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SDMO Generating set General considerations Safety instructions

1. Remove the release cable from the hitching plate 29 75 NB wear indicator on certain models The coupling head has a wear indicator figure 5 3 that tells you whether the wear limit of the towing vehicle s hitching joint or of the towed vehicle s coupling has been reached To use this indicator couple the trailer and drive the towing vehicle around 500 m so that the coupling head is positioned When you have done this check the wear as indicated below Figure 5 3 Wear indicator If the green section of the indicator can be seen on the coupling Secured the coupling head is in good condition or the hitching joint wear is less than the prescribed limit If the green section of the indicator is completely masked and only the red section is visible it can be assumed either that the hitching joint has reached the wear limit diameter lt 49 61 mm or that the coupling head and hitching joint both show signs of wear or finally that the hitching joint is in good condition diameter 50 mm but that the coupling head is worn In these conditions the coupling head may come free from the hitching joint and the trailer detach from the towing vehicle Therefore the coupling head and hitching joint must be checked before they are reused Any defective part must be replaced Important 30 75 EN 5 2 1 2 Site trailer Before hitching the trailer check the hitching system of the towing vehicle it must be perfectly
2. Figure 6 23 Examples of exhaust chimneys 46 75 Cooling Four types of produced heat must be dissipated v Heat from the engine cooling circuit s v Heat radiation from the engine and exhaust Y Room ventilation air v Exhaust gases The systems described below evacuate and channel the heat produced by the engine cooling circuit a Ventilated radiator The engine cooling circuit is connected to a tubular ribbed radiator at the end of the frame in order to implement this procedure This radiator is cooled by the fan controlled directly by the engine In all cases the air is blown in the direction from the fan to the radiator Cooling is ensured by the circulation of air across the room An expansion vase can compensate for the variations in the volume of coolant fluid according to the temperature b Air cooler The engine cooling circuit is connected to an air cooler located inside or outside the room in order to implement this procedure When located in the room it operates in the same way as a ventilated radiator The fan or fans are either coupled to the diesel engine or driven by one or more electric motors If the air cooler is moved outside on the roof or in another room the coolant pipes are extended meaning that ventilation of the room is separate from the cooling In these installations the degassing conditions should be considered even more carefully than for a radiator In all cases the air cooler is cooled by the
3. Soundproofed door for access to the room and if required to the pressure lock for a very low sound level Sound traps fitted to the air inlet and outlet sleeves NAAN AON Sound trap Silencer Sound trap Soundproofed doors Figure 6 5 Example of an installation Ventilation A heat engine generates a certain amount of heat which must be evacuated outside the room to ensure the set works properly The heat released by the set originate from different sources Y Cylinder cooling v Radiation from the engine unit and exhaust duct v Alternator cooling Also the room must be fitted with air inlet and outlet openings suitable for the conditions of use and cooling system As you know insufficient ventilation will cause the atmospheric temperature to rise and lead to problems ranging from at least a loss of engine power to the set stopping altogether Air must flow through the set room from alternator gt engine gt radiator This solution also supplies the quantity of fresh air needed for combustion The openings should be of ample size Air intake and emission will be as direct as possible The cooling system will be connected to a sealed emission sleeve or cover to prevent hot air from being recycled The air inlet and emission openings should not be located close to one another Crankcase ventilation The vapours from the crankcase should preferably be removed outside the room in which the generating set is located
4. The maintenance manual for the alternator fitted to the generating set This documentation may be supplemented by Y Y The spare parts catalogue for the engine fitted to the generating set which enables a qualified user to identify a part and order it Composition list marker name reference and illustrations marker These parts catalogues are primarily available in English regardless of the engine manufacturer However this fact does not prevent identification of a part for subsequent ordering The part can always be identified using the illustrations contained in these catalogues and the order is made via the reference of the part found in the corresponding parts list see example below 1B24 1102 1102 VALVE COVER CDPa46108 ANA LINDE Part to identify for ordering Read marker number number 7 Find marker number f read ordering reference RE502987 CDP4510B To co t mco PART NAME e 3 SERIAL NO REMARKS PLUG NUT MB O RING 7505 X 2616 MM MEDIAL LIA FILLER CAP SUB FOR R500001 MARKED 1135380 SUB FOR RE7D400 ae aes m m e Je le SEHR ES def Dr Sx cen ye et et ope det oye GASKET KIT Ay INCL INSTRUCTIONS ANLEMUN 5 ES TRUZIONI INSTRUCCIONES ANVWISNIHGAR A SUITABLE FOR HISH TEMPERATURE CONWENT POUR HAUTES TEMPERATURES The workshop repair manual contains the information required for major servicing of the generating set or power plant enabling an exper
5. Voltage selector This function should be used by qualified persons only WARNING Adjust the output voltage correctly before connecting a load WARNING The voltage selector must not be used when the generating set is operating Figure 1 2 continued Pictograms and their meanings 9 75 EN 2 Safety THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows You should also refer to any local and national regulations that apply in accordance with your own jurisdiction KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries 2 1 General advice Use Y The operating and safety instructions must be made known to operating personnel They will be regularly updated Y Read and understand the manuals provided with the generating set pump unit or lighting column properly The manufacturer s instructions must remain at the disposal of technicians if possible in situ v The facility must be operated under the direct or indirect supervision of a person appointed by the operator who is familiar with the operation of the facility and the dangers and drawbacks of the products used or stored in the facility Y Do not wear loose clothing or
6. The whole site must be kept clean and in good condition v The premises must be kept clean and cleaned regularly with in order to avoid piles of dangerous or pollutant material or dust that could be susceptible to catching fire or causing an explosion The cleaning equipment must be adapted to accommodate the risks presented by such products and dust Y The presence of dangerous or combustible materials on premises where combustion apparatus is sheltered is limited to what is required for the operation Y The installations must be operated under the constant supervision of a qualified person This person should periodically check that the safety devices are working properly and ensure the correct fuel supply to the combustion apparatus v Apart from combustion apparatus flames in any form are prohibited This should be displayed in bold on a sign Y Residual water mud and waste spray is prohibited v The fuels to be used should correspond to the ones in the declaration file and the specifications prescribed by the combustion apparatus manufacturer v The fuel is considered as being in the physical state that is introduced into the combustion chamber Y Burning waste in the open air is prohibited v Except for where a specific agreement has been made once the gas supply main unit has been closed it can only be reopened by the gas distributor However the user may conditionally have access to it Check for each site Y Always protect your han
7. capacity and of the securing devices Blanking of apertures air inlets and outlets exhaust is obligatory for containers used in rail transport Generating sets must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during transportation of generating sets refer to section 5 1 General recommendations 33 75 EN 5 5 Shipping 5 5 1 Generating set with without enclosure Generating sets must be transported in a shipping container Transportation must be carried out in accordance with the rules of shipping The transport equipment must be appropriate for this usage and have all the safety guarantees load securing device In the case of a grouped load container SEl cases must be used for packing Generating sets must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during transportation of generating sets refer to section 5 1 General recommendations 5 5 2 Container CSC certified containers may be stacked in a cellular ship and have top grips Most of these containers are ISO containers which meet the standards stipulated by the International Organisation for Standardisation ISO Blanking of apertures air inlets and outlets exhaust is obligatory for containers with or without CSC certification Container Safety Convention CSC International convention governing container safe
8. etc o Check of the cooling equipment o Check of the equipment mountings correctly tightened retightening of the bolts v Electrical o Electrical checks check of the automatic and safety functions Check of the electrical regulation devices Check of the alternator insulation Retightening of the alternator bus bars Check of the auxiliaries insulation and their current consumption Check of the starter battery charge system o Check of the batteries These checks must be carried at the following recommended intervals or in accordance with the manufacturer s instructions Y Operation of the generating set in emergency x 100 hours per year once per year Y Operation of the generating set in emergency x 500 hours per year 3 times per year v Continuous operation of the generating set o Mechanical checks during oil changes o Electrical checks every 6 months O OOOO 10 2 Enclosure sealing A seal is used between the cover and the chassis and between the chassis and the retention cover to ensure leaktightness This seal must always be replaced whenever the cover is removed 10 3 Container servicing Y Lubricate the hinges and locks regularly Y Lubricate the joints with silicone grease v Wash and clean the bodywork using products designed for car bodywork Y Check the condition of the bodywork and retouch any scratches straight away to prevent the start of corrosion 10 4 Operation Notes on operation at no load
9. 1 20 13 5 2 Storage and transport v Batteries ready for use must be stored in a cool and dry place frost free protected from the sun self discharge v Batteries must be transported and stored vertically risk of acid spillage Y Leave the terminal cover on the positive terminal 71 75 EN 13 5 3 Installation v Batteries filled with acid have a density of 1 28 g ml and are charged v For dry batteries fill each part of the battery with acid to the maximum level marker or to 15 mm above the plates Leave the battery to rest for 20 minutes Y Before fitting the battery switch off the engine and any current consumer clean the terminals and coat them slightly with grease When connecting first connect the positive terminal and then the negative terminal Temperature during activation gt 10 C Fill with acid up to the mark or appr 1 cm above the edge of the plates yes The battery heats up Wait 5 to 20 mins v 12 5V Charge for 10 minutes Voltage check Fit on the generating lt 13 5 4 Check Aciddensity Chargestatus Voltagewhenidle O eT 1006 AAboe i 260V O pe 12 36 V From 50 recharge 12 18 V Risk of sulphation Under 11 88 V Unusabe 72 75 EN 13 5 5 Load preconization Y Highly discharged or sulphated batteries formation of whitish lead sulphate deposit on the pla
10. RENE E ETT REA 17 3 3 1 High capacity containers HC High Coba tratte po eo eb ane eco eo ato eee unio eo glos e ainia 17 o SIMIC EI Sexe ra DELIS ETE TEE A A N 17 bs M NEM E PSU ONL Cup 17 SA dH DL CPP 18 340 3 A A ON 19 3 4 Ide nv OSC Secs eset onset O daeh obs ooo un 19 5 Axl Generatins set wath and without ene OSUfe dll licita 19 S BABIES O ES 2 ARE a ETATO IST oT n Dnm nmn 22 4 1 Saer na A dolido drill sack did 22 4 2 Example or Hipatia dll 22 4 3 Pani Wire IN SthUCH ONS a n A sib Modes Lao L dina 22 27 3 IL Generate sel with and Without enelosuf eiie adi rode am tee oboe 22 Ally Shngme oreeneratme set without enelosufe ine roter dls 22 3 52 Sshnegmeo or enclosed eeneratime illa doa isti b Lia 23 A TROPK Tit CHUCK dec css 24 AL Handlins ASCE CH OMS A A ed eae R 24 Me MS MEE Ie SINE Uc 25 AR OMA AINA E o Roe EE 26 AI Container iuum oes 26 A rod A dim 27 LN SUA AR UTE 2v z Movie TT AILS ORC sie M T endo 28 5 1 General recommendations m es 28 5 2 Generatdmp SES OD Tallers uocis E di disp oodd a UR ee 28 23 31 Hitchins and unhitchine the trawler oet oret e Ep vv rv Ex vat bnt ene a eed aan 28 SI WOnsoad all ici 28 ee A a ho ac tse e inline aaisost iat isse getesent a it betont acne me teda tata
11. TNS system In the TN system the alternator neutral is earthed and the user grounds are connected to the main protective conductor PE itself connected to the earth socket v TN S earth and neutral separated Figure 7 2 TNS neutral system In the TN S system the power supply is automatically cut by the opening of the over current protection circuit breaker protecting the faulty circuit v TN S is obligatory for networks with conductors of cross section lt 16mm Aluminium 58 75 7 2 4 IT system Ph 1 Ph 2 Ph 3 PE Neutral Ground earth earth Figure 7 3 Neutral system IT In the IT earthing system the alternator s neutral is earthed via an impedance device Z greater than 1000 Ohms or insulated Z The facility s grounds are earthed see diagram above It should be noted that an IMD Insulation Monitoring Device is connected in parallel to this impedance device Z to monitor the circuit s insulation at all times Upon a first fault nothing happens the current flowing through the metal frame passes through the neutral impedance device Z which means a very low current or practically zero if neutral is insulated so the contact voltage is not dangerous That is why hospitals concert halls etc use this system to avoid outages in the case of a first fault The IMD Insulation Monitoring Device detects this leak and reports it via an indicator light and or an alarm However upon a second fault both con
12. amate cat nian 31 5o AN A O o Pe E O seca Da ai os cusa d ai fpi codes td ak Copias eniti desires bid 32 PPP T rrr 32 5 3 PO S PONE a TE T TTE T TO T t E 33 Do Generatim Set WIL nou enc IOSUEE siciliana 33 VESPA DII SET rct 33 5 4 A A A A creta oo Gates ce ached ak E E E S 33 SE T Generdtme Set Willi witDioub enc lOSUEE sidad lcd 33 A mrt 33 5 5 OP ia a E a E s tedbL iu Desedentadits 34 ILGS Set ith without e nc OSUDS crisi a a a a didas 34 SEPA A E EAEE A cn 34 5 6 Alr Transpo mme 35 25 6 1 Generating set With without enc Us ii 35 0 2 CONAM ia 35 SR FOIE EO RE HIE ERREUR 36 6 1 SER S UIS M SIRE SSC EI T ET TOTO E A 36 6 1 1 Indoor installation of a generating set with or without enclosure oooocccooccncnocnnonncnnononnnoncnnononononnnnonnononccnnnnncnnoncnnnns 37 MN NIME TUUS Um EE 37 64 D2 Measurements and la OU nd 37 SU EPA GS DUUM NUES 48 A EO DIO ERR TEE STILE 48 Oc NC OU rio eI 49 A A O T 49 A MEME SS SICUTI 50 6 2 Mobile generat ne To NR RR EHE 51 SEAE EE rad TET ON MMO UN Gs conetestuonindati teta tios int utente DE em Ot D E EE AE Ac Stone ctn m tec t ee 51 9 2 2 id A o e o adetust urs isse turtle A A deite Rota 51 0 2 5 Grenetaum SCL On EIEE ld estote lode c au ud 51 0 25 1 Implementation TOE TR SEO aon soc tos 51 0 2 A Enclosed aene AVIA b SEE sooo uere di ide alados Lc a ud 51 02 5 ETT scat st cs o opos ded bon oscula bs nd buts b cd dme a
13. containers are identified via identification plates attached close to the emergency stop T g PM Identification plate Figure 3 10 Location of identification plates for generating sets in containers The description of the plates is given in paragraph 3 4 1 Generating set with and without enclosure 21 75 N 4 Handling 4 1 Safety during handling To unload electrical generating sets from their transport supports with optimum safety and efficiency you must ensure that the following points are observed v The lifting machinery or equipment is suitable for the work required v The slings are positioned in the rings provided for this operation the lifting arms are resting fully underneath the base frame cross members or the lifting bars are inserted in the apertures provided in the base to lift the entire generating set depending on the model Y The ground is able to bear the load of the generating set and its lifting machinery without stress otherwise lay down stabilising beams of sufficient strength Y The generating set is put down as close as possible to its place of use or transport in a clear space with free access 4 2 Example of equipment used v Crane slings lifting beam safety hook shackles v Fork lift truck 4 3 Handling instructions 4 3 1 Generating set with and without enclosure 4 3 1 1 Slinging of generating set without enclosure v Attach the lifting machine s slings to the rin
14. fan s For cooling by radiator or air cooler in the room the increase in temperature due to heat radiation for the sizing of the installation should be taken into account C Lost water exchanger This type of cooling consumes a sizeable amount of water and hence there is an operating cost to be taken into account This the solution when local provisions ensure the flow of water and do not allow the ventilation provisions required for cooling by a ventilated radiator or air cooler to be enacted These lost water installations consist mainly of an exchanger with one of its circuits fitted with an expansion receptacle connected to the engine cooling circuit The latter s water pump ensures circulation The second exchanger circuit known as raw water is connected between the building s water supply and the drain A valve fitted upstream of the exchanger can enable and cut off circulation With automatic sets this valve should also come with an electric control solenoid valve This system s heat exchange ensures engine cooling The room will require a ventilation system and this type of installation requires a detailed study d Ventilation of the room Extractor fans and or air blowers can evacuate heat radiated from the engine and supply fresh air to the room and equipment in the case of external air coolers or lost water exchangers If fans are being used several fans will regulate the temperature than one large one fan Ventilation of the
15. get close to machines in operation Note that the fans are not clearly visible when the engine is running Warn personnel present to keep their distance during operation Do not run the generating set pump unit or lighting column without refitting the protective covers and closing all the access doors Never let a child touch the generating set pump unit or lighting column even when shut down Avoid operating the generating set pump unit or lighting tower in the presence of animals disturbance scares etc Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site When chocking the trailer on a slope ensure that there is nobody in the path of the trailer Never start the engine without an air filter or exhaust Engine with turbocharger never start the engine without fitting the air filter The compressor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage Y Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube causing bodily injury Y Do not touch the lighting column lights when they are switched on SENS SS SUS Maintenance Y Follow the maintenance table and its instructions v Always use tools in good condition which are suited t
16. in the open air is prohibited Always protect your hands when checking for leaks Pressurised liquids may penetrate body tissue and cause serious damage Risk of blood contamination Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil Except by special agreement once closed the gas supply main unit must only be re opened by the gas distributor However the user may access it under certain conditions Check these for each site 2 2 Risks relating to supply gases applies to gas generating sets The gas is explosive It is forbidden to smoke go near or create sparks when the tank is being filled and near to the generating set SENS S Request the user technical notes and LPG or NG safety data sheets from your gas supplier Gas installations must be installed maintained and repaired by recognised specialists Do not attempt to open unseal or operate on gas supply pressure relief valves and on the gas line in general Gas supply procedures must be carried out in the open air outside in accordance with local regulations in an area well away from fire people or animals Check the sealing of the gas supply circuit using soapy water with the circuit pressurised or using a leak detector 2 3 Risks related to exhaust gases and fuels The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high Always use g
17. lights are obligatory for on road driving Signalling must comply with regulations in force in the country of use Red rear lights Front reflective devices white direction indicators stop lights Rear reflective devices red triangle Side reflective devices orange Figure 5 4 Example of French signalling 32 75 EN 5 3 Road transport 5 3 1 Generating set with without enclosure Road transportation of generating sets must be carried out in accordance with the regulations of the countries concerned The transport equipment trailer semi trailer etc must be suitable for this usage and have all the safety guarantees in terms of load bearing capacity and of the securing devices Driving should also be on truck roads of sufficient quality not to damage the generating sets on board Put a plastic cover over non enclosed generating sets during transportation Chock and fix the generating sets on the lorry floor and strap them down Generating sets must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during transportation of generating sets refer to section 5 1 General recommendations 5 3 2 Container Road transportation of containers must be carried out in accordance with the regulations of the countries concerned The transport equipment trailer semi trailer container carrier etc must be suitable for this usage and have all the safety guar
18. off valve for which the control must be located outside the room INGRE See eRe TTT TTT TTT ttt ett tt 1 Daily service tank V1 10 Non return valve 19 Filler 2 Retention tank V2 V1 11 3 way valve 20 Dipstick 3 Electro pump 12 Filter 21 Tank vent 4 Manual pump 13 Meter 22 Earth plate 5 DT leak detection 14 Shut off valve 23 Safety valve 6 DT dipstick 15 Engine isolation valve 24 Safety valve casing 7 DT vent 16 Single or double wall tank 25 Shut off valve casing 8 Isolation valve 17 Filling limiter 26 Tracking 9 Filter 18 Foot valve with filter 27 Leak detection for DP tank Figure 6 6 Example of an installation 40 75 EN Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container if the generated set is fitted with this option The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Three different fittings are available Figure 6 7 Fluid retention container integrated into the tank chassis Figure 6 8 Offset fluid retention container underneath the generating set chassis Figure 6 9 Offset fluid retention container integrated into the chassis and tank Generating sets fitted with the option shown in diagram 6 9 above are also equipped with a high level i
19. premises requires a detailed study and should take into account the atmospheric air temperature and loss of pressure of components located in the air inlet and outlet grilles sound traps etc in particular 47 75 EN 6 1 2 Container 6 1 2 1 Location The position should first be considered in relation to the electricity distribution centre fuel storage the general environment and type of ground before the equipment can be accommodated The installation area should be flat enough for the frame to rest level on it and strong enough so that the container does not sink down miim gt il l Ant i H Du MES y a TA mu NO iis RE Weisel ESE uL oy T a u 2 ia a y a a 4 zl ai A y d TL a TAL n 3i QAM n Y 4 NUBE Mete UE a VO Vr maed e ce ca aerea i peal gcc eres DEE E RA amp nr ns iat n a Ea MEC EUST a Pa eE FE A a pede TI ee Nae NE 9o A eT mu e E m c PRA A ee A recess should be made in the concrete slab at the ISO corners above all the container must not rest on the ISO corners YES Figure 6 24 Positioning containers 48 75 EN 6 1 2 2 Acoustics The environmental impact should also be analysed so that the disturbances to be caused by the equipment will not affect those living close by Therefore it is essential to be aware of the regulations in force in order not to be vulnerable to future legal action On
20. sucks or discharges v There is air intake check all the seals and the suction pipes v The foot valve suction valve no longer works there is probably dirt or some waste under the valve that it stopping it from resting on its seat check it Y There is dirt inside the pump blocking the valves remove the cover clean inside and check that the valves move freely Cable gland leak v Tighten the two cable gland bracket nuts alternately by one or two turns Otherwise remove this bracket take out the cable gland which is located in its housing Clean this housing and remove the residual lining Replace it with graphite braiding v Ifitis a pump without cable gland model 254 remove the cover replace the O ring checking that the piston axis is not oxidised If it is clean it carefully Also reline the groove with graphite braiding Frost The draining bolt is inefficient and the Japy pump has not been supplied by it for a long time except for special requests using the control On the other hand it is indispensable if the pump is exposed to frost to use a small draining tap on the suction pipes about 0 75m above the pump In any case the pipes must be fitted with a foot valve This device is necessary for draining the pump If there is a threat of frost do not forget to open this tap while checking that the discharge port is free to let air in Draining should take place normally but for increased safety after the water has flowed out pu
21. this subject the sound level of the set and reverberation effects on buildings must be taken into account B ll UN Figure 6 25 Examples of increase in sound level caused by reverberations and the sound directivity 6 1 2 3 Ventilation The installation of the equipment must also be carried out taking the prevailing winds into account the air inlets must be facing away to ensure there are no difficulties in adverse weather conditions entry of air snow sand etc The container air inlets and outlets must not be blocked A minimum distance of 2 metres must be kept between the container air inlets and outlets and any obstacle to ventilation ALLE LELLE ELE ELE CEE EEE ELE LEELE LEE EEE EEE ELE EEE ELE EEE EEE EL EEE LEC A Air inlet Air release a Al BEI A e ANA m Ti E umm e 4 D N mni A se R i 1 l DL A PDF T1 E a ne MV UR IK Air inlet f f Figure 6 26 Positioning constraints 49 75 6 1 2 4 Exhaust The equipment should also be installed taking the prevailing winds into account the air inlets must be facing away to ensure there are no difficulties in adverse weather conditions intake of air snow sand etc Be sure to remove the blanking cover s from the exhaust outlet s used for transport and replace them with the extension s provided with the generating set Figure 6 27 Removing the blanking cover If using a high chimney it is preferable to use a f
22. to prevent these vapours from being deposited on the radiator causing it become dirty and thereby reducing its cooling capability 39 75 EN Fuel Since the fuel is classed as a dangerous product certain regulations for storage and distribution must be followed It is also necessary to consult current laws when carrying out the installation It is usual to fit fixed installations with a daily service tank and storage tank These two tanks can be joined into one if the generating set consumption is low Do not used galvanised receptacles or brass coated receptacles for storing fuel Important Manual filling tank Solution for a manual starting generating set that is visually monitored This tank is often part of the frame and has a mechanical gauge filler neck and drain port Automatic filling tank located in the room This type of installation is subject to regulations Solution for automatic starting generating sets The tank is automatically filled by an electric drawing pump in a main storage tank Moreover it should be fitted with a retention container capable of collecting leaks with a capacity at least equal to that of the tank There must be an overflow pipe going back to the main tank Its section should be at least twice that of the supply pipes To prevent unpriming the tank is fitted slightly filled in relation to the diesel engine except in covered parking areas This tank must also be fitted with a shut
23. ION DUCT L ALUMINIUM MOUNTING BRACKET CENTRE OF THE REGULATOR AND OIL LEVEL TO MAINTAIN AT THE REGULATOR INLET SUPPLY OPENING BETWEEN THE THE OIL PRESSURE MUST BE LOWER REGULATOR AND THE ENGINE THAN 4 LBS Figure 13 5 Oil make up regulator 70 75 13 5 Battery maintenance 13 5 1 General information Safety Fit the battery so that it is properly ventilated Maintenance should only be carried out by qualified personnel If replacing the batteries use the same type of batteries Do not throw the old battery in the fire Only use insulated tools the operator should not be wearing a watch chain or any metal object Never use sulphuric acid or acid water to top up the electrolyte level Use an approved battery fluid Batteries release oxygen and hydrogen gas which are flammable Never bring flames or sparks near the battery risk of explosion Discharge any static electricity before handling the batteries by first touching an earthed metal surface Do not use the battery when the fluid level is below the minimum required level Using a battery with a low electrolyte level could result in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables remove the cable from the negative terminal first When reconnecting the battery connect the positive lead first Charge the battery in a well ventilated place with all the filler caps opened Ensure that the batt
24. SET PLAQUE CONSTRUCTEUR MANUFACTURER PLATE GROUPE ELECTROGENE GENERATING SET PLAQUE CONSTRUCTEUR MANUFACTURER PLATE PUISSANCE ACOUSTIQUE SOUND POWER EC 2000 14 SORAD tc 17 ex nue de la enm poe 105 MODAS 290m nma Caes bp TB 130098 da di 41 Far X307 90 41 E07 dave qim Dom Enclosed generating set and container GENERATING SET nrtu Dieselmotor J O H N B E R E Engine Serial Number CD4045T123456 Type 12V 4000 G60 Motor Nr 526 100 950 Abs Baujahr 2002 CD4045TF150 Coeff X XX DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE RG7935 UN 13NOV97 Masse Kg MTU Motoren und Turbinen Union Friedrichshafen GmbH O WOIVO PE RTA O ENGINE MODEL XXXXXXXX g3 TE g SPEC NO XXXXXX FRIEDRICHSHAFEN Dieselmotor SERIAL NO XXXXXXXXXX RATED NET POWER Leistung 1330 cW without fan kW hp XXX XXX with fan kW hp XXX XXX Drehz 1500 mi SPEED AT RATED POWER rpm TET pees ERU eee ae PRELIFT mm INJ TIMING X X X X XXxX X J Motoren und Turbinen Union Friedrichshafen GmbH O MADE IN SWEDEN 3826077 o ENGINES Figure 3 8 Examples of identification plates 20 75 LSA 4425705 Date ORE mama PUISSANCE RATING Hz ALTERNATEURS PAR R T NER ALTERNATORS Designation ARMOIRE DE 400K VA A0217010 Cde AVP31650 01C Reference SOREEL 371562 03 No OF 02280753 ELECTRICAL CABINET Figure 3 9 Examples of identification plates 3 4 2 Container Generating sets in
25. User quide and maintenance SDMO Generating set General considerations Safety instructions Installation Special maintenance advice MUE SD C_7 EN 33522903401 7 1 APEE AC arate E TR 4 1 1 lingo O E 4 Lil Generale conmenda OS cado be poire E A E E 4 RE Descapionor the Feference miatertalos aii iia adios dicas 5 1 2 Pictost als aid tDe re IMC AMAS ardid Ad seek Gentes 6 Dec DAMCU ech Sa mA PA AE dant E 10 2 1 General AG VCC I 10 22 Risks relating to supply gases applies to gas generating sets oocccooncncoocnncnnnnnnncnnononnnoncnnnnnnononncnnnnnononnnnnonnrnoncnnnononos 1 2 3 Risks related to exliaustedses and FUCKS tii dido deaidcida 11 2 4 Risks PelatedO O Produc T m 12 2195 Risk Or hire DUES and expos ON adosada 12 2 6 Risks related toc lectrical net WOERS isso E t de Die Ae Ae 13 2 7 Dangers presented by electric currents Edad A A A dise 13 2 8 RSS tela tedio momo Me Sel E 13 29 Recommendation for the operator and environment s sseesssesssessseesserssersseesseesssessserssersseesserssersserosesessereseessserss 14 PNEU LES EN EE Tm 14 S Gene Fe descrip 1 OMS o A a dae oes aee neat 15 3 1 Generatino ser WIM OUT enclose upein eie E a a a a a e a e e dedu sa ciese 15 23 2 FSC LOSE Gl Sonera nno Se Lou isdem seb case semen dr tildes celosos 16 3 3 OS IA PEINE LS
26. and under load When operating at no load or low load 30 of nominal power the operating conditions do not allow optimum running of the engine The main causes are as follows Y The low volume of fuel burned in the combustion chamber leads to incomplete combustion the resulting thermal energy means that the optimum engine operating temperature cannot be reached Y Overheated engines have lower compression ratios low compression ratio without turbocharging which are defined for full load and not suitable for good combustion at low load All of these factors lead to choking of the engine in particular the piston rings and valves which leads to Y Accelerated wear and glazing of the cylinder liners v Loss of sealing of seats and sometimes sticking of valve stems Consequently operating any turbocharged engine at low load 3096 can only have adverse repercussions on an engine s operation and its service life Maintenance intervals will have to be shortened to accompany harsh operating conditions Shortening draining intervals among other things will enable you to change the oil more frequently which will tend to be choked with unburnt particles and contaminated with fuel Adding a load bench is generally used to limit low load phases and obtain the periodic full loads necessary to unchoke the engine Finally when operating under load we advise vigilance towards the oil breather circuit and more particularly towards engines w
27. antees in terms of load bearing capacity and of the securing devices Driving must also be on truck roads of sufficient quality not to damage the container and its contents Blanking of apertures air inlets and outlets exhaust is obligatory for containers used in road transport Containers must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during transportation of generating sets refer to section 5 1 General recommendations 5 4 Rail transport 5 4 1 Generating set with without enclosure Rail transport of generating sets must be carried out in accordance with the specific rules of rail transport The transport equipment must be appropriate for this usage and have all the safety guarantees both in terms of load bearing capacity and of the securing devices Put a plastic cover over non enclosed generating sets during transportation Generating sets must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during transportation of generating sets refer to section 5 1 General recommendations 5 4 2 Container Rail transport of containers must be carried out in accordance with the specific rules of rail transport Containers must receive the necessary approvals for rail transport The transport equipment must be appropriate for this usage and have all the safety guarantees both in terms of load bearing
28. are not the main considerations in your choice it can be installed under a basic shelter to protect it from bad weather rain snow storms etc If a low noise level and fast start are important criteria e g emergency set or noise sensitive area particular attention will be given and the room will be built of framing concrete or solid concrete blocks 20 cm minimum covered in absorbent fireproof and insulating material A The fire test should comply with current legislation according to the type of building Base of the set An operating generating set generates a certain amount of vibratory energy This vibratory energy makes its way to the floor plate via the frame Mounted on elastic mountings our generating sets do not require a special floor plate in principle However a floor plate will be sufficiently strong and detached from the rest of the construction It will also be level smoothed by the flow and unshackled If there is a risk of vibrations being transmitted the set can be mounted on a separate floor plate insulated if necessary by a resilient material This solution is mainly used with very powerful generating sets Openings The room should include a certain number of openings which are required for it to operate v A door giving access to the generating set and its accessories preferably in line with the set s floor plate v Ventilation openings fresh air inlet and hot air outlet located so that scavenging takes
29. attachment points on an enclosed generating The lifting rings or brackets are intended for lifting the generating set only Do not lift a generating set on a trailer with these rings or brackets Important 23 75 EN 4 3 1 3 Fork lift truck v Position the forklift arms under the base frame except with generating sets fitted with forklift pockets in which case position the forklift arms in these pockets making sure that only its cross members are resting on the arms v Lift the equipment handling it gently v Set down the generating set in its unloading position Figure 4 3 Transporting a generating set using a forklift truck 4 3 1 4 Handling instructions Lift up the edge on the engine side slightly with 2 jacks then slide 3 rollers under the base frame Leave the base frame resting on the rollers then move the generating set manually As the generating set is moved re use the freed rollers by sliding them in turn under the base frame When it has reached its final location position the generating set then lift it up using jacks and support it on chocks Withdraw the rollers and lower the generating set checking that it is in the correct position then remove the jacks NOS S US SO Figure 4 4 Handling a generating set using rollers Only generating sets that do not have brackets built into the base frame can be moved using rollers The base frame support surface on the rollers must be free from defor
30. ay be cut with an axe Take great care to avoid the electric arc that will be generated by this Begin emergency procedures Resuscitation If breathing has stopped begin artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 2 8 Risks related to moving the set To unload the generating sets pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions you must ensure that the following points are observed Y The lifting machinery or equipment is suited to the work required in good condition and with sufficient lifting capacity v The slings are positioned in the rings provided for this operation the forklift arms are resting fully underneath all of the base frame cross beams or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set according to models Y For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set pump unit or lighting column the generating set pump unit or lighting column must be lifted up with an adjustable boom All the chains and cables must be parallel with each other and as perpendicular as possible with the upper edge of the generating set pump unit or lighting column Y If other equipment fit
31. bends needed must have a large radius For any suction over 2 metres a foot valve must be installed suction valve to hold the fluid in the pipe The pipe must not have any cracks or leaks The suction pressure height should not be confused with the vertical distance of the expanse of water to the pump Losses of pressure are inevitable and are related to Y The length and diameter of the pipe used according to the flowrate v The presence of a non return valve or elbows in this pipe A non return valve or elbow causes a loss of pressure equivalent to 5 metres of straight pipes Above a certain length of pipework or suction height or discharge height a larger diameter pipe than usual should be used Discharge Pumps tested to a pressure of 1 5 kg to 2 kg may therefore be deployed for a discharge of 15 m However the force to be generated by the person operating the pump will increase with flowrate and elevation head suction discharge Therefore with a low flow the fluid can be raised higher than with a large flow pump Draining It is essential to fit a small tap or screw on the suction pipe about 0 70 m below the pump Fitting The pump should be installed on a strictly vertical plane with the Japy logo on the discharge side Check that the mounting has a flat surface and that the nuts are tightened moderately and alternately to prevent distortion of the body 13 2 3 Maintenance and repair Faults The pump no longer
32. boxes packing in a SEI 4 C case solid case with waterproof cover is obligatory 5 6 Air transport The UN has classified generating sets as dangerous goods listed under UN code 3166 class 9 Engine internal combustion flammable liquid powered Any air shipment of generating sets must be subject to prior declaration to the air freight company in accordance with form MOD3909 For control boxes packing in a SEI 4 C case solid case with waterproof cover is obligatory 5 6 1 Generating set with without enclosure Air transport of generating sets must be carried out in accordance with the specific rules of air transport The transport equipment must be appropriate for this usage and have all the safety guarantees both in terms of load bearing capacity and of the securing devices Generating sets must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during transportation of generating set refer to section 5 1 General recommendations 5 6 2 Container Air transport of containers must be carried out in accordance with the specific rules of air transport The transport equipment must be appropriate for this usage and have all the safety guarantees both in terms of load bearing capacity and of the securing devices Generating sets must not be stacked Generating sets must not be operated during transport For the recommendations to be observed during trans
33. ch off the generating set for maintenance operations DANGER Use diesel fuel only The fuel is highly flammable handle with care Do not smoke near the generating set or expose it to a naked flame or sparks Shut down the generating set engine before filling the fuel tank Fill with fuel outside To prevent fire risks clean the generating set regularly Wipe away any dirt and traces of grease or fuel WARNING DANGER The exhaust gases from the engine are toxic and can affect health or even cause death Use the generating set outdoors only in well ventilated areas or fit an exhaust extension to discharge the exhaust gases outside Figure 1 2 Pictograms and their meanings 7 75 IDD Ee Hot coolant can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Do not open radiator while hot Moving parts can cause serious injury Do not operate with doors open Do not operate with guards removed Stop genset before servicing Avoid skin contact with exhaust manifolds turbochargers and mufflers Keep flam mable materials clear of the hot parts Do nottouch until the machine has sufficiently cooled Battery gas can explode Keep sparks and flames away from batteries Sulfuric acid in battery electrolyte is poisonous WARNING DANGER Hot coolant can cause serious burns Switch of
34. cidents For generating sets fitted with 4000 series MTU engines it is essential to remove the flywheel locking device crankshaft protection during transportation when commissioning the generating set before first start up Important 8 1 Installation checks Y Check that the general recommendations from section 6 Installation ventilation exhaust fluids etc are followed v Carry out level checks oil coolant diesel battery v Ensure that the generating set earth socket is earthed 8 2 Connection checks Y Check the remote controls by section and number sector auxiliaries LVCCP etc v Power up the auxiliaries to check the following components non exhaustive list o Fuel pump consumption and direction of rotation o Water preheating amperage and voltage o Battery charger o Etc v For generating set fitted with connectors for supply from an external tank monitor the first complete filling cycle after connecting to make sure that anti overflow mechanism is working properly 8 3 Operations before start up v Carry out the safety checks emergency shutdown oil pressure coolant temperature etc Y Open the oil make up tap if fitted 9 Checking after start up Y Mechanical checks oil pressure coolant temperature absence of noise etc v Rotary field check v Voltage frequency and amperage check Y Check on Normal Emergency Inverter switching or coupling if fitted 10 Maintenance 10 1 Main
35. ciwtsuandeinnsteataaeste sa desse ssa d po fopad sodas den stessa idet aeaceatacieces tino ute 65 15 2 Jay pumi TOL Cle dEEUlCISscecoeioktsonie ies dasarnicashasnsedineseiaead qeatedtacsp cond Seni a os in DAN Lopes Dun inita des oae Do co on edunt oaa en datus 66 15 2 AM Technica ks pee MCa O voodosteonsdson eode nos aoEsoi seni ica iii 66 15 2 2D a TE PP a DEEE o arcana tbt ete ner seda arf cess Pot esses ia opus aic o dapi 67 15 22 92 d i te rame e ambe DATE ici lll ici 67 2 75 AR a T m Sie 68 Sissi Tecnica data uocat it nuu vtt Era o EEN A ica uM 68 15 90 CCI Cabal d sidonia 68 ESA A oo A tics Ae iudi Diss U E Eit EEev iac UE 68 I5 T PROMI CAINS oes esie o ss usu tutes diabetes busta iu tienda Disi Ati oo pimus bend di dier LAE Si Md Euer Aa EUE 68 LEER SW VTA A CO RSS TE o ETT 69 o O UM SANG AILS tii ia podido A tisse LES adi s 69 154 RENsRAB automatic om auxiliary Ad Uste anida pipes ipid 69 EA PC IDEO LONE ERE o a 69 NF ONO IRSE RTT EET Ter 69 S De rail OM RE E T TT 70 ES d ATQUE PAN E T E 70 SAM Ine AMICIS IS LIT rmn 71 LONE E Susp Morna AES SALSA ETT Emm 71 15 5 A AN 71 A e e omm 72 MPS he o E A IN 72 530 Odd preconizado eii 73 A A O A eaten ee eae pela A aee oue 74 A O A 723 3 75 1 Preface 1 1 Introduction 1 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to he
36. ds when detecting leaks Pressurised fluids can enter body tissues and cause severe harm Risk of blood poisoning v Drain and discard engine oil in a designated container the fuel distributors can collect your used oil 2 10 Risks related to noise Dangerous noise Risk of hearing loss Important Non enclosed generating sets generate an airborne noise level of over 85 dBA of sound pressure level at a distance of 1 metre Prolonged exposure to this level of noise may cause permanent damage to hearing Therefore it is recommended that ear defenders are used when working in close proximity to a generating set which is in operation 14 75 3 General description 3 1 Generating set without enclosure Figure 3 1 General description of a generating set without enclosure Alternator 6 Protective grille for rotating parts Identification plate 15 75 3 2 Enclosed generating set hz Figure 3 2 General description of a generating set with enclosure Air filter Protective grille for rotating parts Identification plate 4 Suspension mounts 9 Rar M Come 16 75 EN 3 3 Container The name container is a generic term used for a box designed for transporting merchandise sufficiently solid for repeated use generally stackable and equipped with components enabling intermodal transfer There are 3 types of container Y Miscellaneous containers dry open top open side base flat
37. ductors concerned by insulation faults are interconnected leading to a short circuit The power supply is automatically cut by the opening of the over current protection circuit breaker as in the TN system It should be noted that the IT neutral system must not be used if you do not have a technician on call 24 7 For the IT neutral system in the case of a 20 kV 400V step down transformer it is necessary to provide overvoltage protection for the 400V network This protection must be mounted between earth and the neutral point if available or a phase if not available For an LV generating set with IT system this protection is not necessary as the voltage cannot be over 500V The network s insulation voltage must be the value of the phase phase voltage 7 3 Overvoltage Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 59 75 8 Preparation before starting The inspections referred to in this section enable the electrical generating set to operate Specific skills are required to carry out these operations They must only be entrusted to personnel with the necessary skills Failure to follow these instructions in any way could lead to incidents or very serious ac
38. e customer network Expansion bottle This is used for compensating for volume variations to which the mass of a fluid in the facility is subjected due to temperature fluctuations 15 75
39. e engines may be fitted with specific electrical wiring different to that described in the engine documentation 4 75 EN 1 1 2 Description of the reference material The documentation delivered with the generating sets defines all of the use and servicing operations for the generating set or power plant This reference material enables you to get to know the equipment operate it and maintain it both on a daily basis and periodically The documentation for the engines and alternators fitted to the generating sets consists of engine user and maintenance manuals from the manufacturer and alternator user and maintenance manuals from the manufacturer The documentation contains Y NS The user and maintenance manual containing among other things o General recommendations and safety rules to be observed o General rules for installing generating sets o General instructions for preparing generating sets prior to commissioning o Tables of capacities lubricants and coolants and fuel tanks for the various engines that can be fitted on the generating sets according to their configurations o Special maintenance advice o The descriptions and or maintenance instructions for certain optional equipment User manual for the control unit if fitted Wiring diagrams these diagrams are supplied with the documentation or delivered with the generating set The user and maintenance manual for the engine fitted to the generating set
40. ed or repeated contact with the skin In ream the event of contact with the skin wash thoroughly with water and soap CONSULT A DOCTOR IMMEDIATELY KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN Warning The anti rust product is toxic and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging Y Y Y Y Caution fuels and oils are dangerous to inhale Ensure proper ventilation and use a protective mask Never expose the equipment to liquid splashes or rainfall and do not place it on wet ground The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 2 5 Risk of fire burns and explosion SS SS The engine should not be operated in environments containing explosive products As not all of the electrical and mechanical components are shielded there is a risk of sparks forming Make sure not to create sparks or flames and not to smoke near the batteries as the electrolyte gases are highly flammable especially if the battery is charging Their acid also poses a risk to the skin and in particular to the eyes Never cover the generating set pump unit or lighting tower with any material during operation or just after shutdown wait for the engine to cool Do not touch ho
41. emain in the horizontal position If necessary adjust the height using the jockey wheel The coupling head will be engaged automatically accompanied by a clearly audible click then lower the coupling handle The coupling mechanism will then be engaged and the coupling handle cannot adopt a lower position when manoeuvred by hand Once this has been done raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load 8 Lift up the jockey wheel fully and lock it in position If the coupling head is not correctly attached to the hitching joint the trailer will separate from the towing vehicle Uncoupling a trailer fitted with a hitching rin Immobilise the trailer by placing chocks under the wheels O Release the hitching ring by lowering the jockey wheel When you are sure that the wheel can bear the load you can unhitch the trailer from the vehicle Uncoupling a trailer fitted with a coupling head O Immobilise the trailer by placing chocks under the wheels O Open the coupling handle and lift up the coupling head while lowering the jockey wheel to release it from the hitching joint When you are sure that the wheel can bear the load you can unhitch the trailer from the vehicle 31 75 5 2 2 Check before towing Before towing check the following v Tightness of the generating set enclosure bolts v Wheel tightness Y Hitching hook locked v Tyre pressure Y Signalling light
42. enerating sets pump units or lighting towers in a well ventilated place where gases cannot accumulate In case of indoor use v Be sure to evacuate exhaust gases outdoors v Provide appropriate ventilation so that personnel present are not affected Observe the local regulations in force for generating sets pump units or lighting towers as well as local regulations for use of fuel petrol diesel fuel and gas before using your generating set pump unit or lighting tower Fuel filling should be carried out when the engine is off except for generating sets with an automatic filling system Engine exhaust gases are toxic do not run the generating set pump unit or lighting column in unventilated premises If installed in a ventilated room additional requirements for fire and explosion protection must be observed A leaking burnt gas exhaust may increase the sound level of the generating set pump unit or lighting column To check on its efficiency regularly examine the burnt gas exhaust Pipes must be replaced as soon as their condition demands it 11 75 2 4 Risks related to toxic products HET Glycol is a toxic product and dangerous if absorbed lo contains alkali Avoid all contact with the skin and eyes Read the This substance should not come into contact with the inet etn Omi Needing eyes In the event of contact with the eyes rinse immediately with plenty of water for at least 15 i minutes i B Avoid prolong
43. ery terminals are correctly tightened A loose cable clamp can cause sparks that could result in an explosion Before servicing electrical components or performing electric welding set the battery switch to the OFF position or disconnect the battery negative cable to cut off the electrical current Electrolyte contains dilute sulphuric acid Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns Wear safety goggles and rubber gloves when working with the battery topping up fluid charging etc If electrolyte comes into contact with your skin or clothes wash it off immediately with plenty of water then carefully wash the area with soap If electrolyte comes into contact with your eyes rinse immediately with plenty of water and seek medical attention as soon as possible If electrolyte is accidentally swallowed gargle with plenty of water and drink large quantities of water Consult a doctor immediately Large quantities of electrolyte should be rinsed off using a neutralising agent A common method is to use a solution of 500g of bicarbonate of soda diluted in 4 litres of water The bicarbonate of soda solution should be added until the reaction has finished lather The remaining liquid should be rinsed off with water and left to dry Y Dry batteries do not require any servicing Y Batteries ready for use must be recharged at the latest when the acid density drops below
44. etc o Dry containers are containers for dry merchandise o Open top containers have a tarpaulined top o Flat containers have a simple frame Y Isothermal containers v Tank containers 3 3 1 High capacity containers HC High Cube These are ISO standard containers in length and width but have a height of 9 6 2 90 m instead of 8 6 2 59 m These high containers have been standardised by ISO SDMO containers are high capacity containers Some nominal dimensions of common containers ISO dimensions Name of container___ lengh widh S height 40 feet 12 192 m 8 feet 2 438 m 8 oo 1AAA HC 40 feet 12 192 m 8 feet 2 438 m 9 rea 8 feet 6 inches 9 feet 6 inches 1CCC HC 20 feet 6 058 m 8 feet 2 438 m 2 896 m 3 3 2 SDMO range containers The SDMO CONTENENERGY energy range comprises 3 types of container 1 ISO 20 and ISO 40 2 CIR 20 3 EUR 40 All these containers come with fittings The types used are 1AAA 40 and 1CCC 20 The names ISO CIR and EUR are SDMO trade names 3 3 2 1 ISO 20 and ISO 40 ISO 20 and ISO 40 20 and 40 containers comply with the ISO TC104 standards and are CSC certified i e authorised for shipping Silencer Console Sound trap Soundproofed Radiator air inlet grille Figure 3 3 Example of an ISO 20 container In the jargon of international transport a container is often referred to as a box CSC Container Safety Conventi
45. f the engine Do not remove the filler cap until it is completely cold Do not open the radiator when it is hot DANGER Rotating parts can cause serious injury Do not operate the generating set with the doors open Do not remove the enclosures Shut down the generating set before any maintenance or servicing operation DANGER Avoid any contact with the exhaust pipes turbochargers and silencers Keep flammable materials away from hot parts Wait for the machine to cool down completely before touching it WARNING DANGER The gas from the battery electrolyte is explosive Keep the batteries away from any flames The battery electrolyte sulphuric acid is toxic Risk of poisoning Figure 1 2 continued Pictograms and their meanings 8 75 Improper grounding can cause serious injury or death Always complete the grounding path from the ground terminal on this genset to an external grounding source See operator s manual for instructions NOTICE VOLTAGE SELECTOR To be operated only by qualified personnel 31811170401 Equipment damage may occur Properly adjust output voltage before connecting load 31811170501 VOLTAGE SELECTOR SWITCH MUST HOT BE TURHED WHILE THE GE HSET IS RUNNING 3151117001 WARNING DANGER A poor earth connection can lead to serious injuries or death Always connect the earth terminal of the generating set to an external earth terminal WARNING
46. flat iron ring attached to the ceiling The suspension line enables the pipes to expand freely Figure 6 16 Suspension lines Marker 8 needle frame Used for vertical sections the needle frame allows the pipes to expand while holding them laterally Marker 9 column base The column base is designed to hold the weight of the vertical pipes Marker 10 silencer suspension The silencer suspensions are designed to hold the weight of the silencers they can be vertical or horizontal Figure 6 19 Suspensions 44 75 EN Thermal insulation Figure 11 heat insulation Depending on the type of installation you may have to insulate the heat released in the room Once it has been insulated the surface temperature should not exceed 70 C The recommended material is rock wool excluding asbestos and eventually it can be recovered with aluminium sheets to improve the look of the installation and the thermal insulation 50 mm thick glass wool should be considered a minimum requirement Silencer Figure 12 silencers These reduce noise by absorbing or causing phase differences in the sound wave An exhaust should be effectively suspended the supports should never rest on the set except for original fittings An exhaust compensator will be fitted to the engine outlet The pipes will never have a diameter less than the set refer to us about vermin and be directed so that gas cannot return to the room The pipes should be fixed s
47. gs on the generating set provided for this operation Tension the slings slightly Make sure that the slings are correctly attached and the equipment is solid Lift the generating set carefully Direct the generating set towards the chosen location and stabilise it Carefully set down the equipment while continuing to position it Slacken the slings then detach and remove the lifting rings S CN SUN The slings must be perpendicular to the chassis to ensure they do not damage the generating set no friction Important Figure 4 1 Slinging a generating set 22 75 EN 4 3 1 2 Slinging of enclosed generating set The enclosure makes an enclosed generating set easier to handle Attach the lifting machine s slings to the rings or brackets on the generating set provided for this operation Tension the slings slightly Make sure that the slings are correctly attached and the equipment is robust Lift the generating set carefully Direct the generating set towards the chosen location stabilising it Carefully set down the equipment while continuing to position it Slacken the slings then detach and remove the lifting rings NS S SN S The sling attachment points differ according to the enclosure models 3 different configurations are available 2 ee N Enclosure with 1 lifting ring Enclosure with 2 lifting brackets Enclosure with 4 lifting brackets M427 Figure 4 2 Sling
48. hich have the crankcase vent connected to the turbocharger inlet risk of oil or oil vapour absorption and accelerated engine speed On load tests It is recommended to conduct an on load test on the generating set monthly for a period of around 1 hour after stabilisation of the parameters The load must be greater than 50 of nominal power ideally 80 to ensure unchoking of the engine and to obtain a decent picture of the generating set operation Off load test no load This test is not recommended it must not exceed 10 minutes and must not be repeated without a monthly on load test This test only allows you to check for correct engine start up It does not allow you to check that the generating set is working properly 61 75 EN 11 Storage Removal from storage A generating set which is left unused may have a damaging effect on the engine and alternator To reduce these effects it is advisable to prepare and store the generating set correctly Storing the engine To preserve the engine it must be cleaned and all the fluids replaced by protective fluids or fresh fluids For details of storage or removal from storage refer to the manufacturer s documentation Storing the alternator When storing an alternator moisture tends to condense on the coils To reduce this condensation to a minimum it is advisable to store the alternator in a dry place Use of independent radiators is advised to keep the coils dry For details
49. ienced user to repair equipment after damage Composition Illustrated text marker commentary procedure operation time level required and tools list This reference material exists mainly in English regardless of the engine manufacturer 5 75 1 2 Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator s or maintenance technician s attention to the potential dangers and explain the action to be taken in the interest of safety These notices are reproduced in this publication for ease of identification by the operator Replace any notice that is missing or illegible Caution danger Caution risk of electric shock Caution toxic materials Caution pressurised fluids Caution high temperature risk of burns Caution rotating or moving parts risk of getting caught in the machinery Fork pockets for lifting Publications delivered with the generating set must be referred to Protective clothing must be worn Eyes and ears must be protected Periodic maintenance must be carried out Battery level must be checked Lifting point must be used Retention tank level high Caution risk of explosion Naked flames and unprotected lights prohibited No smoking Entry prohibited to non authorised persons Jet washing prohibited Caution corrosive product Important refer to the documentation accompanying the generating set Important emis
50. ies authorised to issue this approval This approval which comes in the form of a standardised plate permanently fixed on each approved container is obligatory for authorisation of shipping The stacked load that the container can bear is indicated on this plate This approval is obtained by the manufacturer for each container model by submitting a technical file subject to validation of standard tests by the approved body High Voltage High voltage A 1000 V lt HVA lt 50 000 V AC High voltage B 50 000 V HVB AC p am d un un 2 ce r L lt Impedance Electrical impedance measures the opposition of an electrical circuit to passage of a sinusoidal alternating current The concept of impedance is a generalisation of Ohm s law in the study of alternating current circuits Forklift pockets These are the rectangular apertures in the lower part of a base frame where the forks are inserted to move the generating set Exhaust head loss When a fluid is flowing in a pipe and energy is lost due to friction we talk about head loss Daily service tank Jockey wheel This is the wheel on the boom of a trailer It may be swivelling and height adjustable Very Low Voltage VLV lt 50 V AC VLV lt 120 V AC g l lt r lt LVCCP Low voltage central control panel This is a low voltage electric panel for large electrical facilities This panel forms the link between the supplier s incoming line and th
51. ifolds while keeping the other hand on the piston rod and the valve gland clamp Do not carry out these removal procedures often Before refitting carefully clean the whole of the inside with a cloth lightly lubricate the internal parts of the chamber with liquid paraffin put the piston back in place by pushing down slowly with a semicircular motion Check that the suction seat is held in place and that the felt pad is properly positioned Put the bolts back in position retighten the blocks moderately and alternately until the cover is locked down 13 3 Japy pump kit 13 3 1 Technical data Max flowrate 37 L min Max pressure 2 2 bar with coolant Rotation speed 2800 rpm Max suction head 6 m Fitted with a bypass Operation with discharge cut off 2 to 3 mins max IP 55 protection i a o SN 13 3 2 Electrical data v Power 0 37 kW Y Engine made for continuous work v JEV 10 658 single phase 50 Hz 220V 2 4 A 240V 2 1 A v JEV 10 658 single phase 60 Hz 208V 3 7 A 277V 3 3 A Figure 13 2 Japy JEV pump v JEV 11 661 three phase 50 Hz 380V 0 8A 415V 1A v JEV 11 661 three phase 50 Hz 200V 1 5 A 240V 1 6 A v JEV 11 661 three phase 60 Hz 380V 0 9 A 480V 1 4 A v JEV 11 661 three phase 60 Hz 208V 1 8 A 240V 2 A The engines are not flame proof Do not use them in locations where there may be flammable vapours 13 3 3 Suitable fluids v Water fuel diesel amp light
52. ite installations and livestock buildings etc For a default voltage of 25 V and a default current of 30 mA this rod must be of a minimum length of see table below Length of Nature of ground rod in metres Thick arable land 1 moist compact ballast Lean arable land 4 Gravel coarse ballast Baredo ioe dyang To obtain an equivalent length you can use several earthing rods y A l 3 6 connected in parallel and set apart by at least their length impermeable rock Example 4 interconnected 1 metre rods separated by 1 metre Note For the United States National Electrical Code reference NFPA 70 The generating set must be earthed To do this use a copper wire with a minimum cross section of 13 3 mm or AWG 6 at most connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically This earthing rod embedded fully in the ground must have a minimum length of 2 5 m 56 75 EN 7 2 Neutral system 7 2 1 General information The Earthing system or SLT formerly Neutral system of the electrical facility defines the situation of the generating set neutral in relation to earth and the grounds of the electrical facility at the user end The purpose of the earthing systems is to protect personnel and equipment by managing risks posed by insulation defects For safety reasons any live conducting part of a facility must be insulated from the earth This insu
53. l become separated from the towing vehicle The release cable engages the parking brake acting as an emergency brake should the trailer detach from the towing vehicle For the braking system to fulfil its role effectively it is essential to observe the following advice 1 The release cable MUST NOT be wound around the guide wheel as this would prevent the emergency brake from working Warnin 2 The release cable MUST run as straight as possible without being impeded at any point J 3 The release cable must be long enough to allow turning and it must not be stretched or impeded in use as this would engage the parking brake while the vehicle is being towed Figure 5 1 Release cable 28 75 EN Coupling a trailer fitted with a coupling head o o e do os Drive the towing vehicle or move the trailer after releasing the parking brake if fitted to the coupling position Open the coupling head To do so pull the coupling handle figure 5 2 in the direction of the arrow The coupling mechanism can remain open as long as the coupling head is not resting on the hitching joint Put the trailer in the horizontal position using the guide wheel jockey wheel and then mount the open coupling head on the hitching joint by lowering the adjustable towbar if fitted or by lowering the front of trailer This must remain in the horizontal position after this adjustment If necessary adjust the height using the jockey wheel The cou
54. lation The installer must check that none of the components installed on the exhaust pipe cause pressure drops greater than the engine s admissible pressure 42 75 Pipework Marker 1 Pipes It is recommended that you use seamless pipes However for weight reasons rolled steel pipes can be used In any event welded bars inside the duct are to be avoided Marker 2 elbows Elbows must have a minimum curve radius equal to 2 times the diameter of the pipe if possible in a single part If the elbow is made of welded steel check that it includes at least 3 sectors for 90 elbows Figure 6 11 Pipes and unions Marker 3 expansion bellows and hoses v The compensator absorbs longitudinal movements due to expansion approx 1 mm metre 100 C v The hose allows for considerable sideways travel but with low longitudinal amplitude Marker 4 condensation and rainwater bleed To be allowed for in the lower section of the installation to protect the silencer and engine or for any changes in horizontal vertical travel Figure 6 13 Bleed valves Marker 5 bulkhead crossing roof outlet For each bulkhead passage and roof outlet Marker 6 exhaust outlet The exhaust outlets disperse the gases in the atmosphere and protect the inner section of the pipes from bad weather Figure 6 15 Exhaust outlet 43 75 EN Pipework and silencer fixtures and suspensions Marker 7 suspension line Generally made up of a
55. lation may be achieved by distance or by using insulating materials But with time insulation may deteriorate due to vibrations mechanical impacts dust etc and therefore generate an earth with dangerous potential This defect poses risks for personnel and property but also continuity of service Earthing systems are codified by two letters that define the connections v The first letter defines the neutral connection NS Insulated or earthed via an impedance device Connected to earth Y The second letter defines the grounding situation of the electrical facility Connected to earth Connected to neutral E g IT Isolated Neutral Ground earthed Speed MUET O Detection Note conductors Measurement of residual current Triggering of 1 fault by RCD TN No measurement of residual current png ated Dover Mien lol upon 1 fault p na IT SN 3 poles Insulation resistance measurement Triggered upon 2 fault by overcurrent protection 57 75 7 2 2 TT system Ph 1 Ph 2 Ph 3 PE Figure 7 1 TT neutral system The alternator neutral is earthed and the grounds of the user equipment have their own earth connection This earthing system is the most frequent in the private sector in France In the TT system automatic power cut off via a Residual Current Device RCD is obligatory at the upstream part of the facility to ensure protection of personnel with a maximum 30 mA device on outlet circuits 7 2 3
56. ll the lever two or three times to complete the draining If the body or cover is cracked by frost do not try to repair it by autogenous welding as this would distort the part Extended lack of use If the pump is not used for a while it is recommended v If frost is not likely to check that the pump chamber is always full of pumped fluid v If frost is likely to o Drain and if possible pull the lever a few times to prevent the internal components from becoming blocked by oxidation if not o Drain and add liquid paraffin by spraying if possible to prevent oxidation and the internal components from becoming blocked 67 75 In the event of oxidation and blocking never force the lever as this risks breaking the piston Remove the cover carefully clean the inside of the pump with an oiled cloth but never with abrasive material Lightly oil before refitting The Japy pump does not normally require any lubrication After several years of service or after use for water or fluids that are full of impurities or slightly acidic it becomes necessary to replace the main internal components This procedure must be carried out by a mechanic In general when pistons and seats need to be replaced we recommend a standard replacement pump To remove the lid and to check inside begin by unscrewing the 6 bolts that attach the lid to the chamber Then to undo the lid hit it preferably with a piece of wood alternately on the discharge and suction man
57. lp you operate and maintain your electrical generating set correctly The information contained in this manual is taken from technical data available at the time of print In line with our policy of continually improving the quality of our products this information may be amended without warning Read the safety instructions attentively in order to prevent any accidents faults or damage These instructions must always be followed You are likely to encounter several warning symbols in this manual This symbol indicates an immediate danger to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure This symbol draws attention to the potential risks to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure This symbol indicates a dangerous situation if the warning is not heeded Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any other object in case of exposure Important In order to obtain optimum efficiency and the longest possible life for the electrical generating sets maintenance operations must be carried out according to the periods indicated in the attached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some
58. mations Important 24 75 EN It is recommended to use a forklift truck with arms that are longer than the width of the base frame Figure 4 5 Handling a generating set using a forklift truck If you are using a rail or mobile winch once the generating set is in position continue in the same way as described in the hoisting section Figure 4 6 Handling a generating set using a mobile winch Some generating sets are equipped with transport brackets which are red facilitating their movement These brackets must always be removed when the generating set is being installed Important 4 3 1 5 Stacking Generating sets must not be stacked 25 75 EN 4 3 2 Container 4 3 2 1 Container slinging SOAS NEA Ne SNC S Attach the lifting machine s slings to the handling rings on the container Slightly tension the slings without lifting the container Check that the sling hooks are correctly attached and that the equipment used is solid Lift the container carefully and without jerking Direct the container towards its final position keeping it stable Manoeuvre the container to its final position while still off the ground Carefully set down the container without jerking while continuing to position it Once the container is on the ground and correctly positioned release the slings check that the container is stable and correcting it if necessary Detach the slings and remove them from the lifti
59. nd service life of cooling system GenCOOL PC 26 is particularly recommended for engines fitted with aluminium or light alloy radiators ALLASAS 63 75 HIGH TEMPERATURE SPECIAL v Promotes heat exchange v Perfect stability at high temperature v GenCOOL PC 26 is especially suited to engines with high power density LONG LASTING PROTECTION v High alkaline reserve stability and service life of corrosion inhibitors o Retains its technical properties in prolonged use at high temperature neutralisation of acidic substances v Ensures maximum heat transfer without formation of deposits in the cooling circuit Y GenCOOL PC 26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use PACKAGING STORAGE v GenCOOL PC 26 is delivered in 210 metal drums with varnished interior v It can be kept in stock for 2 years in its original packaging Y Avoid zinc coated metal containers ADVICE FOR USE v Compatible with the original fluid v It is advisable to completely drain the cooling circuit when replacing the liquid SPECIFICATIONS UNITS SPECIFICATIONS TEST METHODS Freezing point mpi cad olspecimen 156027 Copper Weld Brass Steel Cast iron Cast aluminium Hot Plate Corrosion test on basic antifreeze Dg CUI WEEK 0 17 R 15 602 8 64 75 13 Additional equipment 13 1 Air coolers Before any operation check that the device is switched off Ens
60. nd should check that the apparatus is operating correctly v The user should create or obtain a document describing modifications and showing alterations made to the installations in relation to the original document m Manufacturers notes should be available to technical staff on site if possible The internal network diagram should be displayed as close as possible to the access points showing all the individual points Internal and external network information can be contained in a single distribution diagram Y A sign on the door identifies and gives details of the operating company and includes the telephone number for the gas supplier emergency department v Personnel should be aware of the layout of the premises and they should be identified on site to simplify procedures In the event of a problem this type of knowledge about installations is crucial when poor identification of the premises might make a situation worse v Written operating instructions must be available for operations that involve dangerous handling procedures and driving installations In particular these instructions prescribe o Operating modes o Frequency of testing for safety devices and devices for handling pollution and other harmful substances generated by the installation o Methods for maintenance checking and use of adjustment equipment and safety devices a SOR v The operator should make the necessary arrangements to satisfy site aesthetic requirements
61. ndicator in the retention container In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers either via the drain port or by using the drain pump for containers fitted with this pump Y NOTE Never allow these fluids to drain onto the ground ensure they are collected in a designated container 41 75 EN Exhaust Studying the evacuation of burnt gases by a generating set should not be seen as a minor detail due to the fact that a pipe can always be installed even in the most inaccessible areas In fact there are certain constraints to be considered such as pressure drops caused by the exhaust insulation suspension noise level and air pollution It should be noted that the more complicated a circuit the more it causes drops in pressure and consequently its diameter will be large and heavy and its supports and silencers expensive NOTE Generating sets with a silencer fitted in the enclosure must be fitted with an exhaust compensator This compensator or hose will be fitted to the exhaust outlet in the cover Exhaust pipe Elbows Compensator Condensation bleed Bulkhead crossing roof outlet Exhaust outlet Suspension line Needle frame Column base 10 Silencer suspension 11 Thermal insulation 12 Silencer OONDABRWDNDN Figure 6 10 Example of an instal
62. ng rings Example of container lifting using a lifting beam fitted with Example of attachment by an Example of attachment by a hooks shackles or manually coupled locks ordinary hook safety hook Example of attachment by a manually coupled lock Checking the attachment when the container Lifting is still on the ground Example of lifting Example of a container lifted by four parts in the bottom corners Figure 4 7 Examples of handling equipment 26 75 Figure 4 8 Examples of lifting methods which should not be used 4 3 2 2 Fork lift truck Figure 4 9 Examples of handling methods which should not be used 4 3 2 3 Stacking Containers that cannot bear additional loads stacking prohibited v CIR 20 v EUR 20 Important 27 175 EN 5 Moving Transport 5 1 General recommendations For transporting generating sets the following instructions must be observed Close the tap on the oil make up tank outlet Fill up the oil make up tank with oil Fill up the crankcase with oil Fill up the on board tank with fuel Have the batteries fitted and charged with electrolyte SAN NES 5 2 Generating sets on trailers 5 2 1 Hitching and unhitching the trailer 5 2 1 1 On road trailer Before hitching the trailer check the hitching hook of the towing vehicle it must be perfectly suited to the trailer Any attempt to tow a trailer with a non compliant device bar cables lashing etc runs the ri
63. nt Follow the wiring diagram supplied by the manufacturer Y The generating set should not be connected to any other power sources such as the mains supply network In specific cases where there is to be a connection to existing electrical networks this must only be installed by a qualified electrician who should take the operating differences of the equipment into account according to whether the mains supply network or generating set is being used v Protection against electric shocks is ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications v If the protective plates blanking covers need to be removed to route cables the protector blanking cover must be refitted when the operations are finished Y Due to high mechanical stresses use only strong flexible wiring with rubber sheathing compliant with IEC 245 4 or equivalent wiring SSS 2 7 Dangers presented by electric currents first aid First aid In the event of an electric shock shut off the power immediately and activate the emergency stop on the generating set or lighting column If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire m
64. o gain access to the harness flap oc Motorised Servomotors i ventilation flap Servomotor connection unit Using an industrial vacuum cleaner remove all foreign bodies that might obstruct the harness Blow the harness with compressed air if necessary lf there are any traces of grease use commercial solvents to clean the harness Refit the components in the reverse order to removal then close the circuits and fill the harness with antifreeze coolant 13 2 Japy pumps for clear fluids 13 2 1 Technical specifications Base block Zamak piston seat and valves Steel shaft against mounting clamps and lugs O ring Base block Hydrocarbons Brass piston seat and valves Max viscosity 300 cst Steel shaft against mounting clamps and lugs O ring Pump body Cover Lever Piston Seat Lever nut O ring Suction or discharge clamp Clamp joint 10 Screw with nut for cover or bracket 11 Piston valve 12 Seat valve 13 Valve split pin c co YXODOHDOIAO0ON Figure 13 1 Pump components 66 75 EN 13 2 2 Description Suction Suction capacity is completely independent of the size of the pump These pumps may have a negative pressure suction head of up to 7 m to 7 50 m with cold water at sea level The suction pipes should always be positioned on an upwards slope from the fluid suction point to the pump installation point with no top section and as few bends as possible any
65. o that their weight is not supported by the compensator It should be perfectly straight any misalignment could lead to a rupture Adapted silencer The adapted silencer is fitted directly to the set or cover It is an absorption type silencer A compensator is fitted between the engine and exhaust in the covered version Absorption silencer The gas passes through a sound proof duct made of acoustic high efficiency absorbent material protected by a perforated metal sheet Absorbent reactive silencer The gas enters an expansion chamber lined with absorbent material Supported by perforated metal sheets then into an absorbent sound proof duct Figure 6 22 Absorbent reactive silencer 45 75 Exhaust chimney There are various types of exhaust chimney Self supporting Wall mounted Chimney mounted on a concrete foundation on the ground with load support on the building Free standing Shared chimney Chimney standing solely on a concrete foundation on the In the case of a facility with several generating sets it is ground possible to route the various ducts to a single chimney The sizing of the chimney s support must factor in the It is preferable to use multi duct or telescoping chimneys If constraints of the site and in particular the forces generated there is no other solution than evacuating the smoke emitted in by the wind a single duct each engine duct must be fitted with a non return valve Roof outlet
66. o the work to be done Ensure you have understood the instructions before beginning any operation Y Goggles should be worn when carrying out maintenance operations and watches bracelets etc should be removed v Fit only original parts Y Disconnect the battery and the pneumatic starter if fitted before undertaking any repairs to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt to start Only use the correct crankshaft turning techniques for turning the crankshaft manually Do not try to turn the crankshaft by pulling it or levering the fan This method may cause serious bodily or material damage or damage the vanes of the fan reducing the service life of the fan Clean off any trace of oil fuel or coolant using a clean cloth Do not use a soapy solution containing either chlorine or ammonia as these two chemicals prevent bubble formation Never use petrol or other inflammable substances to clean the parts Use only approved cleaning solvents Do not use a high pressure cleaner for cleaning the engine and equipment The radiator hoses electrical components etc may be damaged Avoid accidental contact with parts at high temperatures exhaust manifold exhaust Before any maintenance operation on a lighting column light cut the electrical power supply and wait for the bulbs to cool down NON SUUS E SS Consumables Y Observe regulations in force concerning use of fuel befo
67. observed Probable origin The acid heats up when a new battery is v Incorrect composition Y Cool filled Y Incorrect storage Y Charge v Prolonged storage in a damp place Y Check the acid density The acid escapes through the filler holes v Battery overflow during filling v Reduce the battery fluid level Acid level too low v Battery tray not leaktight Y Replace the battery Y Significant gas formation caused by v Check the charger and repair if too high a charging voltage necessary Acid level too low v Insufficient charge v Recharge Incorrect operation from start up Y Short circuit in the current circuit v Check the electrical installation v Consumption fault Acid density too high v The battery has been filled with acid v Reduce the acid level and fill with instead of water distilled water Repeat the operation if need be Starting problems v Battery empty Y Recharge the battery Starting test incorrect v Battery used up or faulty v Fita new battery v Capacity too low Y Battery sulphated Y Incorrect battery wiring cables or replace them if necessary high charge The battery discharges very quickly v Charge status too low Y Check the charge Y Short circuit in the current circuit Y Replace the battery Y High self discharge for example through electrolyte contamination Y Sulphation storage of discharged battery Short service life Y Incorrect battery part no Y Define the correct battery part no for v Too many repea
68. of storage or removal from storage refer to the manufacturer s documentation Storing batteries See section 13 5 2 Storage and transport of batteries 12 Fuel and consumables All the specifications product characteristics and capacities are given in the engine and alternator maintenance manuals appended to this manual In addition we recommend the consumables to be used in the Specifications section 12 1 Specifications 12 1 1 Oil grades Engine Make Type Make Type MTU 183 183 Perkins GENLUB TDX 15W 40 Top of the range lubricant recommended for diesel engines for generating sets under harsh service conditions USES Y Particularly suited to the most modern engines whether or not they are equipped with turbochargers intercoolers or sophisticated injection systems HEUI unit injectors v All service types satisfies the most demanding applications Y Clean engines compliant with EURO 2 and EURO 3 technologies and usable with all types of diesel fuel especially eco friendly diesel fuels with low sulphur content PERFORMANCE ACEA E3 API CH 4 v Meets level E3 of the specifications defined by European manufacturers in edition 98 of the ACEA standards ADVANTAGES Y Long oil change intervals thousands of hours on site service in varied applications have confirmed the high quality properties of this product Yv Compliance with new environmental legislation contributes to ob
69. of these periods will be shorter Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training Dealers have this qualification and can answer all of your questions They can also supply you with spare parts and other services The left and right sides can be seen from the back of the electrical generating set the radiator is at the front Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum For any replacement of parts contact your nearest dealer for our company who will have the necessary equipment and can offer properly trained and informed staff to carry out maintenance parts replacement and even total reconditioning of generating sets Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance include the start up and shutdown procedures for the engines Some user and maintenance manuals for the engines fitted to generating sets cover control units and A As the generating sets are fitted with control units that are specific to the generating sets only the information that appears in the documentation for the generating sets control units should be taken into consideration Important In addition according to the manufacturing criteria of the generating sets som
70. oil Y Maximum viscosity of 10 cst at atmospheric temperature 13 3 4 Prohibited fluids Fluids Petrol Flammable fluids with PM below 55 degrees C Supply fluids Corrosive chemical fluids Damage to linings and joints 68 75 13 3 5 Maintenance The pumps do not require any specific maintenance Possible checking for leaks at the joints 13 3 6 Faults and repairs The engine does not work Possible causes Actions No electric current Check the connections Blocked rotor Take apart the engine pump Look for a possible foreign body No flow or insufficient pressure Possible causes Actions Fluid leak Check the pipe connections Replace the seals 13 4 REN RAB automatic oil auxiliary adjuster 13 4 1 Application The REN regulator type RAB 101 70 is an oil level regulator for all engine powers It keeps the oil level in the crankcase correct Set to engine running oil level it regulates the level in line with consumption 13 4 2 Composition The majority of models are equipped with a low level threshold alarm or stop feature to warn operators of a low supply of oil a drop in the oil level in the sump and possibly an overflow of oil A built in oil level threshold triggers an alarm or stops the engine to warn the user of a low supply of oil The engine still consumes oil Figure 13 3 General view of regulator 69 75 EN 13 4 3 Operation When the oil level falls in the sump the float moves down and
71. on 17 75 Fuel tank Silencer Sound trap Sn a EG Z LZ 7 ELLET _ es Soundproof d air inlet grille AIPR Radiator Figure 3 4 Example of an ISO 40 container 3 3 2 2 CIR 20 CIR 20 containers are built based on ISO 20 containers not CSC certified compliant with ISO TC104 on request These low noise level containers are well suited to mobile and rental applications Silencer Radiator Soundproofed air inlet grille Tank Figure 3 5 Example of CIR 20 container 18 75 EN 3 3 2 3 EUR 40 EUR 40 containers are available in 40 only not CSC certified These containers designed for generating sets equipped with series 4000 MTU DDC engines come with 2 soundproofing versions Silent and Supersilent Silencer Air cooler Soundproofed air inlet grille Figure 3 6 Example of a EUR 40 container 3 4 Identifying sets Generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documents contained in this manual 3 4 1 Generating set with and without enclosure Generating sets with and without enclosures are identified via identification plates attached to the base frame Identification plate Figure 3 7 Location of identification plates for generating sets with and without enclosures 19 75 GROUPE ELECTROGENE GENERATING
72. on The choice of conductors must comply with international standard IEC 30364 5 52 Three phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors or single conductor joined when precision 4X 1 Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C Circuit breaker Cable sizes as 0 calibre p 4X 1X70 2 0 4X 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 4X 1X185 0400MCM 4X 1X185 0400MCM Single phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C m gcc i mm AWG mmAlAWG 8 35 2 JDJl A X 95 40 55 75 EN c Battery cables Install the battery or batteries in the immediate vicinity of the electric starter motor The cables will be connected directly from the battery terminals to the starter motor terminals The primary instruction to follow is to ensure that the polarities between the battery and starter motor match Never reverse the positive and negative battery terminals when connecting them This could cause severe damage to the electrical equipment The minimum cross section of the cables will be 70 mm It varies according to the power of the starter motor but also the distance between the batteries and the set voltage drops on
73. on of an underground fuel tank in accordance with requlations in force in France Order of 22 06 1998 articles 9 and 11 VENT 4 m MIN height 3 m from naked flame aperture A 10 metres EMERGENCY l a EXIT T d o d 2 k bw K A i PROPERTY Ss 1 e gt ay UNDERGROUND ey FUEL OR GAS y STORAGE TANK amp Figure 6 29 Example of location of a fuel tank in France Order of 10 August 1998 modifying the order of 25 July 1997 on general prescriptions applicable to installations classified for environmental protection subject to the declaration under section no 2910 Combustion Order of 19 November 2001 relating to approval of provisions supplementing and amending the fire and panic risk safety regulations in public assembly buildings Article EL 7 relating to the location of generating sets Order of 22 26 1998 on underground flammable liquid tanks and their ancillary equipment 52 75 EN 6 3 3 Acoustics The applicable regulations are specific to each country Refer to the rules in force in the country in question Example of regulations in force in France Order of 25 07 97 section 2910 8 1 Y Noise emissions produced by the facility must not in regulated noise emergence zones cause emergent noise greater than the permissible values specified in the table below Existing ambient noise level in regulated Emergent noise permissible for the Emergent noise permissible for the noi
74. ons of the facility expressed in kW 6 3 5 Exhaust emission The regulations for exhaust emissions are specific to each country So the rules in force in the country in question must be observed Example of regulations in force in France Engine with thermal power consumption of over 2000 kW Order of 25 07 97 section 29 10 modified by the order of 15 08 00 v Fuel engine Values expressed in mg nm at s dry O2 Unburnt hydrocarbons ee c a a a a i X Production lt 500 h 2000 t gt 1200 rpm 1500 160 from 2008 Y Gas engine Values expressed in mg nm at 22 dry O2 Unburnt hydrocarbons E EIA Bodon lt 500 h Production gt 500 h 54 75 7 Electrical connection 7 1 Connection a Connections general information As with low voltage electrical installations use and maintenance is governed by standard NFC 15 100 France or by the standards in the relevant country based on international standard IEC 60364 6 61 They must also adhere to the regulations in the NFC 15 401 application guide France or to the regulations and standards in the relevant country b Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose The cable cross section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installati
75. opens a valve When the valve opens oil can flow from the tank into the sump via the regulator As the sump fills the float moves up and eventually closes the valve when the required oil level is reached preventing oil from flowing into the sump The valve is designed to be able to clean itself and consequently cannot become clogged A 3 mm hole in the regulator is wide enough to enable the sump to be filled effectively Thumb Valve HIGH Oil supply t Movement of float l Unit LR857 separator LOW Low level contact Figure 13 4 Simplified diagram of valve operation 13 4 4 Setting After having fitted the unit as illustrated below manually fill the engine to the low or add mark on the oil gauge without starting the engine Position the oil level regulator so that the oil level is in the centre of the front inspection window Give the system some time to balance out the oil level between the regulator and the sump before the sump is finally fixed into position This level depends on the level of use Start the engine and wait a while for the regulator to replenish the measured oil circulating in the sump When the engine is switched off the return of oil from the engine causes the oil level to rise and this can be seen through the front inspection window on the regulator This is normal and as soon as the engine is switched on again the oil level will return to the level required for use previously mentioned VENTILAT
76. place in the direction from the alternator towards the engine Their surfaces depend on the power of the generating set being installed general atmospheric conditions the cooling system selected and the soundproofing procedure Lifting The lifting system should usually be an integral part of the construction It is made up of an H or steel rail embedded in the walls and ceiling and a crab It should be easy to handle and is generally used on top along the longitudinal axis of the set and directed towards the exit Figure 6 4 Example of a lifting system 38 75 EN Soundproofing The room is soundproofed using two procedures Insulation This prevents the noise from crossing the walls and in this case it is the weight then thickness of the wall that is important Absorption These are materials that absorb sound energy and this procedure will be used on ventilation openings As a result of this the air inlet and outlet sections are increased The internal lining of the room can also be covered with absorbent material designed to lower the sound level in the room and consequently through the walls ventilation openings and door General arrangements Building structure made from framing concrete or solid concrete blocks 20 cm thick minimum Anti vibrating floor plate under the generating set when adjoining sensitive areas Ceiling and walls covered if necessary with absorbent materials Choice of adapted exhaust silencer s
77. pling head will be engaged automatically accompanied by a clearly audible click then lower the coupling handle The coupling mechanism will then be engaged and the coupling handle cannot adopt a lower position when manoeuvred by hand Once this has been done raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load Attach the release cable to the attachment point on the hitching plate figure 5 1 then connect the electrical cable plug controlling the lamps indicators etc to the socket on the towing vehicle Lift up the jockey wheel completely and lock it in position making sure that it is not impeding the brake rod or the release cable Ensure that the parking brake if fitted is completely disengaged by pushing its handle down fully If necessary remove the wheel chocks and store them If the coupling head is not correctly attached to the hitching joint the trailer will separate from the towing vehicle The release cable engages the parking brake acting as an emergency brake should the trailer detach from the towing vehicle For the braking system to fulfil its role effectively it is essential to observe the following advice 1 The release cable MUST NOT be wound around the guide wheel as this would prevent the emergency brake from working 2 The release cable MUST run as straight as possible without being impeded at any point 3 The release cable must be long enough to allow turning and i
78. portation of generating sets refer to section 5 1 General recommendations 35 75 6 Installation The contents of this chapter are only general recommendations It is recommended that professionals are employed to ensure correct installation and start up The company cannot be held responsible for breakdowns related to the conditions of installation 6 1 Fixed generating set NOTE If you do not follow the basic principles the installation assembly will suffer damage and abnormal wear The procedure described gives the main requirements for installing a conventional generating set made up of a heat engine a generator and electric panel These requirements are general principles to be observed For any specific applications or if you have any doubts our technical departments will advise you and look at your specific conditions of installation The current regulations provisions and laws in installation locations must be adhered to FIREPROOF DOOR EVACUATION OF EXHAUST GASES AIR EMISSIONS OUTSIDE THE ROOM FUEL STORAGE AIR INLET ELECTRIC WIRES FUEL PIPES SECURING THE EARTH TERMINAL UNIT TO THE FLOOR PLATE Figure 6 1 Example of a generating set site 36 75 EN 6 1 1 Indoor installation of a generating set with or without enclosure 6 1 1 1 Position It should be determined on the basis of use There are no specific rules governing the choice of location other than proximity to
79. r a stripped cable and 16 mm for an insulated cable connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground see 7 1 Connection These sets are to be covered or protected from adverse weather by a suitable construction see previous sections 6 2 3 Generating set on trailer 6 2 3 1 Implementation for installation Operations to be carried out Ensure that the ground is strong enough for the assembly not to sink into it Unhitch the trailer as per paragraph 5 2 1 Hitching and unhitching the trailer Immobilise the trailer by placing chocks under the wheels Fully engage the parking brake if fitted Using the front wheel position the generating set as close to horizontal as possible Lower the stands if fitted and lock them SWS NNN 6 2 4 Enclosed generating set Installation of a mobile generating set with enclosure is the same as indoor installation of a generating set with enclosure refer to paragraph 6 1 1 6 2 5 Container Operations to be performed for installation Y The installation area should be flat enough for the container to rest level on it and strong enough so that the container does not sink down Y The equipment will also have to be installed taking the prevailing winds into account the air inlets must be facing away to ensure there are no difficulties in adverse weather conditions intake of air snow sand etc Exhaust valves must be fit
80. re using your generating set pump unit or lighting tower Y Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit 10 75 EN Environment Y Y NS SSA SN The operator must take the necessary measures to comply with the aesthetics of the site of use The whole site must be maintained in a good state of cleanliness The premises must be kept clean and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust which could ignite or cause an explosion The cleaning equipment must be suited to the risks posed by the products and dust The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements Facilities must be operated under the constant supervision of a qualified person who must regularly check that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply Apart from the combustion devices it is prohibited to use fire in any form This restriction must be clearly displayed Spreading of waste water sludge and waste is prohibited The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the combustion device manufacturer The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber Burning of waste
81. ree standing chimney installed beside the container 7 e Figure 6 28 Free standing chimney for container installation 50 75 EN 6 2 Mobile generating set 6 2 1 General information Besides the rules and advice given for fixed generating sets certain special provisions must be observed for mobile generating sets 6 2 2 Positioning Location An area will be reserved to install the generating set lts should be flat and strong enough so that the generator does not sink into it It could be made of concrete or even large planks fitted together It should be noted that a generating set that does not rest correctly on its base frame or trailer will be subject to vibrations that could cause damage to all the equipment The location of the set on site should be chosen for ease of fuel supply and distribution of current to the users Access to the set s doors should be available at all times for safety and maintenance reasons Ventilation of the generating set should not be affected by objects in the vicinity This would cause abnormal heating and power loss Burnt gas evacuation should take place in such a way that there is no reaspiration into the air filter or cooling system While adhering to current regulations the neutral system of the generating set must be observed in order to ensure protection of personnel The generating set will need to be earthed To do this use a copper wire with a minimum cross section of 25 mm fo
82. s working for on road trailers v Enclosure doors closed Y Parking brake released for on road trailers Y Guide wheels jockey wheels and stands lifted if fitted Y Towbar arm locking levers tightened and pinned if fitted with an adjustable towbar v Brake test for on road trailers v Safety cable fitted for on road trailers 5 2 3 Operation On site trailer These trailers are not fitted with a main brake and so cannot be braked in motion the tyres allow for a maximum speed of 27 km h So it is absolutely prohibited to exceed this speed Nor are these trailers fitted with signalling lights On road use is prohibited On road trailer The driving speed must be suited to the condition of the road and the handling of the trailer Driving at high speed causes heating of the tyres so it is important to stop from time to time and check them Excessive heating may cause a puncture and therefore a serious accident For reversing manoeuvres remember to lock the inertia brake In the first few miles driving heating of the brake hubs and drums will actually reduce the wheel tightness It is therefore essential to check the tightness every 6 miles 10 kilometres until no further loosening is noted Nonetheless the tightness must be checked whenever you are about to tow the trailer Particular attention must be paid to the tightness of the wheels on new vehicles Lights signalling only for on road trailers Warning
83. se emergence zones including period from 07 00 to 22 00 except for period from 22 00 to 07 00 as well as establishment noise eundays and public holidays eundays and public holidays Greater than 35 dB A and equal to or less than 45 dB A Greater than 45 dB A 6 3 4 Chimney height The regulations regarding chimney height are specific to each country So the rules in force in the country in question must be observed Example of regulations in force in France Min ejection speed 25 m s v Back up operation of main power supply Order of 25 07 97 section 2910 6 2 2 E o The height of the evacuation chimney must be 3 metres higher than the buildings within 15 m of the facility but cannot be less than 10 metres d lt 15m Hchem Hobst 3 Order of 25 07 97 on general prescriptions applicable to installations classified for environmental protection subject to the declaration under section no 2910 Combustion 53 75 v Production operation Order of 25 07 97 section 2910 6 2 2 D o 2MW lt Power plant lt 10 MW d 25 m Hchem Hobst 5 25 d 125 m Hchem 1 25 Hobst 5 1 d 125 o 10 MW lt Power plant lt 20 MW d lt 40m Hchem Hobst 5 m 40 lt d lt 200 m Hchem 1 25 Hobst 5 1 d 200 If no obstacles within a 200 m radius 2 lt 4 MW 4 6 MW 6 10 MW 10 15 MW 15 20 MW 18 27 m 20 30 m In brackets cities of over 250 000 inhabitants The powers are the maximum total thermal consumpti
84. servance of anti pollution stipulated for new EURO 2 and EURO 3 engines 62 75 CHARACTERISTICS SAE grade 15W 40 Density at 15 C 0 883 viscosity at 100 C 14 1 mm2 s cSt Viscosity index Standard values given as a guide SAE 15W 40 SAE 10W 40 SAE 5W 30 e se ow 4 3 i a c i1 w o 3 i 12 1 2 Specifications of cooling oils Engine Make Type Make Type GenPARTS GENCOOL PC 26 C GENCOOL PC 26 C LLC aa GENCOOL PC 26 C GenCOOL PC 26 High protection coolant approved by manufacturers GenCOOL PC 26 is a ready to use high protection coolant produced from an antifreeze approved by most European manufacturers v Itis based on antifreeze and G 48 inhibitors v Freezing protection to 26 C v Free from nitrites amines phosphates v Limpid fluorescent orange liquid REFERENCES APPROVALS of the basic antifreeze HEAVY GOODS VEHICLES LIGHT VEHICLES Approved by MTU MERCEDES BENZ Approved by BMW VOLKSWAGEN MERCEDES MAN KHD GENERAL MOTORS PORSCHE Compliant with VOLVO IVECO VAN HOOL and Compliant with specifications of VOLVO OPEL SEAT STAYR TRUCK specifications and SKODA Compliant with standard NF R 15 601 REINFORCED ANTI CORROSION Protects against hot corrosion via oxidation of ethylene cylinder head protection Protects against hot cavitation protection for the cylinder and water pump Not corrosive for seals and hoses Improved efficiency a
85. sion of toxic exhaust gases Do not use in a confined or badly ventilated area Figure 1 1 Pictograms and their meanings 6 75 Thizis a safety aert symbol When you see this symbol on your genset be alert to the potential for persona injury Falla recam manded precautions and safe operating practices Important Read the operator s manua supplied with the genset before operation or seracing 2 ELECTRIC SHOCK HAZARD Do not touch internal wiring or connections while the genset is operating Disconnect power before servicing USE DIESEL FUEL ONLY Handle fuel with care itis highly flamm able Do not refuel the genset while smoking or when near open flame or sparks Always stop the engine before refueling the genset Fill fuel tank outdoors Prevent fires by keeping genset clean of accumulated trash and grease Always clean up spilled fuel Engine exhaust can cause sickness or death Use only in open well ventilated areas or vent exhaust outside with an exhaust pipe extension EN WARNING DANGER This symbol warns of a safety hazard The presence of this symbol indicates a risk of injury Observe the safety instructions and precautions for use Important Carefully read the instructions supplied with the generating set before using or servicing the equipment WARNING DANGER Risk of electrocution Do not touch the cables or connections when the generating set is in operation Swit
86. sk of serious accidents Also check Y That there are no incipient ruptures or significant wear on the hitching system y l That the locking system is working properly Coupling a trailer fitted with a hitching rin O Drive the towing vehicle or move the trailer after releasing the parking brake if fitted to the coupling position O Put the trailer in the horizontal position using the guide wheel jockey wheel Put the hitching ring above the towing vehicle hook and then lower the adjustable towbar if fitted or lower the front of the trailer to secure the ring in the hook the trailer must remain in the horizontal position after this adjustment Make any necessary height adjustments using the jockey wheel to enable coupling O Once this has been done raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load Fix the release cable to the attachment point on the hitching plate figure 5 1 and then connect the electrical cable plug controlling the lights indicators etc to the socket on the towing vehicle Q e Lift up the jockey wheel completely and lock it in position making sure that it is not impeding the brake rod or the release cable Ensure that the parking brake if fitted is completely disengaged by pushing its handle down fully If necessary remove the wheel chocks and store them If the hitching ring is not correctly connected to the hitching hook the trailer wil
87. suited to the trailer Any attempt to tow a trailer with a non compliant device bar cables lashing etc runs the risk of serious YN accidents Also check v That there are no incipient ruptures or significant wear on the hitching system a namor Coupling a trailer fitted with a hitching rin Drive the towing vehicle or bring the trailer up to the coupling point Put the trailer in the horizontal position using the guide wheel jockey wheel Place the hitching ring above the towing vehicle hook and then lower the trailer to secure the ring in the hook Make any height adjustments necessary to enable coupling using the jockey wheel Once this has been done raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load Lift up the guide wheel and lock it in position If the hitching ring is not correctly connected to the hitching hook the trailer will become separated from the towing vehicle oo 0060 Coupling a trailer fitted with a coupling head O Drive the towing vehicle or bring the trailer up to the coupling point O Open the coupling head To do so pull the coupling handle figure 5 1 in the direction of the arrow The coupling mechanism can remain open as long as the coupling head is not resting on the hitching joint Put the trailer in the horizontal position using the guide wheel jockey wheel and then mount the open coupling head on the hitching joint the trailer must r
88. t must not be stretched or impeded in use as this would engage the parking brake while the vehicle is being towed Warning Figure 5 2 Example of coupling head Uncoupling a trailer fitted with a hitching ring O o e Immobilise the trailer by placing chocks under the wheels with the parking brake fully engaged if fitted Release the hitching ring using the jockey wheel The jockey wheel retraction mechanism if fitted must lock automatically before the wheel touches the ground When you are sure that the mechanism is locked and that the jockey wheel can bear the load you can unhitch the trailer from the vehicle Disconnect the electrical cable plug controlling the lights indicators etc from the socket on the towing vehicle Remove the release cable from the hitching plate Uncoupling a trailer fitted with a coupling head O o e o Immobilise the trailer by placing chocks under the wheels after engaging the parking brake if fitted fully Open the coupling handle and lift up the coupling head using the jockey wheel to release it from the hitching joint The jockey wheel retraction mechanism if fitted must lock automatically before the jockey wheel touches the ground When you are sure that the mechanism is locked and that the wheel is bearing the load you can uncouple the trailer from the vehicle Disconnect the electrical cable plug controlling the lights indicators etc from the socket on the towing vehicle
89. t parts such as the exhaust pipe or put combustible materials on it Keep all flammable or explosive materials e g petrol oil cloth etc out of the way when the set is running Proper ventilation is required for your generating set pump unit or lighting column to work properly Without this ventilation the engine would very quickly rise to an excessively high temperature causing accidents or damage to the equipment and to surrounding property Do not remove the radiator cap if the engine is hot and the coolant is pressurised due to risks of burns Depressurise the air oil and cooling circuits before removing or disconnecting all the fittings pipes or connected components Watch out for the possible presence of pressure when disconnecting a device from a pressurised system Do not try to find pressure leaks by hand Oil at high pressure can cause bodily damage Some preservative oils are flammable Also some are dangerous to inhale Ensure proper ventilation Use a protective mask Hot oil causes burns Avoid contact with hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine with the oil filler cap off oil may splash out Never coat the generating set pump unit or lighting column with a thin layer of oil to protect it from rust Never top up the oil or coolant if the generating set pump unit or lighting column is running or if the engine is hot A generating set can onl
90. te a edet dau 51 6 3 Apphcablere oula ONS tri a ns ies 22 O caes spt A Ses cele ise laste dossiers det dass sese eua 52 6 3 2 Location oran underground Tel id dta eod un esa obe lo aio 20 Os O O A dae cute 53 OUS RAS CTC AT HURTS 53 6 95 3 Exhaust OMNIS S ON auis ote ds ie roredo teta do ON 54 Top NCC MIC Aly COUUCCIION aseedoeesbted cie thes iotebonebotat oe bute alii edes ob ds tatit totos 55 Tl Ano A E e do cb EE 55 4 2 Neutral S VSLOPII A AAPP caben cete to eate o atat esta cal daoh iste dust dept te dafs 57 EZ era rora OOO O A O 57 2 252 2 E E S E a E E A O E E tend A E E IN 58 II 58 pro CYS CU eR E 59 Ted ONE ali ns 59 lirios O dul bb tbe deat 60 8 1 Installation Oc ell illo bios 60 8 2 Connec on I CC IS ai EH 60 8 3 Operations DELORE Star A de di comet 60 Os CHECKING AMELIA ia A Weel aad di A 60 ISSN MENAN A cet alec ete ec TEE 60 OL M nte ance plans oi oie vec AA A A ver A AAA A ee Ro pora a suede deeds 60 10 2 Enclos re Sea mo NA AAA A A a a A 61 10 355 CONTA SELVAS AA A A Gust doa A A e a td A 61 o Ecce A ee HM 61 DLL REMOVAL from SIOFAEE o ep arc Y oo Eod iet E Ec quive Y vus pe A a e OU pd REDE AE 62 TD Fueland consumables NOR D m 62 ds SP CUNT CAC ONS E A Salwar A e a Seen 62 LEN gM AAA Cr 62 12 1 2 Speeticatrots OE COOIN Slidecasts 63 15 7 Xdcditronab COUDDINGIN oir naci 65 A sani ues Doie ined o toot dd dodanntccouaaditenaean
91. ted deep discharges the recommended use v Battery stored too long without v Think about charging the battery charge using a regulator High water consumption Y Overload Y Check the charger voltage regulator v Charging voltage too high The battery explodes v Spark after battery charging Y Replace the battery beware of fire Y Short circuit and sparks Y Connection or disconnection during v Ensure there is sufficient ventilation charging Y Internal fault for example interruption and low electrolyte level 74 75 Name given by SDMO to designate an electrical device cabinet or box housing the master circuit breaker downstream of the power alternator and the auxiliary outgoing terminals The AIPR is generally mounted on the generating set base frame It is used for housing circuit breakers of 800 A or more Retention tank This is a vessel for collecting generating set leaks to prevent them from polluting the environment Welding seam This is a welding bead This is a common name given to an ISO container Low Voltage Low voltage A 50 V lt LVA lt 500 V AC Low voltage B 500 V lt LVB lt 1000 V AC Insulation monitoring device CSC Container Safety Convention International convention governing container safety or CSC convention which was rendered in France by Decree no 80 837 of 20 October 1980 and the orders issued for its application These orders define the process for obtaining CSC approval and list the bod
92. ted in the same direction as the prevailing winds see figure 6 27 The operator must not be subject to exhaust fumes when operating the console prevailing winds at their back The container air inlets and outlets must not be blocked A minimum distance of 2 metres must be kept between the container air inlets and outlets and any obstacle to ventilation v The container must not be positioned in the immediate vicinity of residences to avoid causing a disturbance excessive noise SS 91 75 EN 6 3 Applicable regulations 6 3 1 Fuel The regulations for fuel are specific to each country So the rules in force in the country of use must be observed Example of regulations in force in France Order of 10 08 98 Order of 19 11 01 Article EL7 v Fuel daily service tank The maximum capacity of the DT daily service tank in the generating set room is 500 L in the case of a Public Assembly Building If the DT is greater than 500 L it must be situated in a separate room v The capacity of the retention tank must be equal to or greater than the DT capacity v Fuel pipe If pipe under load and underground double lining Safety valve between Tank and DT Shut off valve between DT and engine Hoses are prohibited in ERPs 6 3 2 Location of an underground fuel tank Regulations on the location of underground fuel tanks are specific to each country Refer to the rules in force in the country in question Example of locati
93. ted on the generating set pump unit or lighting column alters its centre of gravity special lifting devices may be necessary to maintain correct balance and completely safe working conditions v The ground must be able to withstand the load of the generating set pump unit or lighting column and its lifting machinery without stress otherwise put down beams of sufficient strength in a stable configuration Y Position the generating set pump unit or lighting column as close as possible to its place of use or transport in a clear space with free access Y Never perform work on a generating set pump unit or lighting tower just hanging from a lifting device 13 75 N 2 9 Recommendation for the operator and environment v Operating personnel should be aware of the safety and operating instructions These will be regularly updated Y Operating should be monitored directly or indirectly by someone designated by the operator who is familiar with the installation and dangers and problems regarding products stored and used in the installation Y No one from outside the establishment should be able to access the installations freely unless designated by the operator Y The user should check the service pressures of the different pressure stages making sure that they are in accordance with the prescribed operating requirements The user is also responsible for making the apparatus adjustments according to the manufacturer s instructions a
94. tenance plans The user should continuously check that the installation is in good working condition The maintenance operations outlined in the documentation supplied with the generating set must be also carried out In addition regular checks and tests are recommended as these will ensure the correct operation of the installation The regular checks and tests may require the test report to be filled in including the following information interval nature of the inspection and or test performed date and time carried out report of operations name and signature of technician The maintenance plans periodic maintenance tables are outlined in the respective documentation maintenance manual for the engines alternators and for some accessories As a general rule these plans make a distinction between use under continuous operation and use under emergency operation They also take the consumables used into account for example the sulphur content of the diesel or the grade of lubricant oil These maintenance plans must be referred to as soon as the generating set is received so that taking the aforementioned elements into account the service intervals to be adopted can be defined 60 75 EN In addition to the maintenance plans mentioned above it is also recommended that the following checks are carried out the checks must be carried out by specialist personnel Y Mechanical o Mechanical checks mechanical adjustments belt tension
95. tes which becomes hard and insoluble to acid this deposit reduce the active surface of the plates and increases their internal resistance can no longer regenerate or be charged in a generating set A A discharged battery should be recharged immediately or else it will suffer irreparable damage Important Battery charge When several batteries are connected together the following points should be checked Are the batteries connected in series Has the correct voltage been chosen 1 battery x 12 V 3 x 36V batteries Adjust the charge current to the lowest battery The power difference between the batteries must be as low as possible LASA Example of charge 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery is short 30 Ah and this must be recharged Charge factor 1 2 Ah x 1 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required VAS SN Recharging is complete when the battery voltage and the acid density stop increasing The charging current must always be 1 10 of the nominal capacity of the battery The power of the charger must be suitable for the battery to be charged and the charging time available You need to use an automatic charger able to provide a sufficient voltage and charging current as well as a compensation voltage to handle spontaneous battery discharge 73 75 13 5 6 Fault finding Fault
96. the electric distribution panel and disturbances caused by the noise However fuel supply burnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered as fe Jis Incorrect exhaust and ventilation Ground too uneven or soft Reduced access Set incorrectly positioned Fuel filling impossible Opening cover doors impossible Figure 6 2 Examples of problems that may be encountered 6 1 1 2 Measurements and layout These are governed by two types of requirement Static requirements These are the dimensions of the equipment installed and its surroundings namely daily service fuel tank cabinet silencer batteries etc Dynamic requirements These are the dimensions which must be left around each piece of equipment to allow for any servicing and dismantling About a 1 metre space around the set is considered the minimum required for carrying out problem free maintenance This will give enough space to check that the doors of covered sets open fully that equipment can be accessed for maintenance and that full removal of the set can be carried out Figure 6 3 Example of the size of a site for a generating set with enclosure 37 T5 EN Construction All sorts of shelters can be designed to house a generating set If noise level and speed of starting
97. the line d Safety guidelines References NFC 15 100 2002 France IEC 60364 5 54 In order to protect personnel against electric shocks this generating set is equipped with a differential residual current protector factory set to trigger instantly with a sensitivity of 30 mA must only be performed by qualified and authorised personnel When the generating set is disconnected from a facility after use the master differential protector must be important returned to its factory settings and this must be checked by trained personnel Any modification to this setting could endanger personnel Any modification would render the user liable and For effective protection against electric shocks the generating set needs to be earthed To do this use a copper wire with a minimum cross section of 25 mm for a stripped cable and 16 mm for an insulated cable connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground The earthing rod resistance value should comply with the values shown in the table below Note use the highest differential setting from the installation as a guideline R Ul The resistance value is calculated in the following way EAS Maximum resistance value of the earth socket R Q according to the differential unit operational current operation time should not be longer than 1 second An differential The UI value 25 V is required for work s
98. ty or CSC convention which was rendered in France by Decree no 80 837 of 20 October 1980 and the orders issued for its application These orders define the process for obtaining CSC approval and list the bodies authorised to issue this approval This approval which comes in the form of a standardised plate permanently fixed on each approved container is obligatory for authorisation of sea transportation The stacked load that the container can bear is indicated on this plate This approval is obtained by the manufacturer for each container model by submitting a technical file subject to validation of standard tests by the approved body Figure 5 5 Example of a CSC plate 34 75 EN CSC approval 1 ISO type ISO 20 and 40 containers are basic ISO boxes to which modifications have been made doors intake grille exhaust outlet These containers in spite of their modifications have received CSC approval i e are authorised for shipping 2 CIR and EURO type The modifications made to these containers relating to the basic ISO box doors apertures for cooling exhaust etc disqualify them from CSC approval and therefore prohibit them from being shipped as a container In this case special transport is recommended flat container carrier CSC approval YES X X Our CIR 20 and EUR 20 containers cannot bear additional loads stacking prohibited Shipped with chocks Important For control
99. ure that the power supply has been made safe For an operation on the harness lower the temperature and the pressure Operations should only be carried out by qualified personnel The cleanliness of the device is a factor which will determine its performance and length of service life Regularly check that the harness fins are not clogged and clean as often as local conditions require As the engines are fitted with an oil vapour recirculation system the harness should not get greasy As a general rule using compressed air directed parallel to the fins should be sufficient to clean the harness In all cases cleaning should be undertaken with care to ensure the surface of the fins is not damaged The operating procedure described below is a theoretical operating procedure It will have to be adapted to the installation which is actually fitted If in any doubt please refer to a specialist O Drain the high temperature HT and low temperature LT Remove the engine connection hoses cooling circuits via tapping points in the lower section of the Disconnect the wiring on all the extractor fans after making air cooler drain lobe and vents provided on the manifolds or the power supply safe and then remove the fans starting pipes at the top of the air cooler LT circuit drainage point HT circuit drainage point 65 75 Disconnect the servomotors from the motorised ventilation Remove the motorised flap t
100. y operate when stationary and cannot be installed on a vehicle or other mobile equipment without a prior study taking into account the various specific features of using the generating set 12 75 N P 6 Risks related to electrical networks The electrical equipment supplied with the generating set complies with standard NF C15 100 France or with the standards of the countries in question v The earth connection must be installed in accordance with the standards in force in each country in question and with the neutral system sold Y Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Never accidentally touch stripped cables or loose connections Never handle a generating set with wet hands or feet Maintain electrical wires and connections in good condition Using equipment in poor condition can lead to electrocution and damage to equipment SN CN El v Always disconnect the power to the equipment or facility generating set voltage battery voltage and network voltage before any operation The electrical connections must be made in accordance with current standards and regulations in the country of use Do not use faulty poorly insulated or provisionally connected wires Never reverse the positive and negative terminals on batteries when connecting them This could cause severe damage to the electrical equipme

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