, wind driven precipitation, flood

water, direct sunlight, freezing temperatures.
or excessive heat.

WARNING
! Never lift the generating set by attaching to

the engine or alternator lifting lugs.

Protection from exposure to airborne

structure is in good condition and is suitably

rated.
! Keep all personnel away from the generating
set when it is suspended.
! If the generating set is going to be lifted, it
should be lifted by the lifting points fitted
on canopied sets and most open sets.

Floor of generating set room must be smooth

contaminants such as abrasive or conductive

dust, lint, smoke, oil mist, vapors, engine
exhaust fumes or other contaminants.

! Ensure the lifting rigging and supporting

and strong.

Protection from impact from falling objects

such as trees or poles, or from motor

vehicles or lift trucks.

4.7. COOLING AND VENTILATION

Clearance around the generating set for cooling

and access for service: at least 1 meter (3.3

feet) around the set and at least 2 meters (6.6
feet) headroom above the set.
Access to move the entire generating set into
the room. Air inlet and outlet vents can often
be made removeble to provide an access point.
Limited access to unauthorized personnel.

The engine, alternator, and exhaust piping

radiate heat which can result in a temperature
high enough to adversely affect the performance
of the generating set. It is therefore important
that adequate ventilation is provided to keep
the engine and alternator cool. Proper air flow,
as shown in Figure 4.4, requires that the air
comes in at the alternator end of the set, passes
over the engine, through the radiator and out
of the room via a flexible exhaust duct. Without
the ducting of the hot air outside the room,
the fan will tend to draw that hot air around
and back through the radiator, reducing the
cooling effectiveness.

If it is necessary to locate the generating set

outside of the building, the generating set should

be enclosed in a canopy. A canopy is also useful
for temporary installations inside or outside
the building.

4.5. FOUNDATIONS VIBRATION ISOLATION

The generating set is shipped assembled on a
rigid baseframe that precisely aligns the
alternator and engine and needs to be bolted
down only to a suitably prepared surface.
Foundation
A reinforced concrete pad provides a rigid
support to prevent deflection and vibration.
Typically the foundation should be 150 mm to
200 mm (6 to 8 inches) deep and at least as
wide and long as the generating set. The ground
or floor below the foundation should be
properly prepared and should be structurally
suited to carry the weight of the foundation
pad and the generating set. (If the generating
set is to be installed above the ground floor
the building structure must be able to support
the weight of the generating set, fuel storage
and accessories). If the floor may be wet from
time to time such as in a boiler room, the pad
should be raised above the floor. This will
provide a dry footing for the generating set
and for those who connect, service or operate
it. It will also minimize corrosive action on the
baseframe.

Figure 4.2 Directing the air thrown from the

radiator with deviating wings

Sharp corners on the radiator, hot air outlet

channel or its chimney must be avoided. Some
rearrangements to turn thrown air should be
done (Figure 4.2 and 4.3).

4.6. COMBUSTION AIR INLET

Air for engine combustion must be clean and
as cool as possible. Normally this air can be
drawn from the area surrounding the generating
set via the engine mounted air filter. However,
in some cases due to dust, dirt, or heat, the
air around the set is unsuitable. In these cases
an inlet duct should be fitted. This duct should
run from the source of clean air (outside the
building, another room, etc.) to the engine
mounted air filter. Do not remove the air filter
and mount it at a remote location as this can
increase the possibility of dirt leaking through
the ductwork and into the engine inlet.

Figure 4.3 Weak ventilation installation

The air inlet and outlet openings should be

large enough to ensure free flow of air into
and out of the room. As a rough guide the
openings should each be at least 1.5 times
the area of the radiator core.
Both the inlet and outlet openings should
have louvres for weather protection. These
may be fixed but preferably should be
movable in cold climates so that while the

generating set is not operating the louvres

can be closed. This will allow the room to
be kept warm which will assist starting and
load acceptance. For automatic starting
generating sets. If the louvres are movable
they must be automatic-ally operated. They
should be programmed to open immediately
upon starting the engine.

Figure 4.4 Air ventilation

4.8 EXHAUST
The purpose of the engine exhaust system
is to direct the exhaust outside to a location
and height where the fumes and odors will
not become an annoyance or hazard, and to
reduce noise. A suitable exhaust silencer
must be incorporated into the exhaust piping
to reduce the noise level from the engine.
(See Figure 4.4-4.5)

Ensure hot exhaust silencers and piping are

clear of combustible material and are guarded
for personnel protection per safety
requirements.
Ensure that fumes from the exhaust outlet
will not be a hazard.
In designing an exhaust system, the primary
consideration is to not exceed the allowable
back pressure permitted by the engine
manufacturer. Excessive back pressure
seriously affects engine output, durability
and fuel consumption. To limit the back
pressure the exhaust piping should be as
short and straight as possible. Any required
bends should have a curve radius of at least
1.5 times the inside diameter of the pipe.

WARNING:
Engine exhaust
emmissions are hazardous
to personnel. The engine
exhaust for all indoor
generating sets must be
piped outdoors via leakfree piping in compliance with relevant
Codes, Standards and other requirements.

10

Other exhaust design criteria are as follows:

A flexible connection between the exhaust
manifold and the piping system should be
used to prevent transmission of engine
vibration to the piping and the building and
to allow for thermal expansion and any slight
misalignment of the piping. (See Figure 4.4)
The exhaust gas pipes should be supported
by the building in order to prevent the dead
weight carried by the engine manifold
and turbocharger. For that, stretching,
elements should be used. (See Figure 4.5)
Exhaust system components located within
the generator room should be insulated to

Figure 4.5 Generating set room

11

reduce heat radiation and noise levels. Pipes

and the silencer, whether located inside and
outside the building, should be located well
clear of any combustible material.
The outer end of the exhaust pipe, if
horizontal, should be cut at 60 to the
horizontal or should be fitted with a rain
hood or cap, if vertical, to prevent rain or
snow from entering the exhaust system.
The exhaust pipe must not be connected to
exhausts from other generating sets.
Exhaust pipes must be made up of black iron
pipe.

Generating Sets
Model

Dimensions
(m)

Standby

Room
Dimensions
(m)

Power
(kVA) Length With Height Length With

Radiator Hot
Air Outlet
Openings
Louvers
(m)

Height

Air Inlet
Openings
Total Area
(m2)

Rooms
Door

Dimensions

Exhaust

(m)

P
M (inch) (m)
Diameter

ALP 8

8.5

1.37

0.75

0.97

2.5

0.55

0.4

0.4

0.5

2.2

1.5

ALP 12

12

1.45

0.8

1.04

2.5

0.55

0.5

0.4

0.5

2.2

1.6

ALP 15

15

1.37

0.75

0.97

2.5

0.55

0.4

0.4

0.5

2.2

1.5

ALP 18

17.5

1.45

0.8

1.04

2.5

0.55

0.5

0.4

0.5

2.2

1.6

ALP 22

22

1.45

0.8

1.04

2.5

0.55

0.5

0.4

0.5

2.2

1.6

ALP 30

30

1.45

0.8

1.04

2.5

0.55

0.5

0.4

0.5

2.2

1.6

ADZ 110

110

2.15

1.53

0.55

0.75

0.56

0.5

1.2

2.2

3.5

2.1

ADZ 175

175

2.46

1.1

1.62

0.75

0.8

0.46

1.3

2.2

2.2

ADZ 360

360

2.96

1.37

2.1

0.85

1.05

0.45

1.5

1.6

2.5

2x4

2.6

ADZ 400

400

2.96

1.37

2.1

0.85

1.05

0.45

1.5

1.6

2.5

2x4

2.6

ADZ 490

490

3.2

1.43

2.07

1.5

1.6

0.25

1.8

2.5

2x4

2.6

ADZ 538

538

3.2

1.43

2.07

1.5

1.6

0.25

1.8

2.5

2x4

2.6

ADZ 550

550

3.2

1.43

2.07

1.5

1.6

0.25

1.8

2.5

2x4

2.6

AP 500

500

3.6

1.22

2.1

1.3

1.4

0.4

1.8

2.5

2.7

AP 550

550

3.6

1.22

2.1

1.3

1.4

0.4

1.8

2.5

2.7

AVP 515

515

3.6

1.3

1.96

3.5

1.35

1.35

0.4

1.5

1.5

2.5

2.5

AVP 550

550

3.6

1.3

1.96

3.5

1.35

1.35

0.4

1.5

2.5

2.5

AKMTU 720

720

1.58

1.9

1.6

1.3

0.4

2.5

2.2

2.7

2x6

2.7

AKMTU 780

780

4.1

1.58

1.6

1.3

0.4

2.5

2.2

2.7

2x6

2.8

AKMTU 925

925

4.38

1.58

1.6

1.55

0.3

2.2

2.7

2x6

2.8

AKMTU 1030

1030

4.38

1.76

2.2

2.2

0.25

4.5

2.4

2x6

AKMTU 1500

1500

3.85

1.8

2.3

Remote Radiator

2.4

2x12 3.1

AKMTU 1700

1700

3.85

1.8

2.3

Remote Radiator

2.4

2x12 3.1

AKMTU 2050

2050

4.55

1.8

2.33

Remote Radiator

2.4

2x12 3.1

AKMTU 2250

2250

4.55

1.8

2.33

Remote Radiator

2.4

2x12 3.1

Table 4.1.1 Aksa open type diesel (look figure 4.5 genset room) gen-sets dimensions, room dimensions, air inlet
and outlet openings dimensions and exhaust pipe dimensions.
Please contact us for gen-sets which have remote radiator system.

12

Generating Sets

Model

Standby

Dimensions
(m)

Radiator Hot
Air Outlet
Openings
Louvres
(m)

Room
Dimensions
(m)

Power
A
B
(kVA) Length With Hight Length With

Height

Air Inlet
Openings
Total Area
(m2)

Rooms
Door

Dimensions

Exhaust

(m)

P
M (inch) (m)
Diameter

AC 39

39

1.86

0.9

1.3

3.5

2.5

0.7

0.75

0.45

0.8

1.5

AC 55

55

1.86

0.9

1.3

3.5

2.5

0.8

0.85

0.4

0.8

1.5

AC 66

66

1.86

0.9

1.3

3.5

2.5

0.75

0.8

0.5

0.8

1.5

AC 70

70

1.86

0.9

1.3

3.5

2.5

0.75

0.8

0.5

0.8

1.5

AC 90

90

1.86

0.9

1.3

3.5

2.5

0.75

0.8

0.5

0.8

1.5

AC 115

115

2.15

1.67

2.5

0.8

0.9

0.45

1.5

AC 150

150

2.31

1.1

1.6

2.5

1.1

0.55

1.3

1.5

AC 160

160

2.15

1.1

1.67

2.5

0.8

0.9

0.45

1.5

AC 200

200

2.31

1.1

1.6

2.5

1.1

0.55

1.3

1.5

AC 250

250

2.53

1.1

1.6

2.5

1.1

0.55

1.3

1.5

ACL 250

250

2.9

1.15

1.73

3.3

2.5

1.2

0.45

1.5

1.5

2.2

AC 275

275

2.9

1.15

1.73

3.3

2.5

1.2

0.45

1.5

1.5

2.2

AC 350

350

3.23

1.15

3.3

1.25

1.2

0.7

1.5

1.5

2.5

2.5

AC 400

400

3.23

1.15

3.3

1.25

1.2

0.7

1.5

1.5

2.5

2.5

AC 500

500

3.4

1.3

2.1

5.5

3.5

1.5

1.5

0.52

1.7

2.6

2.5

ACQ 515

515

3.6

1.3

5.5

3.5

1.5

1.5

0.4

1.7

2.6

2.5

AC 550

550

3.43

1.3

2.1

5.5

3.5

1.5

1.5

0.5

1.7

2.6

2.5

ACQ 550

550

3.6

1.3

5.5

3.5

1.5

1.5

0.4

1.7

2.6

2.5

AC 650

650

3.6

1.3

5.5

3.5

1.5

2.5

0.4

2.5

1.7

2.6

2.5

AC 703

703

3.9

1.4

2.13

5.5

3.5

3.3

1.6

1.5

0.5

3.6

2.6

2x6

2.6

ACQ 720

720

4.2

1.7

2.2

3.7

3.5

1.8

1.8

0.3

2.5

2.7

2.7

AC 825

825

3.9

1.4

2.13

5.5

3.5

3.3

1.6

1.5

0.5

3.6

2.6

2x6

2.6

ACQ 830

830

4.2

1.7

2.2

3.7

3.5

1.8

1.8

0.3

2.5

2.7

2.7

ACQ 881

880

4.2

1.7

2.2

3.7

3.5

1.8

1.8

0.3

2.4

2.7

2.7

AC 1030

1030

4.3

1.8

2.4

6.5

3.5

2.2

0.3

2.5

2x6

ACQ 1030

1030

4.23

1.8

2.35

6.5

3.5

2.3

0.3

2.5

2x6

AC 1130

1130

4.35

1.8

2.35

6.5

3.5

2.2

0.3

2.5

2x6

ACQ 1130

1130

4.4

2.3

6.5

3.5

2.3

0.3

2.5

2x6

AC 1435

1435

4.95

2.15

2.3

4.5

3.5

2.5

0.3

2.7

2x8

AC 1675

1675

5.5

2.15

2.9

7.5

4.5

2.5

0.3

2.7

3.4

2x8

3.5

ACQ 2100

2100

6.05

2.5

3.22

4.5

0.3

3.5 2x12

ACQ 2250

2250

6.05

2.5

3.22

4.5

0.3

10

3.5 2x12

Table 4.1.2

Aksa open type 50 Hz diesel gen-sets dimensions, room sizes, air inlet and outlet openings
dimensions (look figure 4.5. genset room) Without acoustic treatment. Single sets.

13

Generating Sets

Model

Standby

Power
(kVA)

Dimensions
(m)
Length With

Room
Dimensions
(m)

Height Length With

Radiator Hot
Air Outlet
Openings
Louvers
(m)

Height

Air Inlet
Openings
Total Area
(m2)

Rooms
Door

Dimensions

Exhaust

(m)

P
M (inch) (m)
Diameter

ALP 10-6

10

1.38

0.77

0.98

2.5

2.5

0.55

0.4

0.4

0.5

2.2

1.5

ALP 15-6

15

1.45

0.82

1.04

2.5

2.5

0.55

0.5

0.4

0.5

2.2

1.6

ALP 21-6

21

1.45

0.82

1.04

2.5

2.5

0.55

0.5

0.4

0.5

2.2

1.6

AP 616-6

616

3.6

1.3

2.1

5.5

3.5

1.5

1.5

0.4

1.8

2.6

2.5

AP 693-6

693

3.6

1.3

2.1

5.5

3.5

1.5

1.5

0.4

1.8

2.6

2.5

Table 4.1.3

Aksa 60 Hz, open type diesel gen-set dimensions, air inlet and outlet openings dimensions and exhaust
pipe dimensions. (look figure 4.5. genset room) Without acoustic treatment. Single sets.

14

Generating Sets

Model

Standby

Power
(kVA)

Dimensions
(m)
Length With

Room
Dimensions
(m)
A

Height Length With

Radiator Hot
Air Outlet
Openings
Louvers
(m)

Height

Air Inlet
Openings
Total Area
(m2)

Rooms
Door

Dimensions

Exhaust

(m)

P
M (inch) (m)
Diameter

AC 44-6

44

1.86

0.9

1.3

3.5

2.5

0.7

0.75

0.45

0.8

1.5

2.2

AC 66-6

66

1.86

0.9

1.3

3.5

2.5

0.8

0.85

0.4

0.8

1.5

2.2

AC 77-6

77

1.86

0.9

1.3

3.5

2.5

0.75

0.8

0.5

0.8

1.5

2.2

AC 100-6

100

1.86

0.9

1.3

3.5

2.5

0.75

0.8

0.5

0.8

1.5

2.2

AC 135-6

135

2.15

1.67

3.5

2.5

0.8

0.9

0.45

1.5

2.2

AC 165-6

165

2.31

1.1

1.6

2.5

1.1

0.55

1.3

1.5

2.2

AC 225-6

225

2.31

1.1

1.6

2.5

1.1

0.55

1.3

1.5

2.2

AC 275-6

275

2.9

1.15

1.73

3.3

2.5

1.1

1.2

0.45

1.5

1.5

2.2

2.1

AC 350-6

350

3.23

1.15

3.3

1.25

1.2

0.7

1.5

1.5

2.5

2.5

AC 383-6

383

3.23

1.15

3.3

1.25

1.2

0.7

1.35

1.5

2.5

2.5

AC 450-6

450

3.23

1.15

3.3

1.25

1.2

0.7

1.35

1.5

2.5

2.5

ACQ 498-6

498

3.6

1.3

5.5

3.5

1.5

1.5

0.4

1.7

2.6

2.5

AC 550-6

550

3.43

1.3

2.1

5.5

3.5

1.5

1.5

0.5

1.7

2.6

2.5

AC 616-6

616

3.43

1.3

2.1

5.5

3.5

1.5

1.5

0.5

1.7

2.6

2.5

ACQ 616-6

616

3.6

1.3

5.5

3.5

1.5

1.5

0.4

1.7

2.6

2.5

AC 754 6

754

3.9

1.4

2.13

5.5

3.5

3.3

1.6

1.8

0.5

3.6

2.6

ACQ 758-6

758

4.2

1.7

2.2

3.7

3.5

1.8

1.8

0.3

2.4

2.7

2.7

ACQ 935-6

935

4.2

1.7

2.2

3.7

3.5

1.8

1.8

0.3

2.4

2.7

2.7

ACQ 1030-6

1030

4.2

1.7

2.2

3.7

3.5

1.8

1.8

0.3

2.4

2.7

2.7

ACQ 1025-6

1025

4.23

1.8

2.35

6.5

3.5

2.3

0.3

2.5

2x6

AC 1150-6

1150

4.3

1.8

2.4

6.5

3.5

2.2

0.3

2.5

2x6

ACQ 1160-6

1160

4.23

1.8

2.35

6.5

3.5

2.3

0.3

2.5

2x6

ACQ 1232-6

1232

4.4

2.35

6.5

3.5

2.3

0.3

2.5

2x6

AC 1450 6

1450

4.95

2.15

2.3

4.5

3.5

2.5

0.3

2.7

2 x8

AC 1590-6

1590

4.95

2.15

2.35

4.5

3.5

2.5

0.3

2.7

2x8

AC 1930-6

1930

5.5

2.15

2.9

7.5

4.5

2.5

0.3

2.7

3.4

ACQ 2200-6

2200

6.05

2.5

3.22

4.5

0.3

3.5 2 x 12 4

ACQ 2500-6

2500

6.05

2.5

3.22

4.5

0.3

10

3.5 2 x 12 4

2 x 6 2.6

2 x 8 3.5

Table 4.1.4 Aksa 60 Hz, open type diesel gen-set dimensions, room sizes. air inlet and outlet openings dimensions
and exhaust pipe dimensions. (look figure 4.5. genset room) Without acoustic treatment. Single sets.

15

4.9 FUEL SYSTEM

4.9.2 Bulk Storage Tanks: For extended

operation. a separate bulk fuel storage tank
is required. The bulk tank should generally
be located outside the building where it will
be convenient for refilling, cleaning and for
inspection. It should not, however, be
exposed to freezing weather because fuel
flow will be restricted as viscosity increases.
The tank may be located either above or
below ground.
A vent must be installed on the bulk tank to
relieve the air pressure created by filling the
tank or created by evaporation and
expansion. It will also prevent a vacuum as
the fuel is consumed. The base of the tank
should have a slope, so the water and the
sediment can be collected. A sludge drain
valve should be installed at the low point to
allow removal of water and sediment on a
regular basis.

The fuel system for the generating set must

be capable of delivering a clean and
continuous supply of fuel to the engine. For
most installations this will include a small
day tank, a bulk storage tank and fuel lines.

WARNING:
For stationary generating sets with remote
fuel storage systems,
make sure such
systems are installed in
compliance with
relevant Codes,
Standards or other
requirements.
Do not smoke or allow sparks, flames or
other sources of ignition around fuel. Fuel
vapours and oil vapours are explosive.

4.9.3 Fuel Lines: The fuel lines can be of

any fuel compatible material such as steel
pipe or flexible hoses that will tolerate
environmental conditions.

4.9.1 Day tank: Day tanks provide a readily

available supply of fuel directly to the
generating set and should therefore be
located within the generator room. The
baseframe is designed to contain a day tank
up to 700 kVA.

Flexible piping should be used to connect

to the engine to avoid damage or leaks
caused by engine vibration.
The fuel delivery line should pick up ful from
a point no lower than 50 mm (2) from the
bottom at the high end of the tank (away
from the drain plug).

16

Figure 4.6.1 Typical fuel installation using a base tank fed from a bulk tank

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Fill cabinet with overfill alarm and gauge

Tank fill line
Vent
Contents gauge
Bulk storage tank
Sludge drain
Bund tank
Outlet valve
Supply line to day tank
Electric fuel transfer pump

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

Electric fuel shutoff valve

Optional band
Day tank incorporated in baseframe
Float Control switches
Manual fill and vent
Level gauge
Drain
Leakage alarm unit (optional)
Fuel filter
Engine fuel pump

RECOMMENDATIONS FOR FUEL PIPING

Recommended
Pipe Diameter
(inch)

Generator
Stand-By Power
(kVA)

Maximum Fuel
Pipe Length
(m)

Maximum
Vertical Height
(m)

Maximum Pipe
Fittings Quantity

40-800

0,9

800-1500

0,9

1 1/2

1500-2200

0,9

Figure 4.6.2 Recommendations for fuel piping

17

!
!

Figure 4.8 Fuel tank which is put 1500 mm

above the fuel conversion

Figure 4.9 Float tank used with elevated fuel tank

0-1800 mm

WARNING
The fuel must be clean and must not contain
any water or any erasive liquids.
Fuel pipes must best made of black pipe, not
galvanized pipe.
When the engine stops, there should not
be any gravitational free flow in the fuel pipes
towards of the engine.
The fuel temperature is a critical factor for
appropriate working conditions of the engine.
Fuel temperature above 71C, due to
expansion of the fuel, will decrease the engine
output power.
The connection pipe from the bulk storage
tank to the day tank must be equal or greater
than the daily feed pipe.
In fuel system line, using the water filter
seperators will prevent the injectors and
fuel pump, and it will be usefull for healthy
working of the engine.
In the simplest tank settlement, the fuel level
should not be above the injectors and should
not be lower than the fuel pump for more
than 1.8 m, see Figure 4.7.

CHECK VALVE

Figure 4.7 Typical fuel drawing of a fuel tank

placed below the engine

If the fuel tank is set 1.5 meters above

injectors, two check valves must be
connected like in Figure 4.8 in order to
prevent the engine from hydraulic lock. The
protection capacity of these valves is 0 to
1.5 meters in elevation. If fuel tank will be
mounted at an elevation and at a distance,
Figure 4.10 shows a tank mounted below
the engine level and at a distance.

Figure 4.10 Fuel tank which is put below

1500 mm

18

MTU

Volvo Perkins

Deutz

Lister Petter

Coolant Capacity

Oil Capacity

Model

Fuel Tank
Capacity

Engines

Stand by
Power Engine Model
(kVA)

Fuel Consumption
at Full Load

Generating Sets

L/h

Lt

Lt

Lt

ALP 8

8.5

LPW 2

1.9

80

5.5

3.2

ALP 12

12

LPW 3

2.8

90

6.5

ALP 15

15

LPW 2

3.9

80

5.5

3.2

ALP 16

16.5

LPW 4

3.8

90

7.5

5.8

ALP 22

22

LPW 3

5.9

90

6.5

ALP 30

30

LPW 4

7.8

90

7.5

5.8

ADZ 110

110

BF4M 1013 EC

23.8

140

22

13

ADZ 175

175

BF6M 1013 EC

34

270

28

20

ADZ 360

360

BF6M 1015 C

67.6

500

57

38

ADZ 400

400

BF6M 1015 C

68.6

1000

57

38

ADZ 490

490

BF8M 1015 C

88.5

1000

77

38

ADZ 538

538

BF8M 1015 C

88.5

1000

77

38

ADZ 550

550

BF8M 1015 CP

101

1000

77

38

AP 500

500

2806C-E16TAG1

97

665

50

68

AP 550

550

2806C-E16TAG2

108

665

50

68

AVP 515

515

TAD1630GE

96.1

520

64

64

AVP 550

550

TAD1631GE

107

520

64

64

AKMTU 720

720

12V2000G23

132

1000

180

82

AKMTU 780

780

12V2000G63

147

1500

180

82

AKMTU 925

925

16V2000G23

169

1500

205

110

AKMTU 1030

1030

16V2000G63

187

1500

205

110

AKMTU 1500

1500

12V4000G21

275

2000

815

260

AKMTU 1700

1700

12V4000G61

305

2000

870

260

AKMTU 2050

2050

16V4000G21

362

2000

910

290

AKMTU 2250

2250

16V4000G61

400

2000

970

290

Table 4.2.1

Oil Specifications
Not: Lubricating oil viscosity level will
be chosen from Table 4.3 according
to the ambient temperature

Lister Petter:
Recommends API CC at first use
Heavy load conditions and below
25 C temperatures. At other
conditions recommends
API CD lubricating oil

Deutz: Recommends API CF, API

CG-4, API CH-4, ACEA E1-96,
ACEA E3-96, ACEA E4-98
Lubricating oils

Perkins:
Recommends API CG4
Volvo: Recommends API CD, API CE,
API CF, API CF4, CCMC D4
CCMC D5 lubricating oils

MTU; Recommends
API CG-4
ACEA E2-96
ACEA E3-96
lubricating oils

Coolant and oil capacities and lubricating oil specifications (50 Hz, Gen-sets).

19

CUMMINS ENGINE

Fuel Tank
Capacity

Coolant Capacity

Oil Capacity

Model

Stand by
Cummins
Power
(kVA) Engine Model

Fuel Consumption
at Full Load

Generating Sets

L/h

Lt

Lt

Lt

AC 39

39

4B3.3-G1

8.4

132

12

7.5

AC 55

55

4BT3.3-G2

11.5

132

15

AC 66

66

4BT3.9-G4

14

132

19

11

AC 70

70

4BT3.9-G4

15

132

19

11

AC 90

90

4BTA3.9-G3

18

132

20

11

AC 115

115

6BT5.9-G6

24

220

23

16.4

AC 150

150

6CT8.13-G2

30

370

36

23.8

AC 160

160

6BTA5.9-G2

31

220

26

16.4

AC 200

200

6CTA8.3-G2

40

370

36

23.8

AC 250

250

6CTAA8.3-G2

51.3

370

32

23.8

ACL 250

250

LTA10-G2

48.4

420

37

36

AC 275

275

LTA10-G3

51

420

37

36

AC 350

350

NT855-G6

69

420

70

38.6

AC 400

400

NTA855G4

76

420

70

38.6

AC 500

500

KTA19-G3

97

550

92

50

ACQ 515

515

QSX15-G6

95.9

620

90

91

AC 550

550

KTA19-G4

107

550

92

50

ACQ 550

550

QSX15-G8

105

620

90

91

AC 650

650

KTA19-G8

135

750

130

50

AC 703

703

VTA28-G5

140

920

176

83

ACQ 720

720

QSK23-G1

134

600

120

103

AC 825

825

VTA28-G6

164

920

176

83

ACQ 830

830

QSK23-G2

151

600

120

103

ACQ 881

881

QSK23-G3

161

600

120

103

AC 1030

1030

KTA38-G3

198

1250

280

135

ACQ 1030

1030

QST30-G3

184

1250

175

154

AC 1130

1130

KTA38-G5

209

1250

280

135

ACQ 1130

1130

QST30-G4

202

1250

342

154

AC 1435

1435

KTA50-G3

261

2000

315

177

AC 1675

1675

KTA50-GS8

309

2000

375

204

ACQ 2100

2100

QSK60-G3

363

2000

380

280

ACQ 2200

2200

QK60-G4

394

2000

380

280

Table 4.2.2

Oil Specifications
Not: Lubricating oil viscosity level will
be chosen from Table 4.5 according
to the ambient temperature

API CH
API CI-4
API CF4

Fuel consumption and coolant, fuel and lubricating oil capacities (50 Hz, Gen-sets).

20

Perkins

Lister
Petter

Coolant Capacity

Oil Capacity

Model

Fuel Tank
Capacity

Engines

Stand by
Power Engine Model
(kVA)

Fuel Consumption
at Full Load

Generating Sets

L/h

Lt

Lt

Lt

ALP 10-6

10

LPW 2

2,3

80

5,5

3,2

ALP 15-6

15

LPW 3

3,4

96

6,5

ALP 21-6

21

LPW 4

4,6

96

7,5

5,8

AP 616-6

616

2806C-E16TAG1

117

665

50

68

AP 693-6

693

2806C-E16TAG2

127

665

50

68

Table 4.2.3

Oil Specifications
Not: Lubricating oil viscosity level will
be chosen from Table 4.3 according
to the ambient temperature

Recommends API CC at first use

Heavy load conditions and below
25 C temperatures. At other
conditions recommends
API CD lubricating oil
Recommends API CG4

Coolant and oil capacities and lubricating oil specifications (60 Hz, Gen-sets).

21

CUMMINS ENGINE

Fuel Tank
Capacity

Coolant Capacity

Oil Capacity

Model

Stand by
Cummins
Power
(kVA) Engine Model

Fuel Consumption
at Full Load

Generating Sets

L/h

Lt

Lt

Lt

AC 44-6

44

4B 3,3-G1

9.7

132

12

7.5

AC 66-6

55

4BT 3,3-G2

13.4

132

15

AC 77-6

77

4BT 3,9-G4

17

132

19

11

AC 100-6

100

4BTA 3,9-G3

22

132

20

11

AC 135-6

135

6BT 5.9-G6

29

220

23

16.4

AC 165-6

165

6CT 8.3-G2

37

370

36

23.8

AC 225-6

225

6CTA 8.3-G2

48

370

36

23.8

AC 275-6

275

LTA 10-G2

56.4

420

37

36

AC 350-6

350

NT 855-G6

74

420

70

38.6

AC 383-6

383

NTA 855-G2

79

420

70

38.6

AC 450-6

450

NTA 855G3

87

420

70

38.6

ACQ 498-6

498

QSX 15-G6

97.6

620

90

91

AC 550-6

550

KTA 19-G3

111

620

90

50

AC 616-6

616

KTA 19-G4

122

550

92

50

ACQ 616-6

616

QSX 15-G9

117.8

620

90

91

AC 754-6

754

VTA 28-G5

154

920

176

83

ACQ 758-6

758

QSK 23-G1

137

1000

120

103

ACQ 935-6

935

QSK 23-G2

176

1000

120

103

ACQ 1030-6

1030

QSK 23-G3

189

1000

120

103

ACQ 1025-6

1025

QST 30-G2

197

1250

175

154

AC 1150-6

1150

KTA 38-G3

217

1250

280

135

ACQ 1160-6

1160

QST 30-G3

207

1250

175

154

ACQ 1232-6

1232

QST 30-G4

240

1250

342

154

AC 1450-6

1450

KTA 50-G3

265

2000

315

177

AC 1590-6

1590

KTA 50-G3

291

2000

315

177

AC 1930-6

1930

KTA 50-G9

330

2000

375

204

ACQ 2200-6

2200

QSK 60-G5

400

2000

380

280

ACQ 2500-6

2500

QSK 60-G7

471

2000

380

280

Table 4.2.4

Oil Specifications
Not: Lubricating oil viscosity level will
be chosen from Table 4.5 according
to the ambient temperature

API CH
API CI - 4
API CF4

Coolant and oil capacities and lubricating oil specifications (60 Hz, Gen-sets).

22

4.10 LUBRICATION OIL

4.10.4 Lubricating oil
recommendations by Lister Petter

Oil system of diesel engine is one of the

most important elements of the engine.
Correctly made engine overhaul (this subjet
includes oil change periods, filter change
periods, paying attention about selecting the
true type of oil) prolongs the life of the
engine and it decreases the life cycle cost of
the engine.

To help assist engine running, all engines are

dispatched with an initial fill lubricating oil
which must be changed after 100 hours.
Lister Petter engine manufacturer
recommends the following oils;
API CC Def2101 D MIL-L-46152 B
MIL-L-2104 B

4.10.1 Oil Performance Properties

The American Petroleum Institute (API) the
American Society for Testing and Materials
(ASTM) and Society of Automotive Engineers
(SAE) has developed and preserved a system
in order to classify the lubrication oils for
their performance categories.

4.10.5 Lubricating oil

recommendations by Deutz
Deutz engine manufacturer recommends
the following oils.
For turbocharged engines:
API CF-4, API CG-4, API CH-4
ACEA E1-E3-96 + E4-98

4.10.2 Lubrication Recommendations

for Cummins Engine

4.10.6 Lubricating oil

recommendations by Volvo

Cummins recommends that high quality multi

grade SAE 15W/40 high service engine oil
in diesel engines are used. At ambient
temperatures above -15 C is 15W 40.
The minimum API oil quality levels
recommended for use is CH / CI-4, CH or
CI/4 oil can be used in areas where CF4 oil
is not yet available, but the oil change interval
must be reduced API CA, CB, CC, CD, CE,
CG4 categories not recommended, do not
use.

Volvo engine manufacturer recommends the

following oils.
For turbocharged engines:
API American Petroleum Institue
API CE, CF, CF-4, CG-4
CCMC Commitee of Common Market
Automobile Constructors
CCMC D4, D5
VDS Volvo Drain Specification
VDS, VDS-2, VD5-3
ACEA (European automobile
manufacturers association)
ACEA E1, E2, E3

4.10.3 Recommended Oil Properties

for Perkins Diesel Engines
Recommended lubriation oil specifications
for Perkins Diesel Engines:
If the ambient temperature of the engine is
above -15C, use lubricating oil as SAE
15W/40. If ambient temperature is above
-15C and below 25C, 10W/30 grade
lubricating oil is recommended. API CH-4
classification is required to neet Perkins oil
change intervals.
Temperature F
-40 -20 0

5W40-15W40

All Seasons

CI-4 and 10W30

10W30

Winter Conditions
Arctic Conditions

MTU engine manufacturer recommends the

following oils, for 2000 and 4000 series
engines. The luboil will be monograde
specification.
API CG-4
ACEA E2-96 + E3-96

20 40 60 80 100 120 140

All Seasons

Winter Conditions

4.10.7 Lubricating oil

recommendations by MTU

5W30
0W30

-40 -30 -20 -10 0 10 20 30 40 50 60

Temperature C

Figure 4.3 Recommended SAE Oil Viscosity

Grades vs. Ambient Temperatures

23

4.11BATTERIES
4.11.1 MAINTENANCE BATTERIES
1.

WARNING
! Do not smoke or allow sparks, flames or
other sources of ignition around batteries.
Hydrogen gas generated by charging batteries
is explosive.
! Wear an acid resistant apron and face shield
or goggles when servicing the battery. If
electrolyte is spilled on skin or clothing, flush
immediately with largequantities of water.
! Take out the metalic things in your wrist
and protect your wrist and hand.
! Disconnect the battery negative (earth) lead
first and reconnect last.
! Always ensure that battery charging is carried
out in a well ventilated area.
The starting batteries should be located as
close as possible to the generating set while
still being accessible for servicing. This will
prevent electrical losses
from long
cale that could impact on the engine starting
capability of the batteries.

2.

4.11.1.1 First filling of Acid Water to

the battery

2.

3.
4.
5.

6.

1.

4.11.1.2 Battery Maintenance

Keep the top of the battery and its
terminals clean.
Cover the battery terminals and its
connections with vaseline.
Tighten the terminals but not tighten it
hardly.
Control the electrolyte level periodically.
It must be 10 mm. above the plates.
Control the abrasion in the charge
alternator belt and check periodically the
belt tension according to the producers
recommendation.
Ensure that your battery is not
uncharged.
4.11.1.3 Testing The Battery
Conduct an inspection every time before
testing the battery.
A white powdered element causes
abrasion to the pole-heads, its surroundings and the connections. Remove
the connections and wash them with
hot water to purify the axidation.
Reconnect it and coat with vaseline.
Check if any untightened connections
exist.

4.11.1.4 Hydrometer Test

Sulphuric acid density and its charge
situation has been determined by using a
hydrometer.
1. Dont add distilled water.
2. Keep the barrel part of the equipment in the
vertical position and pull on the sufficient
amount of electrolyte. Inside the tube there
must be a free float and it should be readable
at the eye level.
Evaluation is as the following;
Between 1.270 and 1.280 density level is fully
charged,
Between 1.220 and 1.230 density level is half
charged,
Between 1.150 and 1.220 density level is low
charged

1. Take out the protective cover above the

taps and tear down the air outlet taps.
2. Fill the battery with a clean accumulator
acid having a density of 1.280 at 20 C until
the point 15 mm. above plates. Battery
an acid teperature must above 10 C.
3. Let the battery to stand still 15 minutes.
After that point battery pockets will start
to become heated and gas bubbles will
rise at the surface of electrolyte.
4. Attach the air outlet taps to their place.
5. After waiting at least 15 min. control the
battery with a hydrometer.
6. Minimum charge time is 6 hours.
If the charge voltage and electrolyte level
does not increase in at least one hour
period that means battery has been
charged.
7. Control the electrolyte level after two
hours from the charge and if necessary
add distilled water so that it is 10 mm.
above plates.

4.11.2 Maintenance Free Batteries

Ensure that all battery connections are correct
and batteries are always charged. After that
there is not any procedure for this batteries.
4.12 ELECTRICAL CONNECTION
Only fully qualified and experienced electrical
technicians should carry out electrical installation, service and repair work.
WARNING:
! Make electrical connections in compliance
with relevant Electrical Codes, Standards or
other requirements.

24

4.12.1 Cabling: Due to movement of generating sets on their vibration mounts, the
electrical connection to the set should be
made with flexible cable.
The cable should be protected by laying it in
a duct or cable tray.
The cable must be suitable for the output
voltage of the generating set and the rated
current of the set. In determining the size,
allowances should be made for ambient temperature. method of installation, proximity
of other cables. etc.
All connections should be carefully checked
for integrity.
Current carrying capacity of power cables
that will be used for generator has been given
in table 4.4. and the cable cross sections
which must be used according to the generator powers has been given in table 4.5.14.5.2
On the other hand, there is a one more
important point while cable cross sections
are being selected. If the distance between
load and generator is too length, voltage falling
at the load side can be too much at the
transient current duration. In this case you
should calculate the cable cross sections with
electrical formula which has been given below.
e=
x L x x (R Cos + X Sn )
e : Voltage falling (volt)
L : Cable length (meter)
: Current (Amper)
R : Resistance of cable (ohm/m)
x : Reactance of cable (ohm/m)

4.12.2 Protection: The cables connecting

the generating set with the distribution system
are protected by means of a circuit breaker
to automatically disconnect the set in case of
overload or short circuit. (Manual models
only).
4.12.3 Loading: When planning the electrical
distribution system, it is important to ensure
that a balanced load is presented to the
generating set. If loading on one phase is
substantially higher than the other phases it
will cause overheating in the alternator windings, imbalance in the phase to phase output
voltage and possible damage to sensitive 3
phase equipment connected to the system.
Ensure that no individual phase current exceeds the current rating of the generating
set. For connection to an existing distribution
system, it may be necessary to reorganize
the distribution system to ensure these loading
factors are met..
4.12.4 Power Factor: The power factor
(cos) of the connected load should be determined. Power factors below 0.8 lagging
(inductive) can overload the generator. The
set will provide its kilowatt rating and operate
satisfactorily from 0.8 lagging to unity power
factor (1.0). Particular attention must be given
to installations with power factor correction
equipment such as capacitors to ensure that
a leading power factor is never present. This
will lead to voltage instability and may result
in damaging overvoltages. Generally whenever
the generating set is supplying the load any
power factor correction equipment should
be switched off.

PVC - ISOLATED CABLES YVV (NYY) SUITABLE TO 0.6/1KV VDE NORMS AND TS

Wire
Section
(mm2)
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240

0,6/1 KV, YVV type Cable Current Capacity

Soil

%25C @ Air

Multiple
Core
36
46
58
77
100
130
155
185
230
275
315
355
400
465

Multiple
Core
25
34
44
60
80
105
130
160
200
245
285
325
370
435

%40C @ Air

Multiple
Core
22
30
38
53
71
94
114
138
176
212
248
283
322
380

Single
Core
25
33
42
57
76
101
123
155
191
228
267
305
347
-

HO7RN-F
21
28
36
50
67
8/8
110
138
170
205
245
271
310
-

Table 4.4: Current carrying capacity of power cables PVC insulated conductors in accordance with VDE 0298

25

Cummins Engine

GENERATING SETS

Full Load
Current
U=400 Vac
Cosj: 0,8

Current
Capacity of
Cable at Air
(Ampere)

Cable Section
YVV 25C
(mm)

Model

Stand by
Power
(kVA)

AC 39

39

57

80

4 x 16

AC 55

55

80

105

3 x 25 / 16

AC 66

66

95

130

3 x 35 / 16

AC 70

70

101

130

3 x 35 / 16

AC 90

90

130

160

3 x 50 / 25

AC 115

115

166

200

3 x 70 / 30

AC 150

150

216

245

3 x 95 / 50

AC 160

160

230

285

3 x 120 / 70

AC 200

200

288

325

3 x 150 / 70

AC 250

250

360

400

2 x (3 x 70 / 30)

AC 250

250

360

400

2 x (3 x 70 / 30)

AC 275

275

396

400

2 x (3 x 70 / 30)

AC 350

350

504

570

2 x (3 x 120 / 70)

AC 400

400

576

650

2 x (3 x 150 / 70)

AC 500

500

720

855

3 x (3 x 120 / 70)

ACQ 515

515

744

855

3 x (3 x 120 / 70)

AC 550

550

792

855

3 x (3 x 120 / 70)

ACQ 550

550

792

855

3 x (3 x 120 / 70)

AC 650

650

939

1140

4 x (3 x 120 / 70)

AC 703

703

1015

1140

4 x (3 x 120 / 70)

ACQ 720

720

1040

1140

4 x (3 x 120 / 70)

AC 825

825

1192

1300

4 x (3 x 150 / 70)

ACQ 830

830

1199

1300

4 x (3 x 150 / 70)

ACQ 881

881

1267

1425

5 x (3 x 120 / 70)

AC 1030

1030

1483

1625

5 x (3 x 150 / 70)

ACQ 1030

1030

1483

1625

5 x (3 x 150 / 70)

AC 1130

1130

1627

1710

6 x (3 x 120 / 70)

ACQ 1130

1130

1627

1710

6 x (3 x 120 / 70)

AC 1435

1435

2066

2275

7 x (3 x 150 / 70)

AC 1675

1675

2412

2600

8 x (3 x 150 / 70)

ACQ 2100

2100

3024

3250

10 x (3 x 150 / 70)

ACQ 2250

2250

3251

3575

11 x (3 x 150 / 70)

Table 4.5.1: Recommended cable cross sections (50 Hz, Gen-sets). Note: PVC isolated cables YVV suitable 0,6/1kV VDE norms and TSE

26

Current
Capacity of
Cable at Air
(Ampere)

Cable Section
YVV 25 C
(mm2)

Stand by
Power
(kVA)

ALP 8

12

25

4 x 2.5

ALP 12

12

17

25

4 x 2.5

ALP 15

15

21

25

4 x 2.5

ALP 16

16.5

23

34

4x4

ALP 22

22

31

34

4x4

ALP 30

30

43

60

4 x 10

AP 500

500

720

855

3 x (3 x 120 / 70)

AP 550

550

792

855

3 x (3 x 120 / 70)

AVP 515

515

742

855

3 x (3 x 120 / 70)

AVP 550

550

792

855

3 x (3 x 120 / 70)

AKMTU 720

720

1036

1140

4 x (3 x 120 / 70)

AKMTU 780

780

1123

1300

4 x (3 x 150 / 70)

AKMTU 925

925

1332

1425

5 x (3 x 120 / 70)

AKMTU 1035

1035

1490

1625

5 x (3 x 150 / 70)

AKMTU 1500

1500

2160

2275

7 x (3 x 150 / 70)

AKMTU 1700

1700

2448

2600

8 x (3 x 150 / 70)

AKMTU 2050

2050

2952

3250

10 x (3 x 150 / 70)

AKMTU 2200

2200

3168

3250

10 x (3 x 150 / 70)

ADZ 110

110

158

200

3 x 70 / 30

ADZ 175

175

252

285

3 x 120 / 70

ADZ 360

360

518

570

2 x (3 x 120 / 70)

ADZ 400

400

576

650

2 x (3 x 150 / 70)

ADZ 490

483

695

735

3 x (3 x 95 / 50)

ADZ 538

534

768

855

3 x (3 x 120 / 70)

ADZ 550

550

792

855

3 x (3 x 120 / 70)

Deutz

MTU

Lister Petter

Model

Perkins

Full Load
Current
U=400 Vac
Cosj: 0,8

Volvo

GENERATING SETS

Tablo 4.5.2 Recommended cable cross sections (50 Hz, Gen-sets).

Note: PVC isolated cables YVV suitable to 0,6/1kV VDE norms and TSE

27

Current
Capacity of
Cable at Air
(40C ambient
temperature)
(Ampere)

Cable Section
(NYY) Single core
for each phase
(mm2)

Model

Stand by
Power
(kVA)

Lister Petter

Full Load
Current
U=400 Vac
Cosj: 0,8

ALP 10-6

10

14.4

22

2.5

ALP 15-6

15

21.6

30

ALP 21-6

21

30

38

Perkins

GENERATING SETS

AP 616-6

616

890

1068

4x120

AP 693-6

693

1001

1068

4x120

Table 4.5.3 Recommended cable cross sections (60 Hz, Gen-sets).

Note : PVC isolated cables YVV suitable to 0,6/1 kV , VDE norms and TSE

28

Cummins

GENERATING SETS

Full Load
Current
U=400 Vac
Cosj: 0,8

Current
Capacity of
Cable at Air
(40C ambient
temperature)
(Ampere)

Cable Section
(NYY) Single core
for each phase
(mm2)

Model

Stand by
Power
(kVA)

AC 44-6

44

63,5

76

16

AC 66-6

66

95

123

35

AC 77-6

77

111

155

50

AC 100-6

100

144

191

70

AC 135-6

135

195

228

95

AC 165-6

150

238

267

120

AC 225-6

225

325

382

2x70

AC 275-6

275

397

456

2x95

AC 350-6

350

505

534

2x120

AC 383-6

383

553

610

2x150

AC 450-6

450

650

800

3x120

ACQ 498-6

483

698

800

3x120

AC 550-6

550

794

915

3x150

AC 616-6

616

890

1068

4x120

ACQ 616-6

616

890

1068

4x120

AC 754-6

754

1089

1220

4x150

ACQ 758-6

758

1095

1220

4x150

ACQ 935-6

935

1351

1525

5x150

ACQ 1030-6

1030

1488

1525

5x150

ACQ 1025-6

1025

1481

1525

5x150

AC 1150-6

1150

1661

1830

6x150

ACQ 1160-6

1160

1676

1830

6x150

AC 1232-6

1232

1780

1830

6x150

ACQ 1450-6

1450

2095

2135

7x150

AC 1590-6

1590

2297

2440

8x150

AC 1930-6

1930

2789

3050

10x150

ACQ 2200-6

2200

3179

3355

11x150

ACQ 2500-6

2500

3612

3660

12x150

Table 4.5.4 Recommended cable cross sections (60 Hz, Gen-sets).

Note : PVC isolated cables YVV suitable to 0,6/1 kV , VDE norms and TSE

29

4.12.5 Grounding/Earthing Requirements:

The frame of the generating set must be
connected to an earth ground. Since the set is
mounted on vibration isolators, the ground
connection must be flexible to avoid possible
breakage due to vibration.
Ground connection cables or straps should have
at least full load current carrying capacity and
meet applicable regulations.
4.12.6 Alternator Reconnection: Most
alternators can be reconnected to suit different
output voltages. Ensure that all other
components such as circuit breakers, current
transformers, cables and ammeters are suitable
before operating at a different voltage.
4.12.7 Parallel Running: Extra equipment
must be fitted for the standard generating sets
to be operated in parallel with other generating
sets or with mains power.
4.12.8 Insulation Test: Before starting the
generating set after installation, test the insulation
resistance of the windings. The Automatic
Voltage Regulator (AVR) should be disconnected
and the rotating diodes either shorted out with
temporary links or disconnected. Any control
wiring must also be disconnected.
A 500V Megger or similar instrument should
be used. Disconnect any earthing conductor
connected between neutral and earth and
megger an output terminal to earth. The
insulation resistance should be in excess of 1M
to earth. Should the insulation resistance be
less than 1M the winding must be dried out.

sound absorbing wall coverings, that can be

used to reduce the noise levels of generating
sets.
4.14 ENGINE JACKET WATER HEATER
Jacket water heater is used in order to startup
the generating set more easily and to take the
load. In automatic generating sets jacket water
heater is standard. In manual type generating
sets it is an option. Heater warms up the jacket
water of the engine when the generating set is
not working.

4.15. TOWING (Mobile Generating Sets)

4.15.1 Preparing to Tow: Inspect all
components of the coupling equipment on the
towing vehicle and the generating set for defects
such as excessive wear, corrosion, cracks, bent
metal, or loose bolts.
Inspect tyres for condition and proper inflation.
Check that all tail lights, if equipped, are operating
properly and that all reflectors are clean and
functional.
4.15.2 Towing: Whenever towing a mobile
generating set, remember that manoeuvra-bility
and stopping distance will be affected by the
weight of the trailer.
WARNING
When towing mobile generating set, observe
all Codes, Standards or other regulations and
traffic laws. These include those regulations
specifying required equipment and maximum
and minimum speeds.
Do not permit personnel to ride on the mobile
generating set. Do not permit personnel to
stand or ride on the drawbar or to stand or
walk between the generating set and the towing
vehicle.
Avoid gradients and avoid potholes, rocks or
other obstructions and soft or unstable terrain.
Ensure the area behind and under the mobile
set is clear before reversing.
4.15.3 Parking: Park the set on a dry level
area that can support its weight. If it must be
located on a slope, park it across the grade so
that it does not tend to roll downhill. Do not
park the set on grades exceeding 15.

4.13 ACOUSTIC SILENCING

Control of generating set noise is becoming
very important in most installations. There is a
range of components available to control the
noise level.
WARNING
Ear protection must be worn when operating
or working around an operating generating set.
4.13.1 Exhaust Silencers: As discussed in
Section 4.8 the exhaust silencer will decrease
sound levels from the engine.
4.13.2 Canopies: Section 4.2 discusses sound
attenuating canopies that lower the noise level
of the entire generating set.
4.13.3 Other Sound Attenuation: For
installations in buildings there are other types
of equipment such as acoustic louvers, splitter
vents and fan silencers, as well as

4.16 STORAGE
Long term storage can have detrimental effects
on both the engine and alternator. These effects
can be minimized by properly preparing and
storing the generating set.

30

6. GENERAL PRECAUTIONS
AND CONTROLS WHICH
MUST BE DONE BEFORE
STARTING UP THE
GENERATING SET

4.16.1 Engine Storage: The engine should

be put through an engine preservation
procedure that includes cleaning the engine
and replacing all the fluids with new or
preserving fluids.

Make a general visual inspection on the engine

and alternator. Check if there is any breakage,
crack, indentation, leakage or looseness.
Never operate the generating set before
removing any fault, if any.
Take out foreign materials such as keys, tools,
cleaning wool, papers etc. on the engine and
the alternator.
Check the fuel level in the day tank. Refill
with fuel if it is low.
Check the engine oil level on the dip stick.
Refill with an appropriate oil if it is low. Oil
level normally must be close to the maximum
level line.
Look at the water level by opeing the radiator
tap. If it is inadequate add more water. Water
level must be 30 mm. lover than the water
filling neck.
Engine cooling water must include antifreeze
according to the coolest weather conditions
in the area. A mixture of 50% antifreeze and
50% water provides a good protection in all
area.
Inspect the radiator air outlet hood, open if
clogged and clear away all obstructions in
front of the air outlet.
Check the air filter gauge. Clean or replace
the air filter, if necessary.
Keep the inlet opening open.
Make sure that the generating set can easily
take air from te environment.
Check the battery connection cables. Take
care to tighten the loosened battery terminals
with spanner and, cover with special substance
and keep clean in order to avoid oxidation.
Open the battery caps and check the liquid
level in the cells. Add distilled water, if
necessary, so as to be 1 cm higher than the
separation. Never fill the cells with tap water,
acid water or acid.
Check if the circuit breaker outlet switch is
in OFF position.
Make sure that the emergency stop button
is not pressed.

4.16.2 Alternator Storage: When an

alternator is in storage, moisture tends to
condense in the windings. To minimize
condensation, store the generating set in a
dry storage area. If possible use space heaters
to keep the windings dry.
After removing the generating set from
storage, perform an insulation Check as
discussed in 4.12.8.
4.16.3 Battery Storage: While the battery
is stored, it should receive a refreshing charge
every 8 weeks up to a fully charged condition.

5. GENERATING SET
MAINTENANCE
A good maintenance program is the key to
long generating set life. The recommended
maintenance program is provided on the
Periodic Maintenance Chart. This chart is
given with all generating sets.
Maintenance and service should only be
carried out by qualified technicians. The
maintenance and service which are done must
be recorded to the Maintenance Record
Form. In General, the generating set should
be kept clean. Do not permit liquids such as
fuel or oil film to accumulate on any internal
or external surfaces. Wipe down surfaces
using an aqueous industrial cleaner.

31

7. GENERATING SET CONTROL SYSTEMS

To control and monitor the generating set,
an electronic control system has been used.
Depending on the requirements of the set,
one of several different standard control systems
may be fitted. These include ME 30, ME 40
model Manual Control Systems, P 500
Automatic Control Systems (with AMF), P 2010
Auto start Control System and P 2020
Automatic Control System (with AMF). Control
panel provides a means of starting and stopping
the generating set, monitoring its operation and
output and automatically shutting down the set
in the event of a critical condition arising such
as low oil pressure or high engine temperature.

7.2. STARTING WITH P500 AUTOMATIC

CONTROL PANEL (with AMF)
7.2.1 Manual Operation
Check the precautions and controls starting up
the generating set.
To initiate a start sequence in MANUAL, press
the push
button and the start sequence is
initiated.
After fuel solenoid is energised, then the starter
motor is engaged.
Engine cranked for a 10 second period, If the
engine fails to fire during this cranking attempt
then the starter motor is disengaged for a 10
second period. Should this sequence continue
terminated and fail to start
fault will be
illuminated.
When the engine fires, the starter motor is
disengaged and locked out at 20 Hz measured
from the Alternator output.
After the starter motor has disengaged, the
Safety On timer is activated, allowing Oil
pressure, High Engine Temperature, Under
-speed, Charge Fail and any delayed Auxiliary
fault inputs to stabilise without triggering the
fault. The generator will run off load, unless
the mains supply fails or Remote start on
load signal is applied, at which point the load
will be transferred to the generator. If Auto
mode is selected, and the mains supply is
healthy with the remote start on load signal
not active, then the Remote Start Delay Timer
begins, after which, the load is disconnected.
The generator will then run off load allowing
the engine a cooling down period.
Selecting STOP de-energises the fuel solenoid,
bringing to stop.

7.1 Starting with ME 30 or ME 40

Manual Control Panel
Check the precautions and controls before
starting up the generating set
To start the generating set, turn the key
switch to the hand position, which
will
power up the unit (DSE 701 module)
Pressing start button (1) will energise the
Fuel solenoid, then the starter motor. The
button should be pressed for the duration of
the crank period.
When the engine fires, the starter motor is
disengaged and locked out at 20 Hz measured
from the alternator output.
After the starter motor has disengaged, safety
on timer is activated (which is fixed at 12
seconds), allowing oil pressure, high engine
temperature and charge fail to stabilise without
triggering the fault.
If the generator has not started when the
start button has been released or generator
fails once it is running, the key switch must
be turned to stop (0) and then back to hand
position before another start cn be invoked.
Check the alternator output voltage and
frequency and engine oil pressure, engine
temperature.
The gen set should run 2-3 minute no load
When the engine warm after alternator output
circuit breaker sholud be ON position.

7.2.2 Automatic Mode Of Operation

This mode is activated by pressing the A U T O
pushbutton. An LED indicator beside the button
confirms this action. Whether the start sequence
is initiated by mains (utility) failure or remote
input, the following sequence is followed:
After Start Delays the Fuel Solenoid is energised,
then one second later, Starter Motor is engaged.
The engine is cranked for 10 second period. If
the engine fails to fire during this cranking attempt
then the starter motor is disengaged for a 10
second rest period. Should this sequence continue
beyond the 3 starting attempts, the start sequence
will be terminated and Fail to Start
fault
will be illuminated. When the engine fires, the
starter motor is disengaged and Safety On timer
activated.
If the remote start is being used and has been
configured to Remote start is on load or the
mains has failed, the load will be transferred to
the generator.
On the return of mains supply, (or removal of
the Remote Start signal if the set was started by
remote signal), the Stop delay timer is initiated.
Once it has timed out, the load is transferred
back to the mains (utility). The Cooling timer
expires the Fuel Solenoid is de -energised, bringing
the generator to a stop.

Figure 7.2
Model DSE 704 module
Figure 7.1
Model DSE 701 module

32

7.3 Starting with P2010 Autostart

Control Panel
7.3.1 Manual Operation

This mode is activated by pressing the

AUTO
push button. An LED indicator beside
the button confirms this action.
When a Remote Start signal is applied to the
remote start input, the following sequence is
initiated:
The Remote Start Active indicator illuminates
(if configured)
To allow for false signals the Start Delay timer
is initiated.
After this delay the Fuel Solenoid is energized,
then one second later, the Starter Motor is
engaged. The engine is cranked for a pre-set
time period. If the engine fails to fire during
this cranking attempt then the strter motor
is disengaged for the pre-set period. Should
this sequence continue beyond the set number
of attempts, the start sequence will be
terminated and Fail to Start
fault will
be displayed accompanied by a flashing
shutdown
symbol.
When the engine fires, the starter motor
disengaged and locked out at a pre-set frequeny
from the alternator output. Rising oil pressure
can also be used to disconnect the starter
motor, however it cannot be used for under
speed or over speed detection.
If an auxiliary output has been selected to give
a load transfer signal, this would then active.
On removal of the Remote Start signal, the
stop delay timer is initiated, once it has timed
out, the Load Transfer is de-energise, removing
the load. The cooling timer is then initiated,
allowing the engine a cooling down period off
load before shutting down. Once the Cooling
timer expires the Fuel Solenoid is de-energised,
bringing the generator to a stop.
Should the Remote Start signal be re-activated
during the cooling down period, the set will
return on load.

Check the precautions and controls starting

up the generating set.
NOTE: If a digital input configured to panel
lock is active, the LCD will display the
icon. When in panel lock, changing modules
will not be possible.
Viewing the instruments
and event logs
is not affected by panel lock.
To initiate a start sequence in MANUAL press
the pushbutton. When the controller is in
the manual button), pressing the START (1)
button will initiate the start sequence.
NOTE: There is no Start Delay in this mode
of operation.
The Fuel Solenoid is energized, then the
Starter Motor is engaged. The engine is
cranked for a preset time period. If the engine
fails to fire during this cranking attempt then
the starter motor is disengaged for the preset
rest period. Should this continue beyond the
set number of attempts, the start sequence
will be terminated and fail to start
fault
will be displayed accompanied by a flashing
shutdown indicator.
When the engine fires, the starter motor
disengaged and locked out at a pre-set frequency
from the Alternator output. Rising oil pressure
can also be used to disconnect the starter
motor, however it cannot be used for under
speed or over speed detection.
The generator will run off load, unless a Remote
Start signal is applied, and if Load Transfer has
been selected as a control source, the
appropriate auxiliary output selected will active.
If the Remote Start signal is removed, the
generator will continue to run On load until
Auto mode is selected. The Remote Stop Delay
Timer will time out, the load is then
disconnected. The generator will then run off
load allowing the engine a cooling down period.
Selecting STOP (0) de-energises the Fuel
Solenoid, bringing the generator to a stop.

Scroll
button

Config /
log button

LCD display

User configurable
LCD indicators
with text insert

Alarm
indicators

7.3.2 Automatic Mode of Operation

Load
indicators

NOTE: If a digital input configured to panel

lock is active, the LCD will display the
icon. When in panel lock, changing modules
will not be possible.
Viewing the instrument
and event logs
is not affected by panel lock.

Generator
indicators

Stop mode Manual mode Config+ Auto mode

Start button
(config enter) (when in manual)
(config.)

Figure 7. 3 Desription of Controls on DSE5210 module

33

7.4 Starting with P 2020 Automatic

Control Panel (with AMF)
7.4.1 Manual Operation

7.4.2 Automatic Mode of Operation

Check the precautions and controls starting

up the generating set.
NOTE: If a digital input configured to panel
lock is active, the LCD will display the
icon. When in panel lock, changing modules
will not be possible.
Viewing the instruments
and event logs
is not affected by panel lock.
To initiate a start sequence in MANUAL press
the pushbutton. When the controller is in
the manual button), pressing the START (1)
button will initiate the start sequence.
NOTE: There is no Start Delay in this mode
of operation.
The Fuel Solenoid is energized, then the
Starter Motor is engaged. The engine is
cranked for a preset time period. If the engine
fails to fire during this cranking attempt then
the starter motor is disengaged continue
beyond the set number of attempts, the start
sequence will be terminated and fail to start
fault will be displayed accompanied by
a flashing shutdown indicator.
When the engine fires, the starter motor
disengaged and locked out at a pre-set
frequency from the Alternator output. Rising
oil pressure can also be used to disconnect
the starter motor, however it cannot be
used for under speed or over speed detection.
The generator will run off load, unless a
Remote Start signal is applied, and if Load
Transfer has been selected as a control source,
the appropriate auxiliary output selected will
active.
If the Remote Start signal is removed, the
generator will continue to run On load until
Auto mode is selected. The Remote Stop
Delay Timer will time out, the load is then
disconnected. The generator will then run
off load allowing the engine a cooling down
period.
Selecting STOP (0) de-energises the Fuel
Solenoid, bringing the generator to a stop.

NOTE: If a digital input configured to panel

lock is active, the LCD will display the
icon. When in panel lock, changing modules
will not be possible.
Viewing the instrument
and event logs
is not affected by panel lock.
This mode is activated by pressing the
AUTO
push button. An LED indicator beside
the button confirms this action.
When a Remote Start signal is applied to the
remote start input, the following sequence is
initiated:
The Remote Start Active indicator illuminates
(if configured)
To allow for false signals the Start Delay timer
is initiated.
After this delay the Fuel Solenoid is energized,
then one second later, the Starter Motor is
engaged. The engine is cranked for a pre-set
time period. If the engine fails to fire during
this cranking attempt then the starter motor
is disengaged for the pre-set period. Should
this sequence continue beyond the set number
of attempts, the start sequence will be
terminated and Fail to Start
fault will
be displayed accompanied by a flashing
shutdown
symbol.
When the engine fires, the starter motor
disengaged and locked out at a pre-set
frequency from the alternator output. Rising
oil pressure can also be used to disconnect
the starter motor, however it cannot be used
for under speed or over speed detection.
If an auxiliary output has been selected to
give a load transfer signal, this would then
active.
On removal of the Remote Start signal, the
stop delay timer is initiated, once it has timed
out, the Load Transfer is de-energise,
removing the load. The cooling timer is then
initiated, allowing the engine a cooling down
period off load before shutting down. Once
the Cooling timer expires the Fuel Solenoid
is de-energised, bringing the generator to a
stop.
Should the Remote Start signal be re-activated
during the cooling down period, the set will
return on load.

34

8. GENERAL PRECAUTIONS AND

CONTROLS WHICH MUST BE
DONE AFTER STARTING UP
THE GENERATING SET

7.4.3 Test Operation

NOTE: If a digital input configured to panel
lock is active, the LCD will display the
icon. When in panel lock, changing modules
will not be possible.
Viewing the instruments
and event logs
is not affected by panel lock.
To initiate a start sequence in TEST, press
the
pushbutton. When the controller is
in the test mode (indicated by an LED indicator
beside the button), pressing the START (1)
button will initiate the start sequence.
NOTE: There is no Start Delay in this mode
of operation.
The Fuel Solenoid is energized, then the
Starter Motor is engaged. The engine is
cranked for a preset time period. If the engine
fails to fire during this cranking attempt then
the starter motor is disengaged for the preset rest period. Should this sequence continue
beyond the set number of attempts, the start
sequence will be terminated and Fail to Start
fault will be displayed accompanied by
a flashing shutdown indicator.
The generator will continue to run on load
regardless of the state of the mains supply or
remote start input until the Auto mode is
selected. If Auto mode is selected, and the
mains supply is healthy with the remote start
on load signal not active, then the Remote
Stop Delay Timer begins, after which, the
load is disconnected. The generator will then
run off load allowing the engine a cooling
down period.
Selecting STOP (0) removes the Close
Generator output (if configured) and deenergises the Fuel Solenoid, bringing the
generator to a stop.
Scroll
button

Config /
log button

LCD display

Check for any abnormal noise or vibration

on the generating set.
Check if the exhaust system has any leakage.
Monitor the generating set operation by
means of the gauges on the control panel.
Check the engine temperature and oil
pressure by means of the gauges on the panel.
Oil pressure must reach the normal value 10
seconds after the generating set operation.
Monitor the generating set outlet voltage and
frequency by means of the gauges on the
panel. Check on the voltmeter, if the voltage
between phases is 400 V and between phase
and neutral is 230 V. Check that the frequency
at idle is 51-52 Hz (for 50 Hz operation or
61-62 Hz for 60 Hz operation) on generating
sets with mechanical governors and 50 Hz
or 60 Hz on generating sets with electronic
governors. Outlet voltage is adjusted exfactory. Adjustments should be done only by
authorized personnel.
If an engine block water heater is not available,
put the generating set under load after
warming with a 10 minute idle run (manual
models).
Putting the generating set under load must
be done as follows:
Set the alternator outlet switch on the panel
to ON position.
Set the load switches (or fuses) on the
distribution panel to ON position one by one.
This way, the generating set cannot be
suddenly put under full load. Otherwise, the
engine stalling or alternator winding insulation
deformation or burning can occur.
Set the alternator outlet switch on the circuit
to OFF position before you stop the
generating set.
Continue to run the unloaded diesel engine
for the purpose of cooling for 5 minutes and
then stop.
Never operate the generating set before
removing any fault, if any.

User configurable
LCD indicators
with text insert

9. STOPPING THE GENERATING SET

9.1 At Manual Models:

Alarm
indicators
Load
indicators

Before stopping the generator, alternator

output, circuit braker should be OFF position.
The genset should run 2-3 minute with no
load.
To stop the generator turn the key switch
to the STOP O position, de-energises key
switch the fuel solenoid, bringing the generator
to a stop.

Generator
indicators

Stop mode Manual mode Config+ Auto mode

Start button
(config enter) (when in manual)
(config.)

Figure 7. 4 Desription of Controls on DSE5220 module

35

9.2 At Automatic Models:

10.1.1.1 DSE 701 MODULE FEATURES

Engine supervision and protection
Key switch operation on the fron panel

The genset should run 2-3 minute with no

load.
Selecting STOP O position, de-energises
the fuel solenoid, bringing the generator to
a stop.

10.1.1.2 DSE 701 MODULE EMERGENCY LEDs

10. GENERATING SET CONTROL SYSTEMS

To control and monitor the generating set,
an electronic control system has been used.
Depending on the requirements of the set,
one of several different standard control
systems may be fitted. These include ME 40
Model Manual Control panel or P 500, P2020
Auto Mains Failure panel and 2010 Autostart
Panel Control panel provides a means of
starting and stopping the generating set,
monitoring its operation and output, and
automatically shutting down the set in the
event of a critical condition arising such as
low oil pressure or high engine temperature.

High engine temperature, shutdown

Low oil pressure, shutdown
Over speed, shutdown
Charge failure, warning

10.1 CONTROL PANELS

Figure 10.2 DSE 701 Manuel Control Module

Control, supervision and protection panels

are mounted on the generator base frame.

10.1.1 MANUAL CONTROL SYSTEM - ME 40

11

12

AUTO

GE

NC Y

ST
OP

Control with DSE 701 Module

3 Ammeters
1 Hours run meter
1 Volt - Frequencymeter (by LED) and
selector switch
Engine oil pressure gauge
Engine coolant temperature gauge
Emergency stop push button
3 pole alternator circuit braker

EME R

Figure 10.3 P500 Automatic Control Panel

10.2.1 AUTOMATIC CONTROL SYSTEM

P 500 PANEL SPECIFICATION

Figure 10. 1 ME 40 Manual Control Panel

36

Control with DSE 704 module

3 Ammeters
1 Hours run meter
1 Volt-Frequencymter (by LED) and selector
switch
Engine oil pressure gauge
Engine coolant temperature gauge
Emergency stop push button
Static battery charger
Thermally delayed overload protection
Engine water heater control

10.2.1.1 DSE 704 MODULE FEATURES

Three phases mains sensing

Engine protection
Automatic engine starting and stopping
Simple push button controlled operation
Stop-Reset/Manual/Auto
Micro processor based design
Configurable via front panel
Configurable timer setting
Adjustable mains fail voltage level
Mains/Generator, change-over contactor
control
External remote start input

Control with DSE 5220 Full Automatic Mains

Failure Module
Static Battery Charger
Emergency stop shutdown push button

GE

N CY
ST

OP

EMER

10.3.1 AUTOMATIC CONTROL SYSTEM

P 2020 PANEL SPECIFICATIONS

Figure 10.5 P 2020 Automatic Control Panel

Figure 10.4 DSE 704 Automatic Start and

Control Module

10.2.1.2 FAULT CONDITIONS

DISPLAYED BY LED ILLUMINATION

High engine temperature, shutdown

Low oil pressure, shutdown

10.3.1.1 DSE 5220 MODULE FEATURES

Monitoring AC mains supply
Automatic controls generating set, start and
shutdown
Provides signal to change over switch gear
Remote communication via RS 232 port or
RS 485 modbus output.
Front panel programming of the module
settings
Scrolling digital LCD display
Event logging of shutdown alarms
Easy pushbutton control
Stop/Reset, Auto, Manual, Test
Metering via LCD display

Over speed, shutdown

Charge eltarnator fault, warning
Start failure, shutdown

Generator volts (F-F/F-N)

Generator amperes (L1, L2, L3)
Generator frequency (Hz)
Generator kVA
Generator kW
Generator Cosj
Engine oil pressure (PSI & Bar)
Engine temperature (C & F)
Engine speed RPM
Engine hours run
Mains volts (F-F / F-N)
Mains frequency (Hz)
Plant battery volts

Figurel 10. 6 DSE 5220 AMF Control Module

37

Multiple Alarms

10.4.1.1 DSE 5210 MODULE FEATURES

Automatic start and stop the genset
Provides signal to Load Transfer
Remote communication via RS 232 port or
RS 485 modbus output.
Front panel programming of the module
settings
Scrolling digital LCD display
Event logging of shutdown alarms
Easy pushbutton control
Stop/Reset, Auto, Manual, Test

Under/over generator volts; Pre-Alarm and

Shutdown
Under/over generator frequency; Pre-Alarm
and Shutdown
Under/over mains volts
Under/over mains frequency
Over current; Shutdown
Low oil pressure; Pre-Alarm and Shutdown
High engine temperature; Pre-Alarm and
Shutdown
Under/over speed; Shutdown
Low coolant level; Shutdown
Fail to start; Shutdown
Fail to stop; Warning
Low/High Battery volts; Warning
Charge fail; Warning
Emergency stop; Shutdown
Can Data Fail; Shutdown
Can ECU Fail; Pre-Alarm and Shutdown

The Event Log

5220 control module maintains a log of the
last 15 shutdown alarms to enable the
operator or engineer to view the past alarms
history.

Metering via LCD display with the

following instrumentation displays
Generator volts (F-F / F-N)
Generator amperes (L1, L2, L3)
Generator frequency (Hz)
Generator kVA
Generator kW
Generator Cosj
Engine oil pressure (PSI & Bar)
Engine coolant temperature (C&F)
Engine speed RPM
Engine hours run
Plant battery volts

10.4.1 AUTOSTART CONTROL SYSTEM

P2010 PANEL SPECIFICATIONS
Control with DSE 5210 Autostart Module
Emergency stop shutdown push button

GE

N CY
ST

OP

EMER

Figurel 10. 8 DSE 5210 Autostart Control Module

Figure 10.7 P 2010 Autostart Control Panel

38

Multiple Alarms

10.5.4 Frequency Meter

Under/over generator volts; Pre-Alarm and

Shutdown
Under/over generator frequency; Pre-Alarm
and Shutdown
Over current; Shutdown
Low oil pressure; Pre-Alarm and Shutdown
High engine temperature; Pre-Alarm and
Shutdown
Under/over speed; Shutdown
Low coolant level; Shutdown
Fail to start; Shutdown
Fail to stop; Warning
Low / High Battery volts; Warning
Charge fail; Warning
Emergency stop; Shutdown

A meter that indicates the output frequency

of the generating set. The engine maintain a
relatively constant speed under governor
control so as to provide the proper operating
frequency of 50 Hz or 60 Hz when the
generating set is operating at full load. In
practice, if the generating set has a manual
governor control system, no load frequencies
of approximately 52 62 Hz for 50 Hz and 60
Hz respectively, are considered. The frequencies
will fall, as the set is loaded, to 50 Hz and 60
Hz at full load.

10.5.5 Hours Run Meter

A meter that indicates the total number of
hours of generating set operation to aid in
maintenance.

The Event Log

5220 control module maintains a log of the
last 15 shutdown alarms to enable the operator
or engineer to view the past alarms history.

10.5.6 Water Temperature Gauge

A temperature gauge connected to a sensor
in the engine to monitor engine coolant
temperature. Normal level of the engine coolant
temperature is approximately 85C (185F).

10.5 Panel Equipments

Before starting or running the generating set,
the operator should become fully acquainted
with the instruments and controls. The
instuments should be observed from time to
time while the generating set is running so that
any abnormal readings can be detected before
problems arise. Some of our standard manual
and automatic control panels are shown in
figures 10.1, 10.3, 10.5 and 10.7. In addition
optional equipment items can be added to the
panel so the panel fitted on the generating set
may be slightly different from the typical ones
shown.

10.5.7 Oil Pressure Gauge

A gauge to monitor engine oil pressure from
the moment the engine is cranked. On cold
engines the oil pressure will be significantly
higher until the engine warms up.

10.5.8 Emergency Stop Pushbutton

A red lockdown pushbutton that immediately
shut dow the generating set and will inhibit
start until the pushbutton has been released
by turning it.

10.5.1 Ac Voltmeter

10.5.9 Alternator Protection

A voltmeter that indicates the AC voltage

generated at the alternator output terminals.
The reading indicated on the voltmeter will
vary depending on the connections made inside
the alternator terminal box, the setting of the
voltage regulator and the position of the
voltmeter selector switch.

In our standard production, the alternators in

automatic operation generating sets are
protected with a thermic protector against
overload (with P 500 control panel).
In our standard production of manual operated
generating sets, the alternators are protected
against overload and short circuit by a thermic
magnetic switch and then the generating set is
given load.

10.5.2 Voltmeter Selector Switch

A selector switch allowing the operator to
select voltage reading between phases.

10.5.3 AC Ammeter
An ammeter that indicates the AC electrical
current being delivered which is dependend
on the connected load. There are three
ammeters.

39

10.9 ICONS AND LCD IDENTIFICATION ON

DSE 5210 and DSE 5220 MODULE
10.9.1 PUSH BUTTONS
Display

Description

Display

Description

Stop / Reset

AUTO

Auto mode

Manual mode

Start (when in
manual mode)

Scrool

Configure / log

Display

Description

10.9.2 STATUS / MEASUREMENT UNITS

Display

Description

Display

Description

Display

Description

L1

Phase

L2

Phase

L3

Phase

L1 - N

Phase - Neutral

L1 - N

Phase-Neutral

L1 - N

Phase-Neutral

L1 - L2

Phase - Phase

L2 - L3

Phase-Phase

L3 - L1

Phase-Phase

BAR

Pressure

Kpa

KPa Oil Pressure

Units

PSI

Pressure

Voltage

Temperature

Hz

Frequency

Amperes

Temperature

RPM

Speed

kW

KiloWatts

kVA

Apparent Power

Cosj

kW divided by
kVA

Hours Run

AC

Generator

Timer in progress

DC

Factory (load)

Fuel Level

Event log

Configuration
mode active
Panel locked by
configurable input

10.9.3 ALARM INDICATIONS

Display

Description

Display

Description

Description

Warning Alarm

Shutdown Alarm

Fuel

Low Oil Pressure

High Current
Warning

Charge Fail

High Coolant
Temperature
Fail to start
(Over-crank)

v
v

Over Voltage
(AC)
Under Voltage
(AC)

Emergency Stop

Display

Over Voltage
(DC)

Over-Speed

Under Voltage
(DC)

Under-speed
Auxiliary Alarm

Auxiliary Indication

(Warning or Shutdown

40

Electrical Trip

Hz
Hz

Over Frequency
Under Frequency

11. THE PLACEMENT AND INSTALLATION

OF TRANSFER SWITCH
The placement of the transfer switch and its
mountings:
Position the transfer switch near the emergency
power panel.
Locate the transfer switch in a place where it
is clean, not over-heated, and having a good
ventilation. If the environment temperature is
above 40 C, fuses and breakers will open
more easily. There must be enough working
place around the transfer switch.
Having a fuse or breaker between the generating
set and the transfer switch is optional.
(Connection cables used in transfer switch).
Currents from the generating set must be
distributed equally to the three phase if possible.
Current from one phase should not exceed
the nominal current.

MAINS

Current from one phase should not exceed

the nominal current. Two different power
cables, which will be used between the
generating set and the transfer switch is on
the generating set. (Main supply cable and
power cable for emergency power panel)
If the transfer switch panel is apart from the
generating set, transfer switch must be placed
as close as possible to the distributor panel.
In this case power cables are drawn from
generating set, mains panel and emergency
power panel. Furthermore 8 x 2.5 mm control
cable must be drawn from the generating set
control panel.

GENERATING SET

CUSTOMER DISTRIBUTION PANEL

MAINS
BREAKER
EMERGENCY

OVER CURRENT
PROTECTION

TRANSFER
SWITCH

OTHER

CUSTOMER DISTRIBUTION PANEL

Figure 11 Typical emergency power system installation

41

12. DSE 530 MODEL FULL AUTOMATIC

TRANSFER SWITCH CONTROL SYSTEM
Control of the DSE 530 module is by a four position
rotary key-switch, mounted on the front of the
module with Auto, Auto with Manual Restore and
Manual Run On Load and Off-Load position.

12.2 Manual Restore Mode Of Operation

If the module is placed in
AUTO
Manual Restore mode, it will monitor the incoming mains supply. Should the incoming
mains supply fail (or fall outside of pre-set limits),
the following sequence will occur like automatic
mode until the generator close signal will be supplied
and run on load.
On return of the mains supply to within limits, the
mains return delay timer is initiated, once the timer
expires the 530 module will wait for a manual
restore to mains. This is achieved by placing the
keyswitch control into the auto position, the sequence will then continue as described in auto
mode of operation.

Figure: 7.10 DSE 530 Automatic Transfer

Switch Control Module

12.3 Manual Operation

To initiate a start sequence
in manual, turn the selector switch to
Start and Run Generator Off Load. The start and
run generator output relay is de-energised and the
relay contacts close, givin a Remote Start signal to
the engine starting controller.
The engine stating controller should now start the
generator, the 530 module will monitor the generator voltage and frequency and on the monitored
values are above a pre-set Loading level the
generator will become available.

12.1 Automatic Mode Of Operation

If the module is placed in
AUTO
AUTO mode, it will monitor the incoming mains supply. Should the incoming mains
supply fail, the following sequence will occur.
The module will start its Start Delay timer, this
is used to ensure that the start event is really
required and the failure is notjust a momentary dip
in the supply. Once this timer has expired the
module will continue with its normal sequence.
If the mains supply returns to within limits during
the start delay timer the unit will retun to a standby state.
The start and run generator output relay is deenergised and the relay contacts close, giving a
Remote Start signal to the engine starting controller.
The engine starting controller (DSE 560, etc.) will
now start the generator, the 530 module monitor
the generator voltage and frequency (and an optional
generator ready input) and once the monitored
values are above a pre-set Loading level the
generator will become available. This is indicated
by the illumination of the appropriate LED on the
mimic diagram.
As soon as the generator is available the transfer
timer is initiated (3 second). Once the transfer
timer has expired, the generator close signal will
be supplied and run on load.
On return of the mains supply to within limits, the
mains return delay timer is initiated, once the timer
expires the generator close signal is removed,
removing the load. The cooling timer is then initiated,
allowing the engine a cooling down period off load
before shutting down.
Should the mains fall out of limits during the cooling
down period, the set will return on load after the
start delay timer has expired.

To transfer the load from the

mains supply to the generator, turn
the selector switch to Start and Run generator
On Load.
To stop the generator return the selector switch
to the Auto position. The sequence will then continue
as described in auto mode of operation.
12.4 INDICATIONS
The module status is indicated by front panel LEDs.
Mains Available LED: Indicates that the incoming
AC mains supply is within limits and available o
supply the load.
Generator Available LED: Indicates that the
generator output voltage and frequency are within
acceptable limits and available to supply the load.
Generator On Load LED: Indicates that the
generator close signal has been supplied.
Alternatively it can be configured to give true
indication of load switching device status
Mains On Load LED: As above but with respect
to the mains.
Auxiliary LEDs: Use PC808 software to configure
function.
Start Delay Active LED: Indicates that the 530
internal start delay timer is running. Once expired
the start signal will be given to the generator
controller.
Mains Return Timer Active LED: Indicates
that the 530s internal mains return timer is running.
Once expired the load will be transferred back to
the mains supply.

42

13. ALTERNATOR TROUBLESHOOTING

Symptom
Alternator does not excite

Possible Cause
Blown fuse
Insufficient residual voltage
No residual voltage

Connections are interrupted

Corrective Action
Replace fuse
Increase speed by 15%
For an instant apply on the (+) and
(-) terminals of the electronic regulator
a 12 V battery voltage with 30 ohm
resistor in series respecting the polarities.

After being excited

alternator does no excite

Connections are interrupted

Check connection cables as per

attached drawings.

Low voltage at no load

Voltage potentiometer out of setting

Intervention of protection
Winding failure

Reset voltage
Check engine speed
Check wingings

High voltage at no load

Voltage potentiometer out of setting

Failed regulator
Voltage potentiometer out of setting
Intervention by protection

Reset voltage
Substitude regulator
Reset voltage potentiometer
Current to high, power factor lower
than 0.8;
Speed lower than 4% of rated speed

Failed regulator
Rotating bridge failure

Substitude regulator
Check diodes, disconnect cables

Higher than rated voltage

at load

Voltage potentiometer out of setting

Failed regulator

Reset voltage potentiometer

Substitude regulator

Unstable voltage

Speed variation in engine

Regulator out of setting

Check regularity of rotation

Regulate stability of regulator by
acting on stability potentiometer

Lower than rated voltage

at load

43

14. ENGINE TROUBLESHOOTING

The starter motor turns the engine too slowly:
Battery capacity to low
Bad electrical connection
Fault in starter motor
Wrong grade of lubrication
The engine does not start or difficult to start:
Starter motor turns engine too showly
Fuel tank empty
Fault in fuel control solenoid
Restriction in a fuel pipe
Fault in fuel lift pump
Dirty fuel filter element
Air in fuel system
Fault in atomsers
Cold start systems used incorrectly
Fault in cold start system
Misfire:
Restriction in a fuel pipe
Fault in fuel lift pump
Dirty fuel filter element
Air in fuel system
Fault in atomisers or atomisers of an incorrect type

Restriction in fuel tank vent

Wrong type or grade of fuel used
Restriction in exhaust pipe
Not enough power:
Restriction in a fuel pipe
Fault in fuel lift pump
Dirty fuel filter element
Air in fuel system
Restriction air filter/cleaner or induction system
Fault in atomisers or atomisers of an incorrect type
Restriction in exhaust pipe
Restriction in fuel tank vent
Wrong type or grade of fuel used
Restricted movement of engine speed control
Engine temperature is too high or low
Dirty fuel filter element
Restriction air filter/cleaner or induction system
Air in fuel system
Fault in atomisers or atomisers of an incorrect type
Fault in cold start system
Restriction in fuel tank vent
Restricted movement of engine speed control
Engine temperature is too high
Incorrect valve tip clearances
Vibration:
Fault in atomisers or atomisers of an incorrect type
Restricted movement of engine speed control
Engine temperature is too high
Fan damaged
Fault in engine mounting or flywheel housing
The pressure of the lubrication oil is too high:
Wrong grade of lubrication oil
Defective gauge
The engine temperature is too high:
Restriction air filter/cleaner or induction system
Fault in atomisers or atomisers of an incorrect type
Fault in cold start system
Restriction in exhaust pipe
Fan damaged
Too much lubrication oil in sump
Restriction in air or water passages of radiator
Insufficiant coolant system
Crankcase pressure:
Restriction in breather pipe
Vacuum pipe leaks or fault in exhauster

The pressure of the lubriation oil is too low:

Wrong grade of lubrication
Not enough lubrication oil in sump
Defective gauge
Dirty lubrication oil filter element
High fuel consumption:
Restriction air filter/cleaner or induction system
Fault in atomisers or atomisers of an incorrect type
Fault in cold start system
Wrong type or grade of fuel used
Restricted movement of engine speed control
Restriction in exhaust pipe
Engine temperature is too low
Incorrect valva tip clearances
Black exhaust smoke:
Restriction air filter/cleaner or induction system
Fault in atomisers or atomisers of an incorrect type
Fault in cold start system
Wrong type or grade of fuel used
Restriction in exhaust pipe
Engine temperature is too low
Incorrect valva tip clearances
Engine over load
Blue or white exhaust smoke:
Wrong grade of lubrication
Fault in cold start system
Engine temperature is too low
The engine knocks:
Fault in fuel lift pump
Fault in atomisers or atomisers of an incorrect type
Wrong type or grade of fuel used
Fault in cold start system
Engine temperature is too high
Incorrect valve tip clearances

Bad compression:
Restriction air filter/cleaner or induction system
Incorrect valve tip clearances
The engine starts and stops:
Dirty fuel filter element
Restriction air filter/cleaner or induction system
Air in fuel system
The engine shuts down after approximately
15 seconds:
Badconnection towards oil pressure switch/coolant
temperature switch

The engine runs erractically:

Fault in fuel control
Restriction in a fuel system
Fault in fuel lift pump

44

GENERAL PRECAUTIONS ABOUT WARRANTY

DEAR AKSA GENERATING SET OPERATOR
PLEASE TAKE CARE TO THE FOLLOWING IN ORDER TO PREVENT THE GENERATING SET WARRANTY
TO BECOME INVALID BEFORE THE TERMINATION OF THE WARRANTY PERIOD AND TO ENSURE
TROUBLE-FREE OPERATION OF THE GENERATING SET WITH A LONG LIFE!...

MAINTENANCE AND REPAIR WORKS WILL NOT BE COVERED BY THE WARRANTY UNLESS THE
WARRANTY CERTIFICATE, INVOICE OR DELIVERY CERTIFICATE OF THE GENERATING SET IS SUBMITTED.

THE WARRANTY OF THE GENERATING SET WILL BECOME INVALID IN CASE OF ANY INTERVENTION
OF ANY PERSON OTHER THAN AUTHORIZED AKSA SERVICES OR BY PRIOR WRITTEN APPROVAL FROM
AKSA POWER GENERATION ON THE GENERATING SET FOR ANY REASON.

CONTROL AND MAINTENANCE WORKS INDICATED IN THE PERIODICAL MAINTENANCE SCHEDULE AND
THE OPERATING MANUAL MUST BE CARRIED OUT COMPLETELY AND TIMELY. THE FAILURES DUE TO
INCOMPLETE OR UNTIMELY MAINTENANCE ARE NOT COVERED BY THE WARRANTY.

GENERATING SET SHOULD BE MOUNTED AS INDICATED IN THE OPERATING MANUAL. OTHERWISE,

THE PROBLEMS WHICH ARE LIKELY TO OCCUR WILL NOT BE COVERED BY THE WARRANTY.

CUSTOMER IS RESPONSIBLE FOR THE FAILURES WHICH ARE LIKELY TO OCCUR IN CASE THAT THE
DIESEL OIL USED CONTAINS DIRT OR WATER.

THE OIL TYPE INDICATED IN THE OPERATING MANUAL SHOULD BE USED IN THE ENGINE. OTHERWISE,
THE FAILURES WHICH ARE LIKELY TO OCCUR WILL NOT BE COVERED BY THE WARRANTY.

BATTERIES WILL NOT BE COVERED BY THE WARRANTY IF THEY ARE SUBJECTED TO BREAKAGE,
EXCESSIVE ACID FILL OR HARDENING BY LEAVING UNCHARGED.

ON MODEL KSD 501 MANUAL GENERATING SETS WITH START PANEL, THE IGNITION KEY SHOULD
BE RELEASED IMMEDIATELY AFTER THE ENGINE IS STARTED-UP. IN CASE THAT THE ENGINE DOES
NOT START UP, THE STARTING SEQUENCE SHOULD NOT BE APPLIED MORE THAN 3 TIMES EACH
WITH 10 SECOND INTERVALS. OTHERWISE, STARTING GEAR CAN BE BROKEN OR STARTER MOTOR
CAN BURN. THESE CONDITIONS ARE NOT COVERED BY THE WARRANTY.

ON MANUAL GENERATING SETS, NEVER START OR STOP THE DIESEL ENGINE WHEN THE GENERATING
SET IS UNDER LOAD. ENGINE SHOULD BE STARTED AND STOPPED AFTER LOAD IS DISCONNECTED
AND THE GENERATING SET IS AT IDLE CONDITION. OTHERWISE, THE VALVES CAN BE SEIZED, THE
VOTAGE REGULATOR, TRANSFORMER AND DIODES CAN BE BROKEN DOWN. THESE CONDITIONS ARE
NOT COVERED BY THE WARRANTY.

OUR COMPANY DOES NOT TAKE THE RESPONSIBILITY OF THE DAMAGES ON THE MAINS SUPPLY
CONTACTOR OF THE AUTOMATIC GENERATING SETS DUE TO OVERCURRENT, LOW OR HIGH
VOLTAGE.

NEVER REMOVE THE BATTERY TERMINALS WHILE THE GENERATING SET IS IN USE. EVEN A MOMENT
OF DISCONNECTION CAN CAUSE A DAMAGE ON THE ELECTRONIC CLOSING RELAY OF THE CHARGE
ALTERNATOR AND ON THE ELECTRONIC ENGINE SPEED CONTROL CIRCUIT. THESE CONDITIONS
ARE NOT COVERED BY THE WARRANTY.

FAILURES DUE TO OVERLOAD AND UNBALANCED LOAD IN EXCESS OF THE GENERATING SET POWER
(SUCH AS ALTERNATOR AND CONTACTOR FAILURES) ARE NOT COVERED BY THE WARRANTY.

FAILURES DUE TO OVERLOAD AND UNBALANCED LOAD IN EXCESS OF THE GENERATING SET POWER
(SUCH AS ALTERNATOR AND CONTACTOR FAILURES) ARE NOT COVERED BY THE WARRANTY.

WHEN THE MANUAL GENERATING SET IS STARTED UP, IT SHOULD BE WARMED BY OPERATING AT IDLE
FOR 5 MINUTES. WHEN STOPPING THE DIESEL ENGINE, IT SHOULD BE UNLOADED AND THEN
CONTINUED TO BE OPERATED FOR COOLING FOR 10 MINUTES BEFORE STOPPING. OTHERWISE,
PROBLEMS WHICH ARE LIKELY TO OCCUR WILL NOT BE COVERED BY THE WARRANTY.

WARRANTY PERIOD IS 1 YEAR BEGINNING FROM THE PURCHASE DATE.

45

HEAD OFFICE
Aksa Jeneratr Sanayi A..
Glbahar Caddesi 1. Sokak 34212
Gneli, stanbul - Turkey
Tel: +90 212 478 66 66
Fax: +90 212 657 55 16
E-mail: [email protected]
FACTORIES
TURKEY
Glbahar Caddesi 1. Sokak 34212
Gneli, stanbul - Turkey
Tel: +90 212 478 66 66
Fax: +90 212 657 55 11
TURKEY
Taoca Yolu No: 22 Mahmutbey
Baclar, stanbul - Turkey
Tel: +90 212 446 43 01
Fax: +90 212 446 43 00

UNITED KINGDOM
Lister Petter Industrial Estate,
Church Road Cam
Dursley Glos, GL11 5PY - United Kingdom
Tel: +44 1453 549 223
Fax: +44 1453 549 227

BRANCH OFFICES & WAREHOUSES

ALGERIA
Aksa Algeria
20, Rue DAnjou Hydra, Alger
Algeria
Tel
: +213 21 60 81 48
Fax : +213 21 48 41 44
E-mail : [email protected]
CHINA
Aksa China (Suzhou)
Zhongxin City, 128 Donghuan Road,
Room 706 Suzhou China 215021 P.R. China
Tel
: +86 512 6725 1137
Fax : +86 512 6725 1317
DUBAI
Aksa Middle East
Post Box No 18167, Warehouse
No. RA08/LC07 Jebel Ali Free Zone, Dubai
United Arab Emirates
Tel
: +971 4883 3292
Fax : +971 4883 3293
E-mail : [email protected]
IRAQ
Aksa Iraq
Sahet Al-Wathik, Al Wahda St. 909 Baghdad,
Iraq
Tel
: +88 216 333 05 108
+88 216 677 42 506
E-mail: [email protected]

www.aksa.com.tr

IRAN
Aksa Iran
Apartment 22, the 6th. Floor
Dasto Building, No: 1421 Vali-e-Asr Ave.
Tehran, Iran
Tel
: +98 21 205 4212
+98 21 201 6502
Fax : +98 21 201 8921
E-mail : [email protected]
KYRGHYZISTAN
Aksa Central Asia Ltd.
40 Manas Str. Bishkek, Kyrghyz Republic
Tel
: +996 312 21 17 79
Fax : +996 312 66 23 23
E-mail : [email protected]
KAZAKHISTAN
Aksa Central Asia Kazakhstan Ltd.
111/48 Furmanova Str. Almaty, Kazakhstan
480091
Tel
: +732 72 50 67 31 / 41
Fax : +732 72 50 67 91
E-mail : [email protected]
NIGERIA
Aksa Generators (W.A) Ltd.
90, Oduduwa Crescent,
Ikeja Gra, Lagos, Nigeria
Tel
: +234 1 481 3121
Fax : +234 1 320 5681
E-mail : [email protected]

SINGAPORE
Aksa Far East Pte. Ltd.
94 Tuas Avenue 11 Singapore 639103
Tel
: +65 6863 2832
Fax : +65 6863 0392 - 6863 2956
E-mail : [email protected]
UNITED KINGDOM
Aksa International (UK) Ltd.
Lister Petter Industrial Estate, Church Road Cam
Dursley Glos, GLII 5PY / United Kingdom
Tel
: +44 1453 549 223
Fax : +44 1453 549 227
E-mail : [email protected]