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1. 100 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com lask Description Engine Engine Barring with starting system Preconditions External pushbutton Bar engine without starting is provided Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Engine Barring with starting system Press pushbutton Bar engine without starting and keep depressed Let the crankshaft rotate until oil pressure is indicated but not longer than 10 seconds Repeat this procedure after approx 20 seconds if required pM Engine Test run DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone WARNING TE High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run Start engine Perform test run not below 1 3 load and at least until steady state temperature is reached Carry out operational checks Stop engine
2. 70 Wrndng TOT 70 11 8 2 Guidance of Typical INSULATION 70 11 8 3 Winding Condition 70 Tigo Ie DIA COMIGII ur 70 12 Specifications John 71 12 1 Generator Set 71 12 2 UL 2200 Generator Set 72 12 9 Engine Models usce tons ate cete tentoria toS ha eni De UU ECa TEES REESE URS 73 AO ATF O ee een ee een eee ee E 13 2 32 21 eee eee 79 123 3 2 74 5 74 1235 GOA 75 12 9 5 404 AFG e 75 OOOO 20 76 1238 COO GIN re EET Tm T 76 12 39 ODOT A serrer D 77 12 3 FO Vs Oe aes 77 13 Specifications YANMAN PET TOT 78 ox MEME UT 78 ID I 78 13 2 e E E arate 78 ANV 79 ICE ME Ip E 79 14 P
3. 85 17 1 Standard environmental conditions for reference 85 Diesel 0 ENIM 85 S5ynchtrornous 85 17 2 Derating for operative environmental conditions 85 UPC MEG NIME m TNT 86 ce eases 86 86 scoome meeE 86 PONO m rmm 86 gt Single phase load M 87 gt Charge MlaKES EEUU TU 87 gt Asynchronous engines 87 9 GENERALDES SCRIPTION eerie rece 87 18 1 Diesel CNQINGS cccceecccsecccececeeseceececeucecsueccaueeseueesseseceueeeueeeseeesseesseeessees 88 2 21d 2 0 PME m 88 We COMING E m 88 194 SUDDON E 88 18 5 Sound proof bonnet eesssssssssssssssssesee eene nnne nnns 88 18 6 Electrical panel with manual 88 18 7 Electrical panel with automatic 88 18 8 Control and protection 89 DNE bos BM De
4. Se DN qo NE NN NN MEME KENN NE GNE NN NE _ T CeCe _ 2 II uu ow a Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 20 b During engine break in change the oil and filter for the first time before 100 hours of operation c If the recommended engine oils John Deere PLUS 50 ACEA E7 or ACEA E6 are not used the oil and filter change interval is reduced see DIESEL ENGINE OIL AND FILTER INTERVALS chart If diesel fuel with a sulfur content greater than 0 05 is used the oil and filter change interval is also reduced 62 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 ALTERNATOR 11 1 Generator Designation HC K 534C2 eg some applications 11 11 4 Lifting WARNING The generator lifting points are designed to lift HC Standard range Generators HCK Dedicated range HC5 only Applications M Marine Industrial 5 Frame size 4 5 or 6 3 Separate excitation PMG Or 4 Self Excited 4 Number of poles 4 or 6 C C
5. 25 720 DescrpHor ol CONTOlS aeqne aar dade epe 25 7 1 Autostart Control 25 22 AMF Contool Mod le ENTE UT 26 La Quickstart GUNG Ae tmu oomen 27 26 T2228 Stopping TUE ENGNG 2 7 4 Viewing the Instrument Pages cceceeeceeeeeeeeeeeseseeeeeeeseneeanes 28 RESCUE 29 Su MR C C TIU TT 30 TAG lio TEE OI 31 7 5 Viewing the Event 32 CSOT EU m T Tm 33 TON EUU OVET 34 fu PUNO ANIC OUO cath cna rove less viu aean eerta ea 35 rer Waling in AWO Umm TU 35 Vr Staing Oe AUC Nes escas sene Pone TIMERE UU 35 7 8 WARIO OG RETE 36 7 8 1 Waiting in Manual 36 7 8 2 Starting 9SeduelieBaserpR 36 EN E TAEITIBITIO DNE EE EDDA EE 37 7 8 4 Manual Fuel Pump 37 7 8 5 Manual Speed 37 7 8 6 Stopping SCO CCC 38 7 9 Test INOS RR 38 Peg Walng DUE 38 159 2 Staring OC UCN 38 Engine RUNNING EET 39 TNO
6. 97 21 1 Locating the Change Over Board 97 212 Nue MER T T m 97 21 3 120 209 V POSION eee ae eee E 97 21 4 How to change the voltage 98 22 Rear Distribution Panel Description eese 99 22 1 400 Amps Distribution 100 22 2 800 Amps Distribution 100 22 3 1200 Amps Distribution PAN Clissiccsusercasvrcdeadeaszusaeistanruniarartgenddecaiccayentenstsaaaedda 100 23 MIU ENGINE SERVICE MANUAL 2 101 7 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 1 SAFETY 1 1 General Safety Information This manual provides information and procedures to safely operate and maintain your Hipower Generator oet Read understand and observe the safety instructions described in this manual before installing operating and servicing the generator If you have questions about operation or service please contact Hipower Systems The information contained in this manual was based on machines in production at the time of publication Power Systems reserves the right to change any portion of this in
7. 39 7 11 Protections 40 7 11 1 Indications Warnings FANN 40 7 11 2 Shutdown Elecirical Trip rte e tr nes 40 3 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 712 fdati 41 PENS WV aue TET C 41 7 14 High Current Warning Alarm esses 43 NET I T 44 1 10 ede TDS EET UR 46 7 17 High Current Shutdown Electrical Trip Alarm 46 7 17 1 Immediate VV ALIN 47 re ES IR NM 47 1 15 SCION 48 7 19 Maintenance nemen nnns 49 es ero MEET I T UU UT TIME 50 GOD IOC MEME 50 7 20 2 Manual TOO FI NH d RAPPIE 50 203 AUO 50 7 21 Front Panel CODIIOHFAllOTl ER 51 7 22 Accessing the Main Front Panel Configuration Editor 52 221 Eang a i PEE OT 59 7 22 2 Adjustable enne 54 7 23 Accessing the Running Configuration Editor 56 7 23 1 Editing A SPAITIOIG P dE mda 56 ON I es
8. NW 8 F PL P P P E E P f P P E 1 P E P P E P P E 1 1 E 1 f c c A g h cC d lt D TEE 8 Longitud de la tuber a en m In order to calculate the diameter of the exhaust gases pipe it is possible to use the nomogram that can be found below 92 Page For calculation purposes in this nomogram we will use the following backpressure values 800 mm for aspirated engines 400 mm for supercharged engines Exhaust gases airflow in kg h In order to convert into m3 h the data must be divided by the exhaust gases density Request these data to the manufacturer HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com The exhaust pipe cannot have a lower diameter than the collector pipe of the engine exhaust and also the straight stretches must have a slight inclination in order to prevent the return of condensates as shown on the location plan of the generator in the room When the diameter of the pipe is higher the engine joint must have a conic connection element with a conicity below 30 in order to avoid excessive load losses Check with the HIMOINSA engineering department There is backpressure in the outlet of the generator which is caused by the internal pipes It is necessary to know this value so as not to exceed the recommended backpressure when designing the rest of the installation The exhau
9. 1 913 495 5557 TOLL FREE NUMBER 1 866 710 2988 1 913 495 5575 info hipowersystems com www hipowersystems com 12 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Q When the generator is running check to make sure the voltage is correctly If needed this can be regulated via the voltage adjustment dial item 8 at the bottom left illustra tion Auto start is done by closing the contact connections located at the bottom of the main control panel See complete Control Panel illustration to locate the 2 auto start connection knobs Over current relay protection only functions in 277 480 volt If the relay trips and the safety breaker light is on it will need to be reset Push the pictured blue button to reset the over current relay Over current relay Technical details 1 OCR Adjusment 2 OCR test button 3 OCR reset button NOTE If the circuit breaker door is open the breaker will not reset and the safety breaker light will stay on QD Safety breaker light amp circuit breaker o Q Q Complete Control Panel DSE 702 Technical details 1 Three AC amp meters 2 Frecuency meter 3 Volt meter 4 DSE 702 Control 6 5 Battery volt meter 6 Hour meter 7 Voltage phase selector switch 8 Voltage adjustment dial 7 9 Fuel gauge 10 Oil pressure gauge 1
10. Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Tank is pressurized A NOTICE m Contamination of components Damage to component En Observe manufacturer s instructions Check components for special cleanliness Risk of eye injuries resulting from fluid escaping under high pressure Open tank slowly Wear goggles or safety mask Replacing fuel prefilter 1 Remove easy change filter 2 with filter wrench 2 Clean sealing surface filter head 1 3 Lightly lubricate seal on the easy change filter 2 4 Screw on easy change filter 2 by hand un til the seal makes contact with the filter head and tighten manually 08300735 108 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Air Filter Air filter Replacement opecial tools Material Spare parts Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one 2 Reset signal ring of service indicator filter Removal and installation Preconditions LA Engine is stopped and starting disabled Air filter Removal and installa tion Loosen clamp 2 2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Verify that there are no objects in the flange of the intake housing 3 and clean it 4 Pla
11. o 89 19 1 MOOR AM WARMING S seese 89 19 2 O tdoor InstallallOliS i uxessne send 89 S Indoor IristallatiOflS 89 S 89 FOUI ONS RENT 90 Exhaust sacru deinen M 90 A Exhaust pipes measurement for standard static generators 92 6 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com B Exhaust pipes measurement for soundproof static generators 93 E SI AT 93 gd 93 u iaicue 94 i ediecees eiekcfe 94 Generators of manual intervention 94 Generators of automatic 94 gt Gable CIMENSIONS csset in baa ced 94 9 29 0 Je oem 95 G18 0 1916 UU Ie 95 FC Al MG E 95 BEFORE STARTING UP 96 21 VOLTAGE CHANGE OVER BOARD HRMW range
12. HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature switch after the Safety On timer has expired a shutdown will occur The 22 icon will illuminate OVERSPEED if the engine speed exceeds the pre set trip 14 above the nominal frequency a shutdown is initiated Overspeed is not delayed it is an immediate shutdown The lt icon will illuminate During the start up sequence the overspeed trip level is extended to 24 above the normal frequency for the duration of the safety timer to allow an extra trip level margin This is used to prevent nuisance tripping on start up UNDERSPEED if the engine speed falls below 20Hz fixed after the Safety On timer has expired a shutdown is initiated The gt icon will flash eg icon is used to indicate both underspeed and overspeed A flashing icon indicates underspeed A steady K icon indicates overspeed 19 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 6 3110 SERIES CONTROL PANEL 6 1 Description Of Controls The following section details the function and meaning of the various controls on the module REL 1 Navigation Buttons 3 Common Alarm Indicator 5 Select Auto Mode 2 Main Status Display 4 Start engine 6 Select Stop Mode 6 2 Quickstart Guide
13. Run the generating set on no load and check that speed is correct and stable Turn the STABILITY control potentiometer clockwise and then turn slowly anti clockwise until the generator voltage starts to become unstable The correct setting is slightly clockwise from this position i e where the machine volts are stable but close to the unstable region 65 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 5 3 Type SX460 The following jumper connections on the AVR should be checked to ensure they are correctly set for the generating set application 1 Field and sensing connections 2 Voltage adjustment 3 External hand trimmer selection With no external hand trimmer Link 1 2 With external hand trimmer Remove Link 1 2 and connect trimmer across terminals 1 and 2 4 AVR Input Selection High Voltage 220 240V Input No Link Low Voltage 110 120V Input Link 3 4 5 UFRO adjustment 6 UFRO indication LED 7 Frequency selection For 50Hz operation Link C 50 For 60Hz operation Link C 60 8 Stability control During testing it may be necessary to remove covers to adjust controls exposing terminals or components Only personnel qualified to perform electrical service should carry out testing and or adjustments Refit all access covers after adjustments are completed On completion of generating set assembly
14. Warning risk of electric shock do not operate this panel without reading manual or proper training For use by qualified personnel only 21 1 Locating the Change Over Board Panel The voltage quick reconnect panel is located on top of the generator end enclosure Housing Inside this panel are the copper bonding bars as known as jumpers that allow the Voltage Change Over Board VCOB to jump the generator winding from Low Wye to High Wye 21 2 277 480V Position When the VCOB is located in upper position the generator will operate in a STAR CONNECTION common known as High Wye 21 3 120 208V Position When the VCOB is located in lower position the generator will operate in a STAR PARALLEL CONNECTION common known as Low Wye 97 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com For information regarding the electrical wiring diagram Step 3 of the VCOB please see owners manual located Remove the jumper bar assembly by pulling out on inside the generator set the two black handles see BLACK arrow in the illustration to locate HANDLES Reconnect the jumper 21 4 How to change the voltage bar assembly to desire voltage To obtain 120 208V connect the VCOB in the lower position or for Step 1 2 7 480V connect to upper position see BLUE arrow in the illustration In order to access the VCOB loosen the six bolts the
15. hold the access door place see RED arrow the illustration to locate BOLTS To remove the door slide up about 12 follow by pulling out towards the back of the engine see BLUE arrow in the illustration Step 4 Assemble everything back together in the reverse sequence of the three first steps If selecting the 277 480V position all unused nuts must be tighten Step 2 back to original studs for future use see RED arrow in Remove the seven nuts shown in green color that illustration to locate NUTS hold the front panel of the VCOB see RED arrow in the illustration to locate NUTS Do not remove the rest of bolts that hold the jumper buss bar assembly MORE INSTRUCTIONS ARE LABELED INSIDE THE CHANGE OVER BOX 98 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 22 REAR DISTRIBUTION PANEL The panel has three 50 amp twist lock connectors It has three 50 amp breakers for protection for the twist lock 1 phase 120 240 twist lock plugs The panel is equipped with two 20 amp GFI plugs 120 volts protected by two 20 amp circuit breakers DO NOT USE GFI PLUG WHEN SELECTOR IS IN 480 VOLT 3 PHASE POSITION BECAUSE THE VOLTAGE IS TOO HIGH 138 VOLTS The upper portion of the distribution panel is protected by the 50 amp and 20 amp breakers in the front of the panel The cam locks and mounting lugs are protected by the
16. 7 23 1 Editing A Parameter Enter the editor as described above o 9 Press the left or right buttons to cycle to the section you wish to view change o Press the or down buttons to select the parameter you wish to view change within the currently selected section To edit the parameter press to enter edit mode The parameter begins to flash to indicate that you are editing the value Pressthe up or down buttons to change the parameter to the required value Press Y to save the value The parameter ceases flashing to indicate that it has been saved To exit the editor at any time press and hold the 2 button 7 23 2 Adjustable Parameters Running Editor Running Editor Factory default settings are shown in bold italicised text section Parameter as shown on display Factory Setting E 2 C TUTTI m Fuel Pump if manual manua fuel pump contro 14 is enabled om HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 24 Commissioning 7 24 1 Pre Commissioning Before the system is started it is recommended that the following checks are made 10 1 The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system Check all mechanical parts are fitted correctly and that all electrical connections including earths are sound 10 2 The unit DC
17. Coolant Engine coolant change zum i Drain engine coolant 2 Fil with engine coolant 114 Page HIPOWER Systems Inc 16002 W 140th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com WARNING Engine coolant Draining Preconditions Engine is stopped and starting disabled special tools Material Spare parts Designation Use Engine ail Sealing ring Spare Parts Catalog Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps Provide an appropriate container to drain the coolant into switch off preheater if installed Engine coolant Draining Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape Continue to tum breather valve counter clockwise and remove Draw off separated corrosion inhibitor oil in expansion tank through the filler neck Open drain screws and drain engine cool ant at the following drain points p pii T P TESTS on crankcase left side 1 Code Wc un ema Cm 14 on crankcase right side 2 20201583a Insert drain plug with new sealing ring and use torque wrench to tighten to specified tightening torque Name 1 Lubricant Value Standard Drain plug Tightening torque Engine oil 100 Nm Pla
18. Sets for terrestrial use Sets for maritime use The sets for terrestrial use depending on the use they are aimed at have been provided with two types Static sets for fixed installations Mobile sets for mobile installations Both types can be subdivided at the same time into a wide range of models depending on their variety and user demands Manual operation generators Automatic operation generators Continuity sets 18 1 Diesel engines They operate with a four stroke diesel cycle naturally aspirated direct injection turbocharged and or aftercooled The layout of the cylinders depends on the engine model and it can be in line or V type It is a water cooled type of engine 18 2 Monopalier alternator Generator with a horizontal shaft synchronous without brushes auto excited and auto regulated The alternator has an automatic voltage regulator This regulator has got potentiometers in order to adapt the functioning to the different conditions in which the set is used 18 3 Coupling joint It is possible to use two bearing alternators upon request The engine and the alternator are joined by means of elastic coupling and through a hood coupling in order to guarantee a correct coaxial position of the assembly For standard assemblies it is possible to use single bearing alternators and the connection is made by means of flexible disks that are fixed directly to the engine wheel 18 4 Support bedplate
19. This section provides a quick start guide to the module s operation 6 2 1 Starting The Engine 1 First press Stop Reset 1 2 Then press the Start button to crank the engine Depending upon module configuration two presses may be required 6 2 2 Stopping The Engine 1 Select Stop Reset mode 1 The generator is stopped Sas Electronics 1 6 3 Graphical Display A 32x132 pixel LCD 35mm 1 4 is available for the display of generator instrumentation and alarm conditions The display is segmented into areas for instrumentation unit alarm icons and for Front Panel Editor FPE use When not in the Front Panel Editor FPE mode the FPE area of the display is used to display the currently active configuration The letter M is displayed for main configuration active the letter A for alternative configuration active VIEWING THE INSTRUMENTS It is possible to scroll to display the different pages of information by repeatedly operating the scroll button Once selected the page will remain on the LCD display until the user selects a different page or after an extended period of inactivity the module will revert to the status display When scrolling manually the display automatically return to the Status page if no buttons are pressed for the duration of the configurable LCD Page Timer If an alarm becomes active while viewing the status page the display shows the Alarms page to dra
20. C o Room air pressure 1000 Mbars 750 mm Hg o Relative humidity 3096 e Synchronous generator The environmental conditions used as a reference for alternators stationary applications according to the directives IEC 34 1 ISO 8528 3 and 2 3 are the following Room temperature 40 C 30 C according to NEMA o Altitude 1000m ASL 674 mm Hg 17 2 Derating for operative environmental conditions For environmental conditions of installation and operation different from those above specified it is necessary to foresee an eventual loss of power or derating not only in the engine but also in the generator that is fitted into it and therefore in the electric power provided by the generator The user customer must clearly establish the effective environmental conditions in which the Generator Set will operate when placing the order Therefore the derating and declassification must be fixed at the time of signing the agreement so that both the engine and the generator are correctly sized Particularly the user customer must report on the following environmental conditions in which the generator set will operate e The upper and lower room temperature limits e The altitude above sea level or preferably the minimum and maximum values of barometric pressure in the installation area in case of mobile sets the upper and lower limits of altitude above sea level e The humidity valu
21. CIRCUIT AUXILIARY INPUTS An active auxiliary input configured as a shutdown will cause the engine to shut down The display shows the text as configured by the user LOSS OF SPEED SIGNAL The speed signal from the magnetic pickup is not being received by the DSE controller The module is configured for CAN operation and does not detect data on the engine Can datalink the engine shuts down ECU SHUTDOWN The engine ECU has detected a shutdown alarm and has informed the DSE module of this situation The exact error is also indicated on the module s display The measured Total kW is above the setting of the kW overload shutdown alarm NEGATIVE PHASE SEQUENCE Indicates out of balance current loading of the generator DSE7000 series V2 0 or above onl Sometimes also called Negative Sequence Current or Symmetry Fault Indicates that the maintenance alarm has triggered A visit is required by DSE7000 series V2 1 or above onl the Generator service company GENERATOR HIGH CURRENT A High Current condition has continued for an excess period then the alarm escalates to either a shutdown or electrical trip condition depending upon module configuration For further details of the high current alarm MENU _ please see High Current Shutdown Electrical Trip Alarm LOADING VOLTAGE NOT Indicates that the generator voltage is not above the configured loading REACHED voltage after the safety timer The generator will shutdown LOADING FREQUENCY NO
22. Galvanized steel pipelines must not be used Flexible connections must be fitted in order to isolate the static parts of the plant from the new fuel tank in order to avoid the possible vibrations caused by the engine Depending on the type of engine these can be made using the following Stretches with a suitable length made of reinforced rubber pipes with flexible insertions that are resistant to gas oil For the connections with the terminal rubber holders with edges and screw clamps Flexible low pressure type tubes suitable for gas oil protected with metal mesh and with screwed terminals for tightly sealing Synthetic resins must be avoided In complementary areas of the plant maximum attention must be paid to the following issues Fix pipes by means of holders at regular intervals in a way that vibrations and inflexions caused by pipes weight are avoided especially those made of copper tube Couplings must be avoided In case of using them they must be tightly sealed especially in depression conditions parts fuel aspiration intake in order to avoid air filtrations that make the startup more difficult Aspiration pipes below the fuel level must be placed at a distance of 20 30mm from the bottom in order to avoid a possible deactivation of the circuit due to air insufflations Also these must be conveniently separated from each other in a way that the fuel return flow does not block the supply due to the gas oil impur
23. If necessary top up to max mark Insert oil dipstick 1 in guide tube up to the stop 180003176 Checking oil level after engine 15 stopped 5 minutes after stopping the engine remove oil dipstick 1 from the guide tube and wipe It Insert oil dipstick 1 into guide tube up to the stop withdraw after approx 10 seconds and check ail level Oil level must be between min and max marks If necessary top up to max mark Insert oil dipstick 1 in guide tube up to the stop 111 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Engine oil Change Preconditions v Engine is stopped and starting disabled Engine is at operating temperature MTU Fluids and Lubricants Specifications A00 1063 7 are available special tools Material Spare parts Torque wrench 20 100 Nm F30026582 Ratchet F30027340 1 Engine oil Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Draining oil at drain plug on oil pan 1l Provide a suitable container to collect the oil 2 Remove dram plug 2 and drain oil 18000316b Lubricant Valuse Standard Drain plug Tightening torque E
24. MIS 101 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Valve Drive Valve clearance Check and adjustment Preconditions V Engine is stopped and starting disabled V Engine coolant temperature 15 max 40 C 4 Valves are closed special tools Material Spare parts Designation Use Feeler gauge Y20098771 1 Torque wrench 20 100 Nm F30026582 1 Box wrench 14 mm F30028346 1 Allen key set 2 10 mm F30453050 1 Barring gear F6790714 1 Preparatory steps Remove cylinder head cover Page 98 Remove cover on the bottom of flywheel housing A side Install barring gear at opening Rotate crankshaft with barring gear in engine direction of rotation until 1 mark and pointer are aligned Diagram for 8 V engines two crankshaft positions 1 Cylinder is in firing TDG 2 Cylinder 15 in overlap Inlet valve XA Exhaust valve 05500485a 102 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com Diagram for 10 V engines two crankshaft positions 1 Cylinder 1 is in firing TDG 2 Cylinder is in overlap Inlet valve A Exhaust valve Diagram for 12 V engines two crankshaft positions 1 Cylinder 1 is in firing TDG 2 Cylinder 15 in over
25. The different operations and or maintenance procedures which are not specifically indicated in the user handbooks must be notified to the manufacturer for their approval Do not carry out modifications of the product without having the knowledge and exclusive authorization by our technical department Follow the recommended manufacturer s directions concerning oil changes and fuel replacements Do not use oils or fuels that are not specified by the manufacturer opare parts must conform to the manufacturer s standards Use original www hipowersystems com spares only For spares contact original spare suppliers only or workshops in the HIMOINSA assistance network For a correct determination of the spare parts always refer to the data indicated on the plate of the set the type of engine and or alternator and their respective registration numbers Periodically control the condition of the different components of the G S especially of antivibration components the origin of eventual vibrations and or the increase in noise Periodically check if there are any water oil fuel and or acid leaks in the battery batteries Do not modify the engine or other components of the generator set to obtain performances different from those specified by the manufacturer Do not operate the fuel tank or fuel supply conduits when the engine is hot or in operation Wear protective gloves and goggles o When using pressurized air o During batt
26. connections startup batteries and earth connections must be checked The terminals must be firmly connected and all switches must be set to their unlocked positions Cyclical direction of the phases For generators intervention automatic or in those auxiliary hand operated ones for external production lines make sure the cyclical direction of the alternator phases matches the phases of the external producer in order to avoid reversals in rotation and other inconveniences Air filter check up It must not have obstructions or porosities that prevent a good air filtering In case of showing deterioration you must proceed with the maintenance operations of the air filter Radiator intercooler air air check up Verify that the surface of the radiator air intake is clean Checkup of the liquid level in batteries 96 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com The HRMW Rental Ready Generator Set is equipped with a two position voltage Change Over Board This system allows the operator to quick swap from voltage to another without having to touch any of the internal wiring of the alternator Changing the position of the copper buss bars located inside the voltage reconnect board enable the machine to operate in 277 480V High Wye or 120 208V Low Wye DANGER LIVE VOLTAGE
27. cos value comes closer to 0 Therefore the reactive power to be produced increases as the cos decreases The generator reduces its power according to the directions provided by the manufacturer For reference purposes Chart 5 is presented so as to determine these reductions in power For a higher accuracy refer to the documentation provided by the generator s manufacturer oo factor cos ts Chart 5 Coefficients that indicate reductions in power for a generator in a cos function Single phase loads The generators may be supplied with unbalanced loads that can reach the nominal current of each phase This means that between two phases for example L1 and L2 you cannot insert more than 0 58 of the three phase nominal power of the set similarly between one phase and the neutral eg L3 and neutral you cannot insert more than 1 3 that is 3396 of the three phase power of the plate It is necessary to take into consideration that during the single phase operation or with unbalanced loads the voltage regulator cannot hold the expected voltage tolerances Charge intakes When a charge is applied to a generating set a series of transitory variations of voltage and frequency occur The scope of such variations depends on the value of the power both active KW and reactive KVAR of the variations of the load depending on the characteristics of the diesel engine and alter
28. operation The fuel relay is energized and the engine is cranked NOTE If the unit has been configured for CAN compatible ECU s will receive the start command via CAN If the engine fails to fire during this cranking attempt 22 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 then the starter motor is disengaged for the crank rest duration after which the next start attempt is made Should this sequence continue beyond the set number of attempts the start sequence will be terminated and the display shows Fail to Start When the engine fires the starter motor is disengaged Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel Selected by PC using the 3000 series configuration software Additionally rising oil pressure can be used disconnect the starter motor but cannot detect underspeed or overspeed NOTE If the unit has been configured for CAN speed sensing is via CAN After the starter motor has disengaged the Safety On timer activates allowing Oil Pressure High Engine Temperature Under speed Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault Engine Running In manual mode the load is not transferred to the generator unless a loading request is made A loading request can come from
29. pushbutton An LED indicator beside the button confirms this action Manual mode allows the operator to start and stop the set manually and if required change the state of the load switching devices 7 8 1 Waiting in Manual Mode When in manual mode the set will not start automatically To begin the starting sequence press the button 7 8 2 Starting Sequence Anote There is no start delay in this mode of operation The fuel relay is energised and the engine is cranked Awnotz If the unit has been configured for CAN compatible ECU s will receive the start command via CAN If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made Should this sequence continue beyond the set number of attempts the start sequence will be terminated and the display shows Fail to Start When the engine fires the starter motor is disengaged Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel Selected by PC using the 7000 series configuration software Additionally rising oil pressure can be used disconnect the starter motor but cannot detect underspeed or overspeed If the unit has been configured for CAN speed sensing is via CAN After the starter motor has disengaged the Safety On timer a
30. 2 Check UFRO setting 3 Follow Separate Excitation Procedure to check generator and AVR 11 7 2 SX440 AVR No voltage build up when starting set 1 Check link K1 K2 on auxiliary terminals 2 Check speed 3 Check residual voltage Refer to subsection 7 4 7 4 Follow Separate Excitation Test Procedure to check generator and AVR Refer to subsection 7 5 Unstable voltage either on no load or with load 1 Check speed stability 2 Check stability setting Refer to subsection 4 6 High voltage either on no load or with load 1 Check speed 2 Check that generator load is not capacitive leading power factor Low voltage no load 1 Check speed 2 Check link 1 2 or external hand trimmer leads for continuity Low voltage on load 1 Check speed 2 Check UFRO setting 3 Follow Separate Excitation Procedure to check generator and AVR 11 7 3 SX421 AVR No voltage build up when starting set 1 Check circuit breaker ON 2 Check speed 3 Check residual voltage Refer to subsection 7 4 7 4 Follow Separate Excitation Test Procedure to check generator and AVR Unstable voltage either on no load or with load 1 Check speed stability 2 Check stability setting High voltage either on no load or with load 1 Check speed 2 Check link 1 2 or external hand trimmers leads for continuity Check continuity of leads 7 8 and P3 P2 for continuity 3 Check that generator load is not capacitive le
31. 2 STARTING INSTRUCTIONS 702 2 1 Starting Instructions 702 Check oil and coolant fluids before operating generator 1 Turn on battery cut off switch by rotating to vertical position Location label on other side front door To disconnect rotate to horizontal position Located below battery charging alternator on the left side as you face the rear of the generator 2 Check emergency stops you will find one inside on the control panel and one located on the housing exterior Twist clockwise to release 3 Turn on rotary power switch located on lower right of control panel by emergency stop button 4 Check selector for correct operating voltage before starting It is located inside on the front of the generator location label on left side vented door DO NOT CHANGE VOLTAGE SELECTOR WHILE SET IS RUNNING 5 To start turn key to auto on DSE702 control 6 Push green button and wait 10 seconds for glow plugs and engine will start 7 Check for correct voltage and adjust dial labeled Voltage Adjustment Dial if necessary Move safety lock on top to left to release and back to right to lock For more information please see laminated instructions in manual box 11 HIPOWER Systems Inc 16002 W 140th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 2 2 Portable Power Quick Start Manual 702 Portable Power Fo EE Quick Start Manual 2 generating sets Quick overvie
32. Check indicators Equipment Check battery Check engine oil level Engine Oil _ Drain and fill engine oil Replace engine oil filter X 1st time X 2nd and after Engine Check and adjust Speed governor lever and Control engine speed control Inspect clean and test fuel injectors Inspect turbocharger if equipped blower wash as necessary Inspect crankcase breather system Check andrefilfueltank O o _ ___ 0 j Drain fuel water separator Fuel Check fuel water separator Clean fuel water separator Replace fuel filter Hoses Replace fuel system and cooling system hoses Intake and Clean or replace air Exhaust cleaner element Complete Overall visual inspection Engine daily Emission Control Warranty 80 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 15 SAFETY REGULATIONS Before operating the machine read the following safety regulations carefully and find out about the local requirements in safety The installation operation maintenance and repairs must be carried out only by authorized and competent personnel The owner is responsible for maintaining the generating set in good safety conditions The parts and accessories must be replaced if they are not in good working conditions 15 1 General safety precautions e Do not allow non authorized people to
33. HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 3 Quickstart Guide This section provides a quick start guide to the module s operation 7 3 1 Starting the Engine DEEP SEA ELECTRONICS CG eie LLLLLIL First select manual 09777 mode Ac ces AL Ar L then press the decal 25 yn to crank For further details see the section entitled OPERATION elsewhere in this manual 7 3 2 Stopping the Engine Cae DEEP SEA ELECTRONICS oon tall ans cr i For further details see the section entitled OPERATION elsewhere in this manual 27 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 4 Viewing the Instrument Pages It is possible to scroll to display the different pages of information by repeatedly operating the next previous page o buttons If you want to view one of the instrument pages towards the end of the list it may be quicker to scroll left through i Ex am the pages rather than right omes And so on until the last page is reached Status o Engine Generator A Further press of the scroll right button returns the display to the Status page The complete order and contents of each information page are given in
34. KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 15 Shutdowns Shutdown and Electrical Trip alarms be disabled by user configuration See the section entitled Protections Disabled elsewhere in this document shutdowns are latching alarms and stop the Generator Clear the alarm and remove the fault then press Stop Reset to reset the module Example The alarm condition must be rectified before a reset will take place If the alarm condition remains it will not be possible to reset the unit The exception to this is the Low Oil Pressure alarm and similar active from safety on alarms as the oil pressure will be low with the engine at rest Display EARTH FAULT The measured Earth Fault Current has been in excess of the earth fault DSE7300 series V2 0 or above only trip and has surpassed the IDMT curve of the Earth Fault alarm FAIL TO START The engine has not fired after the preset number of start attemp EMERGENCY STOP The emergency stop button has been depressed This a failsafe normally closed to battery positive input and will immediately stop the set should the signal be removed Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller OTE The Emergency Stop Positive signal must be present otherwise the unit will shutdown LOW OIL PRES
35. Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 7300 amp 8600 SERIES CONTROL PANEL 7 0 Description of Controls The following section details the function and meaning of the various controls on the module 7 1 Autostart Control Module Main status and instrumentation display Open generator manual mode only Generator Available LED 4 On when the Close Generator LED generator is On When The Generator within limits Is Required To Be On and able to Load take load Anote Generator on load LED has two modes of operation depending upon the configuration of the controllers digital inputs 1 Digital input configured for Generator closed auxiliary The LED illuminates when the generator closed auxiliary input is active The LED shows the state of the auxiliary contact 2 There is NO input configured for Generator closed auxiliary factory default setting The LED illuminates when the 7x20 gives the loading signal to the generator The LED shows the state of the 7 20 5 loading request 25 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 2 AMF Control Module Main status and instrumentation display Menu navigation Four configurable buttons LEDs Transfer to generator manual mode only Tr
36. Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 7 Automatic Mode If a digital input configured to panel lock is active changing module modes will not be possible Viewing the instruments and event logs is NOT affected by panel lock Activate auto mode be pressing the pushbutton An LED indicator beside the button confirms this action Auto mode will allow the generator to operate fully automatically starting and stopping as required with no user intervention 7 7 1 Waiting in Auto Mode If a starting request is made the starting sequence will begin Starting requests can be from the following sources Mains supply out of limits DSE7220 7320 only Activation of an auxiliary input that has been configured to remote start on load or remote start off load Activation of the inbuilt exercise scheduler Instruction from external remote telemetry devices using the RS232 or RS485 interface DSE7310 DSE7320 only 7 7 2 Starting Sequence To allow for false start requests such as mains brownouts the start delay timer begins There are individual start delay timers for each of the different start request types Should all start requests be removed during the start delay timer the unit will return to a stand by state If a start request is still present at the end of the start delay timer the fuel relay is energised and the engine will be cranked Anote If the unit has been configured for CAN compati
37. a number of sources e Activation of an auxiliary input that has been configured to remote start on load e Activation of the exercise scheduler if configured for on load runs NOTE The load transfer signal remains inactive until the Oil Pressure has risen This prevents excessive wear on the engine Once the load has been transferred to the generator it will not be automatically removed To manually transfer the load back to the mains either e Press the auto mode button to return to automatic mode The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence e Press the stop button De activation of an auxiliary input that has been configured to remote start on load 6 6 3 Stopping Sequence In manual mode the set will continue to run until either e The stop button is pressed The set will immediately stop e he auto button is pressed The set will observe all auto mode start requests and www hipowersystems com stopping timers before beginning the Auto mode stopping sequence Protections When an alarm is present the Common alarm LED if configured will illuminate The LCD display will show an icon to indicate the failure 6 7 Warnings Warnings are non critical alarm conditions and do not affect the operation of the generator system they serve to draw the operators attention to an undesirable condition Warning alarms are self resetting when the f
38. and before starting the generating set ensure that all engine manufacturer s pre running procedures have been completed and that adjustment of the engine governor is such that the generator will not be subjected to speeds in excess of 125 of the rated speed Overspeeding of the generator during initial setting of the speed governor can result in damage to the generator rotating components In addition remove the AVR access cover on AVR controlled generators and turn volts control fully anti clockwise Start the generating set and run on no load at nominal frequency Slowly turn volts control potentiometer clockwise until rated voltage is reached Refer to Fig 1 2 or 3 for control potentiometer location Do not increase the voltage above the rated generator voltage shown generator nameplate The stability control potentiometer should be set to the midway position refer to fig 1 2 or 3 for its location and with the stability selection correctly set should not normally require adjustment Should adjustment be required usually identified by oscillation of the voltmeter proceed as follows Run the generating set on no load and check that speed is correct and stable Turn the stability control potentiometer clockwise and then turn slowly anti clockwise until the generator voltage starts to become unstable The correct setting is slightly clockwise from this position i e where the machine volts are stable but clo
39. and Charge Fail to stabilise without triggering the fault On removal of the Remote Start signal the Stop delay timer is initiated Once this timer has expired the Fuel Solenoid is de energised bringing the generator to a stop 18 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 5 2 Warnings Warnings are used to warn the operator of an impending fault BATTERY CHARGE FAILURE if the module does not detect a voltage from the warning light terminal on the auxiliary charge alternator the icon will illuminate 5 3 Shutdowns Shutdowns are latching and stop the Generator The alarm must be cleared and the fault removed to reset the module In the event of a shutdown the appropriate LED will be illuminated The alarm condition must be rectified before a reset will take place If the alarm condition remains it will not be possible to reset the unit The exception to this is the Low Oil Pressure alarm and similar delayed alarms as the oil pressure will be low with the engine at rest FAIL TO START if the engine does not fire after the pre set 3 attempts at starting a shutdown will be initiated The icon will illuminate LOW OIL PRESSURE if the module detects that the engine oil pressure has fallen below the low oil pressure switch after the Safety On timer has expired a shutdown will occur The YEZ icon will illuminate
40. can control the voltage of the terminals For supercharged engines it is possible to apply an instant voltage equivalent to 8096 of the nominal voltage with a transitory fall in speed within 10 The specified values for both naturally aspirated engines and supercharged engines may vary as usual depending on the type of speed regulator and the generator used Power factor The power of generators is the active power expressed in kW produced by the terminals of the generator The nominal power factor is cos 0 8 therefore the apparently nominal power will be 1 25 times the Nominal Active Power The power factor is a piece of information that depends on the characteristics of the load HIMOINSA generators equipped with an alternator can produce both the active power and the reactive power required by the load but whereas the active power is produced by the Diesel engine transforming mechanical power into electric power by means of the generator the reactive power is produced by the alternator Therefore for a performance with values different from cos 20 8 we must consider Cos 0 8 lt gt 1 load The alternador works perfectly at active nominal power with the cos values between 0 8 and 1 In order to prevent engine overload it is required not to exceed the active nominal power Cos 0 8 load www hipowersystems com The alternator for a certain plate value with reference cos 0 8 overloads more when the
41. details 1 OCR Adjusment 2 OCR test button 3 OCR reset button NOTE If the circuit breaker door is open the breaker will not reset and the safety breaker light will stay on D Safety breaker light amp circuit breaker 0000000 Q Complete Control Panel DSE 3110 Technical details 1 Three AC amp meters 2 Frecuency meter 3 Volt meter 4 Volt meter switch 5 Alarm buzzer 6 Hour meter 7 DSE 3110 Control 6 8 Fuel gauge 9 Oil gauge 10 Temperature gauge 11 Engine diagnostic switch 4 12 Voltage adjustment dial 7 13 Volt meter 14 Panel power switch 15 Emergency stop 16 Auto start connections HIMOINSA POWER SYSTEMS INC 16210 W 110 St Lenexa KS 66219 USA MEMBER A EE AA 1 913 495 5557 TOLL FREE NUMBER 1 866 710 2988 1 913 495 5575 Scene MEMBER info hipowersystems com www hipowersystems com 16 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 4 STARTING INSTRUCTIONS 8610 4 1 Starting Instructions 8610 Manual box is located inside of the door marked with Orange decal MANUAL BOX 1 Check Oil and Coolant fluids before operating generator 2 Turn ON battery cut off switch by turning lever to the right hand Turn lever to the left position of OFF Cut off switch is near the starter motor located inside door marked with Re
42. disengaged for the crank rest duration after which the next start attempt is made Should this sequence continue beyond the set number of attempts the start sequence will be terminated and the display shows Fail to Start When the engine fires the starter motor is disengaged Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel Selected by PC using the 3000 series configuration software Additionally rising oil pressure can be used to disconnect the starter motor but cannot detect underspeed or overspeed NOTE If the unit has been configured for CAN speed sensing is via CAN After the starter motor has disengaged the Safety On timer activates allowing Oil Pressure High Engine Temperature Under speed Charge Fail and any delayed Auxiliary fault inputs to stabilize without triggering the fault ENGINE RUNNING Once the engine is running and all starting timers have expired the animated icon is displayed DSE3110 The generator will be placed on load if configured to do so NOTE The load transfer signal remains inactive until the Oil Pressure has risen This prevents excessive 21 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com wear on the engine If all start requests are sequence will begin removed
43. electrical trip alarms can be disabled by user configuration In this case Protections Disabled will appear on the module display The alarm text will be displayed but the engine will continue to run This is logged by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time This feature is available from V4 The generator output frequency has fallen below the preset level The nerator output voltage has fallen below the preset level speed has fallen below the underspee 7 17 High Current Shutdown Electrical Trip Alarm The overcurrent alarm combines a simple warning trip level with a fully functioning IDMT curve for thermal protection HIPOWER Systems Inc 16002 W 110th Street 46 Page xa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 17 1 Immediate Warning If the Immediate Warning is enabled the DSE7000 Series controller generates a warning alarm as soon as the Trip level is reached The alarm automatically resets once the generator loading current falls below the Trip level unless All Warnings are latched is enabled For further advice consult your generator supplier 7 17 2 IDMT Alarm If the OMT Alarm is enabled the DSE7000 Series controller begins following the IDMT curve when the trip level is passed If the Trip is surpassed for an excess amount of time the OMT Alarm triggers Shutdown or Electric trip as se
44. installations that must be carried out by specialists according to existing regulations Although the power in use is much lower than that of a public supply network the danger of electrical energy is the same The generator set is a production plant that apart from the existing dangers of electrical source from a public supply network also adds other risks derived from the existence of flammable substances the fuel itself or lubricant oils of rotatory parts and secondary waste products exhaust gases and irradiation and cooling heats Although it is possible to take advantage of the heat contained in the exhaust gases and the cooling system in order to boost the thermal efficiency of the process this application must be fitted by specialized 84 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com technicians to achieve a reliable installation and safe for people and things and to prevent the expiration of the warranty Any other uses that have not been previously agreed with HIMOINSA shall be considered as of improper use and therefore they are not acceptable 17 WORKING CONDITIONS 17 1 Standard environmental conditions for reference e Diesel engine Important the power of Diesel engines for stationary applications refers to the following environmental conditions according to the ISO 3046 1 standard o Room temperature 25
45. is indicating the low oil 1 1 o pressure state to the 7300 series controller ____ Engine runs but generator will not Check Warm up limer has timed out Ensure generator load inhibit signal is nol take load present on the module inputs Check connections to the switching device Note that the set will not take load in manual mode unless there is an active remote start on load signal o HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 Fax 913 495 5575 www hipowersystems com DSE Model 7000 Series Control and Instrumentation System Operators Manual SYMPTOM Incorrect reading on Engine gauges Fail to stop alarm when engine is at rest Module appears to revert to an earlier configuration Set will not take load Inaccurate generator measurements on controller display POSSIBLE REMEDY Check engine is operating correctly Check sensor and wiring paying particular attention to the wiring to terminal 47 refer to appendix Check that sensor is compatible with the 7000 series module and that the module configuration is suited to the sensor When editing a configuration using the PC software it is vital that the configuration is first read from the controller before editing it This edited configuration must then be written back to the controller for the changes to take effect When editing a configuration using the fascia editor be sure to press the Accept WW b
46. main circuit breaker by the main control panel The panel has five cam lock plugs Black A phase or L1 B phase or L2 Blue C phase or L3 White Neutral gt Green Ground The control panel also has mounting lugs for A B C amp neutral and ground Amps and the KVA size of the generator determine the number of connections If needed you can also pull power from the lower panel under the circuit breaker located by the control panel 99 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 400 AMPS REAR DISTRIBUTION PANEL HEN HEN AN amp mug du 00 Q generating sets CAUTI Rex of shoc A WARNING 204 vosv Gre HHH ES OO OO E EEBUE OOOOH FRONT PANEL WITH FRONT PANEL OPEN 29 500 1200 AMPS REAR DISTRIBUTION PANEL E E 1 E o o o Q HIPOWEF 00 generating sets c OO OOOO AE EE
47. set and the command panel shall be made with a multiple cable and using the multiple connectors plugs provided with the set Cable dimensions The choice and dimensions of the cables is responsibility of the person who carries out the installation Cable positioning Power cables for both manual and automatic sets must be placed in suitable channeling tunnels or protective conduct holder Do not include 400V and 12V or 24V cables in the same channeling Grounding Metal parts of installations which are exposed to human contact and due to an insulation flaw or other reasons may get in contact with voltage must be connected to land dispersion device The generators and panels have been equipped with their respective grounding terminals The connection of these to the land dispersion must be made with bare copper wires conductors with a minimum section of 16mm2 or if not available galvanized iron with a 50 mme section The resistance of such conductor including the contact resistance must not exceed 0 15 Ohm Heating For automatic start generators the engine room where they are installed must be conveniently conditioned during the cold season in a way that the room temperature is not below 10 15 C a required condition for a quick engine start Electric heaters with thermostatic controls ranging from 500 to 1500W depending on the generator have also been supplied with those sets They maintain the water temperature wit
48. single coil rotor engines and rheostat starters For star triangle startups the voltage of each phase turns out to be reduced and the startup voltage larr decreases in the same proportion 1 4 3 0 58 It is evident that in the case of an engine with larr 6 x In in direct startup with a star triangle startup it reduces approximately up to 3 5xln and as a consequence there is a power request to the generator which is lower than a 6 3 5 ratio In all cases both direct startup and reduced voltage startups it is necessary to control the devices and equipment that are connected to the circuit in use in order to avoid failures eg the opening of contractors due to a transitory fall in voltage at the time of startup 18 GENERAL DESCRIPTION The sets are used for two main types of services Continuous service sets Used for the production of electrical energy in areas where there is no other 87 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com source of production and application for several purposes motion force lighting heating etc Emergency service sets They are used to solve energy interruptions that may cause serious problems to people physical and or financial damage hospitals industrial facilities airports etc or to face consumption peaks Depending on the assigned destination the sets are subdivided into
49. sound absorbing material classified as M 0 material In air intakes and outlets the bonnet is equipped with its respective piping designed for driving air without producing the logical reverberations of a forced air drive The engine exhaust is silenced using a high performance noise reduction silencer that guarantees a correct noise reduction level The bonnet is equipped with perfectly soundproof doors covered with fireproof fiber The locks are supplied with keys that prevent an improper use by unauthorized personnel even in the control area of the generator 18 6 Electrical panel with manual start The HIMOINSA electrical panel is designed to bring together the electrical control equipment the general protections of the engine and alternator the alarms and measure and control equipment 18 7 Electrical panel with automatic start The automatic panels are connected to the power supply and to the set When the electrical supply is suitable the power supply contactors are locked and the supply to the sets comes from the power supply When the electric supply is poor the power supply contractors unlock and the generator starts automatically The generator contactors detect voltage in the terminals and switch in order to make use of the generator www hipowersystems com 19 3 Indoor installations Please contact our commercial department to find out about the possibilities that our control systems can offer 18 8 Contr
50. supply is fused and connected to the battery and that it is of the correct polarity 10 3 The Emergency Stop input is wired to an external normally closed switch connected to DC positive 10 4 To check the start cycle operation take appropriate measures to prevent the engine from starting disable the operation of the fuel solenoid After a visual inspection to ensure it is safe to proceed connect the battery supply Select MANUAL and then press START the unit start sequence will commence 10 5 The starter will engage and operate for the pre set crank period After the starter motor has attempted to start the engine for the pre set number of attempts the LCD will display Failed to start Select the STOP RESET position to reset the unit 10 6 Restore the engine to operational status reconnect the fuel solenoid Select MANUAL and then press START This time the engine should start and the starter motor should disengage automatically If not then check that the engine is fully operational fuel available etc and that the fuel solenoid is operating The engine should now run up to operating speed If not and an alarm is present check the alarm condition for validity then check input wiring The engine should continue to run for an indefinite period It will be possible at this time to view the engine and alternator parameters refer to the Description of Controls section of this manual 10 7 Select AUTO on th
51. the following sections Once selected the page will remain on the LCD display until the user selects a different page or after an extended period of inactivity LCD Page Timer the module will revert to the status display If no buttons are pressed upon entering an instrumentation page the instruments will be displayed automatically subject to the setting of the LCD Scroll Timer The LCD Page and LCD Scroll timers are configurable using the DSE Configuration Suite Software or by using the Front Panel Editor Module Timers Interface Timers The screenshot shows the factory settings for the timers taken from the DSE Configuration LCD Page Timer 5m Suite Software LCD Scroll Timer 5s 3 Alternatively to scroll manually through all instruments on the currently selected page press the scroll PD buttons The autoscroll is disabled If you want to view one of the instruments towards the end of the list it may be quicker to scroll up through the instruments rather than down To re enable autoscroll press the scroll buttons to scroll to the title of the instrumentation page Engine A short time later the duration of the LCD Scroll Timer the instrumentation display will begin to autoscroll When scrolling manually the display will automatically return to the Status page if no buttons are pressed for the duration of the configurable LCD Page Timer If an alarm becomes active while viewing the status pa
52. the stopping 6 5 3 Stopping Sequence The return delay timer operates to ensure that the starting request has been permanently removed and isn t just a short term removal Should another start request be made during the cooling down period the set will return on load If there are no starting requests at the end of the return delay timer the load is removed from the generator to the mains supply and the cooling timer is initiated The cooling timer allows the set to run off load and cool sufficiently before being stopped This is particularly important where turbo chargers are fitted to the engine After the cooling timer has expired the set is stopped 6 6 Manual Operation NOTE If a digital input configured to panel lock is active changing module modes will not be possible Viewing the instruments and event logs is NOT affected by panel lock Manual mode allows the operator to start and stop the set manually and if required change the state of the load switching devices Module mode is active when the button is pressed 6 6 1 Waiting In Manual Mode To begin the starting sequence press the button If protected start is disabled the start sequence begins immediately If Protected Start is enabled the icon is displayed to indicate Manual mode and the manual LED flashes The button must be pressed once more to begin the start sequence 6 6 2 Starting Sequence NOTE There is no start delay in this mode of
53. 0 series V2 0 or above FUEL USAGE LOADING VOLTAGE NOT REACHED LOADING FREQUENCY NOT REACHED PROTECTIONS DISABLED GENERATOR UNDER FREQUENCY GENERATOR UNDER VOLTAGE If generator output in excess of the high current alarm point a warning alarm occurs If this high current condition continues for an excess period then the alarm escalates to either a shutdown or electrical trip condition depending upon module configuration For further details of the high current alarm please see High Current Shutdown Electrical Trip Alarm If an auxiliary input configured as an electrical trip is active the appropriate message will be displayed as configured by the user The measured Total kW is above the setting of the kW overload Electrical Trip alarm _ u __ The measured Earth Current is above the setting of the Earth fault alarm Indicates out of balance current loading of the generator sometimes also called Negative Sequence Current or Symmetry Fault Indicates the amount of fuel used is in excess of the Fuel Usage alarm settings This often indicates a fuel leak or potential fuel theft Indicates that the generator voltage is not above the configured loading voltage after the safety timer The generator will shutdown Indicates that the generator frequency is not above the configured loading frequency after the safety timer The generator will shutdown Shutdown and
54. 1 Temperature gauge 12 Engine diagnostic switch 4 13 Block heater power switch optional 14 Emergency stop 15 Basin alarm optional 16 Panel power switch 4 17 Auto start connections HIMOINSA POWER SYSTEMS INC 16210 W 110 St Lenexa KS 66219 USA MEMBER A GP AA AEM 1 913 495 5557 TOLL FREE NUMBER 1 866 710 2988 1 913 495 5575 soon MEMBER info hipowersystems com www hipowersystems com 13 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 3 STARTING INSTRUCTIONS 3110 3 1 Starting Instructions 3110 Please read laminated instructions before operating generator located in manual box Manual box located inside of door marked Manuals with colored label Check oil and coolant fluids before operating generator 1 Turn on battery cut off switch by turning to right Turn back left to off position located by the starter motor 2 Check emergency stops twist clockwise to release One is located on lower portion of control panel and one is located on outside of housing 3 Turn on rotary power switch located on lower right of control panel by emergency stop button 4 Check selector for correct operating voltage before starting It is located inside on the front of the generator location label on left side vented door DO NOT CHANGE VOLTAGE SELECTOR WHILE SET IS RUNNING 5 To start pus
55. 100kW Fast B C 100 550kW Fast gt 550kW Fast Initial Start Up On completion of generating set assembly and before starting the generating set ensure that all of the engine manufacturers pre running procedures have been completed and that adjustment of the engine governor is such that the generator will not be subjected to speeds in excess of 125 of the rated speed Over speeding the generator during initial setting of the speed governor can result in damage to the generator rotating components Voltage Set Up The voltage is factory set as per the rating plate If necessary adjust the voltage to the no load level as required To adjust the voltage remove the AVR access cover plate use the insulated tool supplied Stability Set Up The STABILITY control potentiometer is pre set and should not normally require adjustment If adjustment is necessary proceed as follows Run the generating set on no load and check that speed is correct and stable Turn the STABILITY control potentiometer clockwise and then turn slowly anti clockwise until the generator voltage starts to become unstable The correct setting is slightly clockwise from this position i e where the machine volts are stable but close to the unstable region 64 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 5 2 Type MX341 The following jumper
56. 3 Monday 00 00 06 06 Monday 00 09 60 00 Clear Monday 80 00 06 06 Ciest Monday 00 00 00 90 Stop Mode Scheduled runs will not occur when the module is in STOP RESET mode Manual Mode Scheduled runs will not occur when the module is in MANUAL mode Activation of a Scheduled Run On Load when the module is operating OFF LOAD in Manual mode will have no effect the set continues to run OFF LOAD Auto Mode Scheduled runs will operate ONLY if the module is in AUTO mode with no Shutdown or Electrical Trip alarm present If the module is in STOP or MANUAL mode when a scheduled run begins the engine will not be started However if the module is moved into AUTO mode during a scheduled run the engine will be called to Start Depending upon configuration by the system designer an external input can be used to inhibit a scheduled run If the engine is running OFF LOAD in AUTO mode and a scheduled run configured to On Load begins the set is placed ON LOAD for the duration of the Schedule 50 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 21 Front Panel Configuration This configuration mode allows the operator limited customising of the way the module operates Use the module s navigation buttons to traverse the menu and make value changes to the parameters 51 HIPOWER Systems
57. 57 7 24 1 57 Fault FINON TL 58 TO Routine Iallte all Oessoeri a 60 10 1 WANN CHA NCE 60 10 2 Lubrication and Maintenance Service Interval Chart Standard POC ANON E E EE E 61 10 3 Lubrication and Maintenance Service Interval Chart Standby PID ONC AUO 62 BP PERITI T TTE 63 11 1 Generator DeSIgtallolic eode rure 63 11 2 Serial Number Location sees meme 63 E N 63 T MS T 63 11 5 Automatic Voltage 64 E E 64 115 2 Waitnsnisacesc ere cncesdsetnctehevsnihiednandead sesadarsoneienteascabegensetas 65 Te 01 0 PTT 66 4 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 TOA Type bec Ni 67 Tce mede aelizeil mE o 67 11 7 meyer 68 EDO CIM ILES 68 11 7 2 8X440 AV Risen XRR 68 ACE C EIU MER 68 11 7 4 Transformer e ehe 69 Teh IGA Fie 69 M ioi E 69 11 8 Alternator
58. 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Engine coolant pump Relief bore check DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Only run the engine at low power Keep away from the engine s danger zone High level of engine noise when the engine 15 running Risk of damage to hearing Wear ear protectors es Engine coolant pump Relief bore check l Check relief bore 1 for coolant discharge Permissible engine coolant discharge Up to 0 1 ml per hour respectively 100 ml per 1 000 operating hours 2 fdischarge exceeds the specified limits contact Service 3 frelief bore 1 is dirty a Stop engine and disable engine start b Clean relief bore 1 with a wire 20201584b 117 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 55 55 5 www hipowersystems com belt Drive Drive belt Adjustment Preconditions Engine is stopped and starting disabled Fan drive Belt tension adjust ment 1 Undo screws 2 2 Screw in nut 1 to set the required belt tension 3 Tighten screws 2 4 Check drive belt tension for compliance with specifications 02800173 Engine coolant pump drive Belt tension adjustment engine with mechanical belt tensioner l Slacken off screws 1 and locknut 3 2 screw in adjusting screw 2 to s
59. 7 9 3 Engine Running Once the engine is running the Warm Up timer if selected begins allowing the engine to stabilise before accepting the load Load will be automatically transferred from the mains supply to the generator In test mode the set will continue to run on load until either The stop button 9 is pressed The set will immediately stop The auto button is pressed The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence 7 10 Protections When an alarm is present the Audible Alarm will sound and the Common alarm LED if configured will illuminate The audible alarm can be silenced by pressing the Mute button The LCD display will jump from the Information page to display the Alarm Page d he oe 1 il vis pressure The LCD will display multiple alarms E g High Engine Temperature shutdown Emergency Stop and Low Coolant Warning These will automatically scroll in the order that they occurred In the event of a warning alarm the LCD will display the appropriate text If a shutdown then occurs the module will again display the appropriate text Example LUE www hipowersystems com 7 11 Protections Disabled User configuration is possible to prevent Shutdown Electrical Trip alarms from stopping the engine Under such conditions Protective Disabled will appear on the module display to in
60. 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 7 Fault Finding A WARNING Service and fault finding procedures present hazards which can result in injury or death Only personnel qualified to perform electrical and mechanical service should carry out these procedures Ensure engine starting circuits are disabled before commencing service or maintenance procedures Isolate any anti condensation heater supply Important Before commencing any fault finding procedure examine all wiring for broken or loose connections Four types of excitation control system involving four types of AVR can be fitted to the range of generators covered by this manual The systems can be identified by a combination of AVR type where applicable and the last digit of the generator frame size designation Refer to the generator nameplate then proceed to the appropriate subsection 11 7 1 SX460 AVR No voltage build up when starting set 1 Check speed 2 Check residual voltage 3 Follow Separate Excitation Test Procedure to check generator and AVR Unstable voltage either on no load or with load 1 Check speed stability 2 Check stability setting High voltage either on no load or with load 1 Check speed 2 Check that generator load is not capacitive leading power factor Low voltage no load 1 Check speed 2 Check link 1 2 or external hand trimmer leads for continuity Low voltage on load 1 Check speed
61. EDY Unit is inoperative Check the battery and wiring to the unit Check the DC supply Check the DC fuse Read Write configuration does not operate Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70 Check the fuse Unit locks out on Emergency Stop If no Emergency Stop Switch is fitted ensure that a DC positive signal is connected to the Emergency Stop input Check emergency stop switch is functioning correctly Check Wiring is not open circuit Intermittent Magnetic Pick up Ensure that Magnetic pick up screen only connects to earth at one end if sensor fault connected at both ends this enables the screen to act as an aerial and will pick up random voltages Check pickup is correct distance from the flywheel teeth Check engine oil pressure Check oil pressure switch sensor and wiring Check configured polarity if applicable is correct i e Normally Open or Normally Closed or that sensor is compatible with the 73x0 Module and is correctly configured uM Check engine temperature Check switch sensor and wiring Check configured polarity if applicable is correct i e Normally Open or Normally Closed or that sensor is patible with the 7000 series module Check relevant switch and wiring of fault indicated on LCD display Check Low oil Pressure fault operates after engine has fired High engine tempe
62. HF285 Bore amp Stroke 4 19 in 106 mm x 5 0 in 127 mm Prime 115 86 Standby 126 94 Prime 772 569 Standby 849 626 74 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 3 5 4045HF 285 4 19 in 106 mm x 5 0 in 127 mm Prime 144 107 Standby 158 118 Prime 772 669 Standby 849 626 12 3 6 4045HF285 4 19 in 106 mm x 5 0 in 127 mm Prime 179 134 Standby 197 147 Prime 961 709 Standby 1057 780 75 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 3 7 6068HF 285 Bore amp Stroke 4 19 in 106 mm x 5 0 in 127 mm Prime 216 161 Standby 237 177 Prime 1151 849 Standby 1266 934 12 3 8 6068HF 485 Bore amp Stroke 4 19 in 106 mm x 5 0 in 127 mm Prime 286 214 Standby 315 235 Prime 1536 1133 Standby 1690 1247 76 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 3 9 6090HF 484 4 661 in 118 4 mm x 5 354 in 136 mm Prime 380 284 Standby 422 315 Prime 2039 1504 Standby 2266 1671 12 3 10 6135HF 485 5 20 in 132 mm x 6 50 in 165 mm Prime 561 419 Standby 617 460 E Prime 3011 2221 S
63. HIPOWER your partner for power Rental Generating Sets Manual John Deere Yanmar MTU 1 1 General Saleiy IDIOT OA see eheu tue od deze ue 8 1 2 Installation And Transporting SZ OS E rero 9 1 3 Operational Fazards uiuecsese tii pe EE PE nio oe E Ponta eh ie En DEP LEER 9 1 4 Maintenance ioa iret oos ires seg ti ice ee en PE 9 2 Starting Instructions 702 11 2 1 Stanno Instructions 11 2 2 Portable Power Quick Start Manual 702 12 crudelia isse coli 14 m 14 3 2 Portable Power Quick Start Manual 3110 15 4 Starting Instructions 9610 ucce reote Eo o Sa Fe t pei d 17 4 1 Starting instructions 3 T10 uc basbet amem Den tia fetu ium de 17 5 Description of Sei o PETRO T EE TE 18 5 1 Description of Operation nor 18 5 1 1 Manual Mode 18 5 1 2 Automatic Mode of 18 SM Ie TNT UII TU UU TTE 19 53 56 262 62204255 lt 02 acc 0deseoisece danse arobiadee tee iarsira iinis 6 3110 Series Control eben uns rope qv dea 20 6A MEET TO OT 20 62 Q
64. Heat Timer HET ternator Fal ure SERIA O 100 _ HE Leenerator Over 3 ver 138 Front Panel Configuration Editor continued section Parameter as shown display Factory Settings Mains Under Voltage Trip 184 Mains Over Voltage Trip 276V Mains Under Frequency Trip 45Hz Mains Over Frequency Trip 55Hz Mains Transient Delay Return Delay 30s Mains Transfer Time 0 75 TIMERS Heat Timer J s O Crank smoke Limiting off o SO OO Speed overshoot Delay im LLL Fail To Stop Battery Voltage High warning Delay Mains Transient Delay Mains Transfer Time 2 SCHEDULE Schedule Load schedule Period Active Inactive only available when Scheduler is active Schedule time and Date Selection 1 16 Schedule time and Date selection 1 16 Press 2 to begin editing then or to select the different parameters in the scheduler 55 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 23 Accessing the Running Configuration Editor The running editor can be entered while the engine is running All protections remain active if the engine is running while the running editor is entered Press and hold the 0 button to enter the running editor
65. ING V REACHED LOADING FREQUENCY NOT REACHED Indicates that the generator voltage is not above the configured loading voltage The generator will not take load when the alarm is present after the safety timer Indicates that the generator frequency is not above the configured loading frequency The generator will not take load when the alarm is present after the safety timer OLTAGE NOT PROTECTIONS DISABLED Shutdown and electrical trip alarms can be disabled by user configuration In this case Protections Disabled will appear on the module display The alarm text will be displayed but the engine will continue to run This is logged by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time This feature is available from V4 onwards LOW OIL PRESSURE The module detects that the engine oil pressure has fallen below the low oil pressure pre alarm setting level after the Safety On timer has expired engine temperature pre alarm setting level after the Safety On timer has expired high engine temperature pre alarm setting level The engine speed has fallen below the underspeed pre alarm settinc GENERATOR OVER The generator output frequency has risen above the pre set pre alarm setting FREQUENCY GENERATOR UNDER The generator output frequency has fallen below the pre set pre alarm setting FREQUENCY after the Safety On timer has expired GENERATOR OVER The gene
66. Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com 7 22 Accessing the Main Front Panel Configuration Editor Ensure the engine is at rest and the module is in STOP mode by pressing the Stop Reset button Press the Stop Reset and Info buttons simultaneously If a module security PIN has been set the PIN number request is then shown E 2 the first amp changes to 0 Press i o up or down to adjust it to the correct value Uh OQ Press right when the first digit is correctly entered The digit you have just entered will now show for security oc Repeat this process for the other digits of the PIN number You can press left if you need to move back to adjust one of the previous digits When is pressed after editing the final PIN digit the PIN is checked for validity If the number is not correct you must re enter the PIN If the PIN has been successfully entered or the module PIN has not been enabled the editor is displayed The PIN number is not set by DSE when the module leaves the factory If the module has a PIN code set this has been affected by your generator supplier who should be contacted if you require the code If the code has been lost or forgotten the module must be returned to the DSE factory to have the module s code removed A charge will be made for this procedure NB This p
67. Limit 2 Light Emitting Diode Charge air cooling Low Low Low Maximum speed governor Lambda Sonde Universa Low Temperature Maximum Continuous Rating Mot Applicable Low pressure Normalnull Memory module for engine data Electronic accelerator pedal Engine monitoring unit Power reduction with extreme site conditions Electronic injection nozzle unit Monitors fuel pressure Monitors fuel temperature Governor cabinet Alarm Measured value exceeds 1st maximum limit Alarm Measured value exceeds 2nd maximum limit Memory module for interface data Initial input of injector code with DiaSys in engine governor International umbrella organization for all national standardization institutes Engine free end in accordance with DIN 150 1204 Engine driving end in accordance with DIN SO 1204 Limit value limit 1 Limit value limit 2 Light emitting diode Alarm Measured value lower than 1st minimum limit value Alarm Measured value lower than 2nd minimum lim it value Torque limitation curve Reference area for heights above sea level 125 16002 W 110th Street Lenexa KS 66219 Ph 913 495 ppm 219127 Fa 9 1 3 495 5 5 7 5 www hipowersystems com OEM Ol OLS OPS OTS TDC PAN PIM RL SAE SD SEL 50 SRS 55 TBS TCI TCO TD TPS TRS PDU BDC VNT VSG VSS T ZKP Original Equipment Manufacturer Optimized Idle O
68. OINSA or ask your regular supplier The alternator derating is not as important as the one of Diesel engines therefore the general derating of the generator generator matches the derating of the engine Chart 4 is a merely indicative way of determining the derating of alternators For a higher precision you must refer to the supplier s documentation ende e e n en Coefficients that indicate the reduction in power of an IP21 air cooled self ventilated alternator depending on the different environmental conditions Both K1 and K2 coefficients must be applied to the nominal power of the generator in order to obtain the power in environmental conditions that are different from the standard ones 85 Page www hipowersystems com Example alternator measuring A 64 KW 80KVA generator set in standard conditions for an engine at 25 C 100m ASL 30 relative humidity RH The set consists of 72kW supercharged engine at 25 C 100m ASL and 30 RH An alternator with sr 80kVA supplied at 40 and 1 000m ASL being the performance of this alternator 89 We want to verify the maximum power that the genset can deliver at 1 000m ASL and at a temperature of 45 C The derating coefficient of the engine specified by the engine s manufacturer is 0 75 Therefore the power of the engine under the specified conditions will be 0 5x 2 54kW Considering the performance of this alternator the power of the genset will
69. ON DE SALA bean cs das EA 271222 ill 7 ELO 2100 Dimensiones Grupo PLANTA DE SALA oundations are approximately 10cm above the floor level and covered with gres industrial sandstone tiles Exhaust installation Exhaust outlet pipes The outlet pipes for exhaust gases are usually made of flat steel with no welding or in other special cases with asbestos concrete pipes The pipes must evacuate the gases to those areas where they cause no danger or damage and must end with a protection cap to protect them from water entry or with a similar system 1 and 2 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com In the part where they run through the walls it is recommended to perform a thermal insulation of the pipes in order to prevent heat expansion to the walls 3 The joints between the different pipe stretches must be perfectly sealed so that there are no gas leaks The connection between flange and gasket is the most ideal one It is also recommended to place a condensation collector with faucet on the bottoms point of the pipelines The connection between the engine s collector outlet or the turbo blower exhaust for supercharged types and the pipe must be made by means of a stretch of flexible tube so that the actions induced by the engine and the thermal expansions of th
70. OP RESET mode will turn on the CAN engine ECU when correctly configured and fitted to a compatible engine ECU Page Pressing this button scrolls the display to show the various instruments 6 5 Automatic Mode Of Operation NOTE If a digital input configured to panel lock is active changing module modes will not be possible Viewing the instruments and event logs is NOT affected by panel lock Activate auto mode by pressing the AUTO pushbutton The line arrow icon around AUTO is displayed to indicate Auto Mode operation if no alarms are present Auto mode will allow the generator to operate fully automatically starting and stopping as required with no user intervention 6 5 1 Waiting In Auto Mode If a starting request is made the starting sequence will begin Starting requests can be from the following sources Activation of an auxiliary input that has been configured to remote start 6 5 2 Starting Sequence To allow for false start requests the start delay timer begins Should all start requests be removed during the start delay timer the unit will return to a stand by state If a start request is still present at the end of the start delay timer the fuel relay is energized and the engine will be cranked NOTE If the unit has been configured for CAN compatible ECU s will receive the start command CAN If the engine fails to fire during this cranking attempt then the starter motor is
71. SURE The engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired The engine coolant temperature has exceeded the high engine BEN _ ip setting level after the Safety On timer has expired FUEL USAGE Indicates the amount of fuel measured by the fuel level sensor is in excess of the Fuel Usage alarm settings This often indicates a fuel leak or potential fuel theft PHASE ROTATION The phase rotation is measured as being different to the configured DSE7000 series V2 0 or above only direction OVERSPEED The engine speed has exceeded the pre set trip NOTE During the start up sequence the overspeed trip logic can be configured to allow an extra trip level margin This is used to prevent nuisance tripping on start up Refer to the 7000 series configuration software manual under heading Overspeed 1 Overshoot for details UNDERSPEED The engine speed has fallen below the pre set trip after the Safety On timer has expired os HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 57 Fax 913 495 5575 www hipowersystems com Display GENERATOR OVER FREQUENCY generator output frequency has risen above the preset level GENERATOR OVER VOLTAGE The generator output voltage has risen above the presetlevel OIL PRESSURE SENSOR OPEN The oil pressure sensor is detected as not being present open circuit
72. T Indicates that the generator frequency is not above the configured loading REACHED frequency after the safety timer The generator will shutdown PROTECTIONS DISABLED shutdown and electrical trip alarms can be disabled by user configuration In this case Protections Disabled will appear on the module display The alarm text will be displayed but the engine will continue to run This is logged by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time This feature is available from V4 onwards 45 HIPOWER Systems Inc 16002 W 140th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 16 Electrical Trips Electrical trips are latching and stop the Generator but in a controlled manner On initiation of the electrical trip condition the module will de energise the Close Generator Output to remove the load from the generator Once this has occurred the module will start the Cooling timer and allow the engine to cool off load before shutting down the engine The alarm must be accepted and cleared and the fault removed to reset the module Example Electrical trips are latching alarms and stop the Generator Remove the fault then press Stop Reset Q to reset the module GENERATOR HIGH CURRENT AUXILIARY INPUTS kW OVERLOAD EARTH FAULT 0567300 series V2 0 or above N EGATIVE PHASE SEQUENCE DSE700
73. The support bedplate or base consists of a folded metal sheet with a suitable stiffness which holds the generator set by means of elastic supports silentblocks that remove the transmission of vibrations to it and therefore 88 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 to the ground The fitting to the foundations is usually made by means of long bolts with nothing in between The fuel tank is located on this support bedplate which depending on the model is equipped with a filling hole a flow meter one or two signals an emptying hole and a vent and it is connected to the aspiration pipes of the injection pump by means of flexible elements and fuel returns from theinjection pump and the injectors drain Due to the specific needs of our customer we can supply high capacity tanks separately However in this handbook we shall only describe the fuel tanks that are fitted into the supporting base Moreover inside the supporting base it is possible to find a suitable housing for the battery batteries with its respective fixing iron fittings 18 5 Soundproof bonnet Depending on our customers demands and applications the generator may be equipped with a protective soundproof bonnet Such bonnet is made of steel sheets of a suitable thickness accordingly treated in order to allow a perfect finish The bonnet is internally covered with a fireproof
74. UICK GAG costae cbr pna metuat 20 6 2 1 Starting the Englfie 20 62 2 Stopping Ne GING NER TUTTA 20 6 3 GIaphieal DISD as easet dut s Ee i t HE 21 6 5 Automatic Mode of ODOIGlIOF 21 6 5 1 Waiting in Auto eme mens 21 6 5 2 Silaring SeguUENCE TO TT mI 21 6 5 3 Stopping SEGUITO caseo edite mmu Ed ER pM D M 22 66 Mammal eiie Mom T 22 6 6 1 Waiting in Manual MOCGG eee pointe edo 22 6 6 2 Starting 22 6 6 3 Stopping SC CISC esc 5 socio seus 22 OL II dae ca yecanncaeeaeceacatendcnaetednenanoseesenaenctuncs ceacterieenwetennesueeeeneseneee 23 0o mere 1 Nm TE 23 69 Mod le DISplay RE ULIm 23 2 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 691 Timer ros ERR 23 DIO OC COLL E EUM E SRM EA EM PENES 28 6 9 3 Running tained q RERUM NE rM ee 23 Si TETTE S 23 6 9 5 Memory ciui rie batnr D 9 5 BACON socios 23 E m T UU 24 7 7300 and 8600 Series Control
75. access the plant Do not allow people with pacemakers to access the plant as it may cause electromagnetic interferences these devices e Do not approach the G S if you are wearing loose clothes or objects that may be attracted by the airflow or by the mobile parts of the engine e t is forbidden to dismantle or disable any safety devices e is forbidden to lean on the G S or to leave objects on it For automatic action generating sets e Place a red light that switches on when the unit is working in a visible place e Place a warning sign alerting of the possibility that an unexpected automatic startup of the machine may occur e Place an obligation sign stating All maintenance operations must be carried out with the generator in the LOCK position e For the emergency stop of the group press the emergency stop button located in the group or the emergency push button to be installed outside the engine room 15 2 Safety at delivery storage and unpacking e Once you receive the lighting tower check that the received goods correspond to those on the delivery note and that all the goods are in perfect conditions e In order to lift and transport the Tower lifting machines of the appropriate capacity must be used All loose and pivoting parts must be safely fixed before lifting it When moving the G S and especially when lifting it it is highly recommendable to use the available points for this pu
76. ading power factor Low voltage no load 1 Check speed 2 Check link 1 2 or external hand trimmer leads for continuity 68 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Low voltage on load 1 Check speed 2 Check UFRO setting Refer to subsection 4 7 1 1 3 Follow Separate Excitation Procedure to check generator and AVR Excessive voltage speed dip on load switching 1 Check governor response 2 Refer to generating set manual Check DIP setting 11 7 4 Transformer Control No voltage build up when starting set 1 Check transformers rectifiers 2 Check transformer secondary winding for open circuit Low voltage 1 Check speed 2 Check transformer air gap setting High voltage 1 Check speed 2 Check transformer air gap setting 3 Check transformer secondary winding for open circuit Excessive voltage speed dip on load switching 1 Check speed drop on load 2 Check transformers rectifiers 3 Check transformer air gap setting 11 7 5 MX341 AVR No voltage build up when starting set 1 Check link K1 K2 on auxiliary terminals 2 Follow Separate Excitation Test Procedure to check machine and AVR Loss of voltage when set running 1 First stop and restart set If no voltage or voltage collapses after short time follow Separate Excitation Test Procedure Generator voltage high followed b
77. aintenance Alarm Reset button in the DSE Configuration Suite SCADA MAINTENANCE section Digital Input A Fine teen Reset maintenance armi Polarity Close to Actwate Arian Aarme Maintenance Alarm Running Time Until Next Mamtenance 18 hrs Date Of Maintenance 13 Jan 2009 Ariat Press reset to schedule mesrdenence 49 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 55 www hipowersystems com 7 20 Scheduler DSE7000 Series contains an inbuilt exercise run scheduler capable of automatically starting and stopping the set Up to 16 scheduled start stop sequences can be configured to repeat on a 7 day or 28 day cycle Scheduled runs may be on load or off load depending upon module configuration Scheduler Example Exercise Scheduler Screen capture from DSE Configuration Suite Software showing the configuration of the Exercise Schedule Penod Weekly Scheduler Monday 93 00 05 00 Monday 00 09 00 00 Chear 3330 06 30 Monday 00 00 00 90 In this example the will start at 09 00 on Monday 1 Loo and run for 5 hours then start at 13 30 on Tuesday T Pe MEM eo E MEM 2 T Monday 90 90 00 09 Clear Monday 09 09 9090 Clear and run for 30 minutes Mond omeo Cear Men gt 7 20 1 7 20 2 7 20
78. alternator when the set is operating since they are live Do not touch any parts in motion until the generator set has stopped completely When the G S is in operation some parts of the engine conduit s and exhaust reach high temperatures Avoid touching them until they have cooled down completely Always wear ear protectors when the generator set is in operation in order to avoid ear damage The labels concerning safety must be kept clean and on the locations designated by the manufacturer Fuels and lubricants may be flammable toxic explosive and corrosive We recommend keeping them in their original containers and storing them in protected areas 15 5 Safety during maintenance 82 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 All checks and or maintenance of the generator set must be always carried out by specialized personnel Maintenance operations must be done when the engine is not working Before operating any components of the electrical installation disconnect the poles from the battery Before opening the electrical panel specialized personnel must take the following precautions o Stop the generator set if it is in operation and set the electric panel in the LOCK position o Disconnect the battery batteries from the generator set o Disconnect the power input o Periodically check both the tightness and insulation of connections
79. ancer birth defects and some other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling The safety information in this manual is denoted by the safety alert symbol A The level of risk is indicated by the following signal words DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury N CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation that could result in damage to the equipment or other property Never go under raised equipment unless properly supported Use properly rated lifting equipment to lift heavy objects Extinguish all smoking material when adding fuel or working around generator Engine must be stopped before adding fuel Clean up fluids and dispose of fluids contaminated material etc in accordance with local regulations Disconnect negative battery cable before performing maintenance on generator set before attempting Allow components to cool any maintenance 8 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575
80. anel The illustration below shows all funtions and safety Deep Sea Electronics Engine diagnostic switch DSE 3110 Control Panel Technical details 1 Navigation Button 2 Main status display 3 Common alarm indicator 4 Stop Reset button 5 Auto start 7 6 Selector switch Start button 6 HIMOINSA POWER SYSTEMS INC 16210 W 110 St Lenexa KS 66219 USA ELL m MEMBER A AA AEM 1 913 495 5557 TOLL FREE NUMBER 1 866 710 2988 1 913 495 5575 ome MEMBER info hipowersystems com www hipowersystems com 15 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Q When the generator is running check to make sure the voltage is correctly See item 12 in the technical detail section on the complete Control Panel illustration this can be regulated with the voltage adjustment dial Auto start is done by pushing the white AUTO button Close the auto start contact connections located at the bottom of the main control panel and the unit will start in Auto See complete Control Panel illustration to locate the 2 auto start connection knobs Over current relay protection only functions in 277 480 volt If the relay trips and the safety breaker light is on it will need to be reset Push the pictured blue button to reset the over current relay Over current relay Technical
81. ansfer to mains manual mode only Start engine when in manual mode Select Stop mode Mute alarm Lamp test Select Auto mode Continued overleaf Select Test on load mode Select Manual DEEP SEA ELECTRONICS On When The Generator On When The Generator Is Required To Be On Is Required To Be On Load Load Generator on load LED has two modes of operation depending upon the configuration of the controllers digital inputs 3 Digital input configured for Generator closed auxiliary The LED illuminates when the generator closed auxiliary input is active The LED shows the state of the auxiliary contact 4 There is NO input configured for Generator closed auxiliary factory default setting The LED illuminates when the 7x20 gives the loading signal to the generator The LED shows the state of the 7x20 s loading request Anote Mains on load LED has two modes of operation depending upon the configuration of the controllers digital inputs 5 Digital input configured for Mains closed auxiliary The LED illuminates when the mains closed auxiliary input is active The LED shows the state of the auxiliary contact 6 There is NO input configured for Mains closed auxiliary factory default setting The LED illuminates when the 7x20 gives the loading signal to the mains The LED shows the state of the 7x20 s loading request 26 Page
82. ault condition is removed The icon will appear steady in the display 6 8 Shutdowns Shutdowns are critical alarm conditions that stop the engine and draw the operators attention to an undesirable condition Shutdown alarms are latching The fault must be removed and the button pressed to reset the module The icon will appear flashing in the display 6 9 Module Display 6 9 1 Timer Icon When the module is controlling the engine starting and stopping an animated timer icon will be displayed in the icon area to indicate that a timer is active for example cranking time crank rest etc A 6 9 2 Stopped Icon When there are no alarms present an icon will be displayed to indicate the engine is stopped and what mode the unit is in M Stop Auto Mode Mode Manual Mode The hand is only displayed when the arming options is enabled otherwise the engine starts when entering the manual mode 6 9 3 Running Icon When there are no alarms present an animated icon is displayed to indicate the engine is running 6 9 4 USB Icon When a USB connection module the USB icon is displayed is made to the 6 9 5 Memory Corruption If either the config file or becomes corrupted the unit will display the icon engine file 6 9 6 Backlight The backlight will be on if the unit has sufficient voltage on the power connection while the unit is turned on unless the unit is cranking for which the backl
83. be 54x0 89 48kW We shall verify that the alternator is the ideal one The alternator s derating is given by two coefficients K1 and K2 shown on Chart 4 or also found in the manufacturer s recommendations of the alternator The apparent power is the one given by KIxK2xSR that is K1 0 96 K2 0 97 The maximum apparent power will be 0 96x0 97x80 74 4kVA and the active power with cos 0 8 will be 74 4x0 8 59 2 kW Therefore the alternator turns to be heavily sized compared to the power that the set can offer 48kW 17 3 Operational limits At the stage of placing the order the user customer must report on all the operative conditions that may affect the working order of the generator Along with the environmental conditions stated above special attention must be paid to the characteristics of the loads the generator is going to feed the power voltage and power factor The connection sequence of the loads must be determined and indicated with high accuracy Power The power of the generator is the active power expressed in kW supplied on generator terminals to the voltage and nominal frequency and for the specified environmental conditions Below their respective definitions can be found The specified features with a 3 tolerance are net and can be obtained after 50 hours of operation Continuous Power COP It is the continuous power that the generator set can produce continuousl
84. ble ECU s will receive the start command via CAN If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt begins Should this sequence continue beyond the set number of attempts the start sequence will be terminated and the display shows Fail to Start The starter motor is disengaged when the engine fires Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel Selected by PC using the 7000 series configuration software Additionally rising oil pressure can be used to disconnect the starter motor but cannot detect underspeed or overspeed If the unit has been configured for CAN speed sensing is via CAN After the starter motor has disengaged the Safety On timer activates allowing Oil Pressure High Engine Temperature Under speed Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault 35 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 8 Manual Mode If a digital input configured to panel lock is active changing module modes will not be possible Viewing the instruments and event logs is NOT affected by panel lock Activate Manual mode be pressing the
85. cal Trip atarm conditions excluding Emergency Stop The alarm is displayed on the screen as detailed in the section entitled Shutdown alarms elsewhere in this document The set continues to run The load switch maintains its current position it is not opened if already closed Shutdown Blocked also appears on the LCD screen to inform the operator that the Protections Disabled feature has blocked the shutdown of the engine under the normally critical fault The shutdown alarm is logged by the controllers Event Log if configured to log shutdown alarms and logs that the Shutdown was prevented 40 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 12 Indications Indications are non critical and often status conditions They do not appear on the LCD of the module as a text message However an output or LED indicator can be configured to draw the operators attention to the event Example Input configured for indication Digital Input A The LCD text will not appear on the Function module display but can be added in the configuration to remind the system Action designer what the input is used for Arming LCD isplay the input is configured to Indication there is no alarm generated e LED Indicator to make LED1 illuminate LED Indicators when Digital Input is active The Insert Card Text allows th
86. cated in the charts of the sections of the installation in which the engine fan draws in the cooling air from the engine room whereas the hot air 93 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com is expelled through the expulsion tunnel placed between the radiator and the room window The expulsion window must have a bigger or same size as the radiator in case of standard static generators and bigger or same as the expulsion grid in case of soundproof sets We must prevent the radiator exhaust hot air from coming back to the engine room making sure the expulsion conducts are leak proof Therefore the air in the engine room is constantly renovated and the dimensions of intake grilles must be big enough for the cooling and combustion In order to achieve a correct air flow the cool air must be introduced through the grilles that are located on the lower part of the engine room wall This wall should be the one located opposite the radiator so that the air flows all over the set before being expelled through the fan Make sure there are no areas in the engine room where the air is deposited This usually happens in rooms with several engines In those cases and whenever possible each group should have its own air intake grille In case you need more details about the air flow required for the different types of HIMOINSA generators
87. ce breather valve on filler neck and close 115 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com Engine coolant Filling Preconditions Engine is stopped and starting disabled MTU Fluids and Lubricants Specifications 4001063 are available special tools Material Spare parts Designation Use Coolant WARNING Coolant is hot and under pressure Risk of injury and scalding A Let the engine coal down Wear protective clothing gloves and goggles safety mask High level of engine noise when the engine 15 running Risk of damage to hearing Wear ear protectors Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 of coolant expan sion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn valve cover 1 counter clockwise and remove 208000186 Coolant Filling 1 Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge of cast in eye or marking plate Check proper condition of breather valve 1 clean sealing faces if required 3 Fit breather valve 1 and close it fsa 116 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS
88. ce new air filter 1 with clamp 2 onto intake housing 3 5 Tighten clamp 2 01000228d 109 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com Air Intake service indicator Signal ring position check Preconditions kA Engine is stopped and starting disabled Checking signal ring position 1 Replace air filter if the signal ring 2 15 completely visible in the red area of the service indicator control window 3 Page 102 2 After installation of new filter press reset button 1 Result Signal ring returns to initial position 123003126 otarting Equipment starter Condition check Preconditions Engine is stopped and starting disabled Checking starter condition Check securing screws of starter for secure seating and tighten if required 2 Gheck wiring 110 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com m Lube Oil System Lube Circuit Engine oil Level check Preconditions 4 Engine is stopped and starting disabled Checking oil level prior to en gine start Remove oll dipstick 1 from guide tube and wipe It Insert oil dipstick 1 into guide tube up to the stop withdraw after approx 10 sec onds and check oil level Oil level must be between min and max marks
89. connections must be in the correct position for the correct number of poles and the operating frequency of the generator Frequency selection terminals 4 pole 50Hz LINK 2 3 4 pole 60Hz LINK 1 3 otability selection terminals LINK A B Excitation Interruption Link K1 K2 O K2 K1 P2 PAXXX 3221 O E je ue t OVER 550kW 4P 60Hz 4P 50Hz 1 Volts 2 Indicator led UFRO 4 Frequency 5 Dip 6 Stability 7 Excitation trip 8 Stability section 9 Droop 10 Trim 11 Link over 550kW 12 Isolation link 13 2x pin 2 use either 14 Std sensing links Initial Start Up On completion of generating set assembly and before starting the generating set ensure that all of the engine manufacturers pre running procedures have been completed and that adjustment of the engine governor is such that the generator will not be subjected to speeds in excess of 125 of the rated speed Over speeding the generator during initial setting of the speed governor can result in damage to the generator rotating components Voltage Set Up The voltage is factory set as per the rating plate If necessary adjust the voltage to the no load level as required To adjust the voltage remove the AVR access cover plate use the insulated tool supplied Stability Set Up The STABILITY control potentiometer is pre set and should not normally require adjustment If adjustment is necessary proceed as follows
90. ctivates allowing Oil Pressure High Engine Temperature Under speed Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault 36 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 8 3 Engine Running In manual mode the load is not transferred to the generator unless a loading request is made A loading request can come from a number of sources Pressing the transfer to generator button Mains supply out of limits DSE7220 DSE7320 only Activation of an auxiliary input that has been configured to remote start on load Activation of the inbuilt exercise scheduler if configured for on load runs Aote the load transfer signal remains inactive until the Oil Pressure has risen This prevents excessive wear on the engine Once the load has been transferred to the generator it will not be automatically transferred back to the mains supply To manually transfer the load back to the mains either Press the transfer to mains button DSE7220 DSE7320 only Press the Open Generator button DSE7210 DSE7310 only e Press the auto mode button to return to automatic mode 7 8 4 Manual Fuel Pump Control NOTE Manual Fuel Pump Control is only available on suitably configured systems with V3 or higher control modules Consult your set supplier for further advice e Navigate to the instruments
91. d decal BATTERY CUT OFF SWITCH 3 Check and reset Emergency stop switches Twist clockwise to release One is located on the lower portion of control panel and second and third device is located outside of housing 4 Turn on rotary power switch located near the emergency stop button on the lower right portion of the control panel 5 Check Voltage change over board for the correct operating voltage before starting equipment Change over board located on the end of the generator WARNING DO NOT CHANGE VOLTAGE while equipment is running 6 To start push RED reset button the Hand and then the GREEN button on the DSE 8610 controller 7 Once the generator is running the voltage will automatically change to correct operating voltage when breaker is on 17 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 5 DESCRIPTION OF OPERATION 5 1 Description of Operation 5 1 1 Manual Mode Operation To initiate a start sequence in MANUAL turn the key to the t position To start the set press the button Preheating will begin indicated by the LED The Fuel Solenoid is energised then the Starter Motor is engaged The engine is cranked for a 10 second period If the engine fails to fire during this cranking attempt then the starter motor is disengaged for a 10 second period Should this sequence continue beyond the 3 startin
92. d value at the intersec tion of display arm and KG scale For specifications refer to table below 02800174 Application Measured value Measured value Operating tension after Minimum operating 1 hour tension Fan drive belt 2250 N 1620 N 1080 N measured values deviate from the specifications above adjust drive tension B Install protective cover Engine coolant pump drive Belt tension check engine with mechanical belt tensioner 1 Remove protective cover 2 set belt tension tester onto the drive belt in the middle between the belt pulleys ar rowed 3 Using pushbutton press vertically on top side of drive belt exerting even pressure until spring disengages noticeably 4 Do not press any further otherwise the dis play value will be faisified 5 Take off tension tester without changing the position of the display arm 6 Read off measured value at the intersec tion of display arm and KG scale For specifications refer to table below 02800176 Operating tension after Minimum operating Fan drive belt 1000 N 20N 480 N Ifthe measured values deviate from the specifications above adjust drive belt tension 8 Install protective cover 120 tems Inc 165002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax You HIPOWER Sy www hipowersystems com Drive belt Replacement Preconditions Engine is stopped and starting disabled sp
93. djust valve clearance Final steps 1 Remove barring gear 2 Install cover 3 Install cylinder head cover 104 Page www hipowersystems com Cylinder head cover Removal and installation Preconditions Engine is stopped and starting disabled Special tools Material Spare parts Torque wrench 10 60 Nm F30510423 1 Ratchet F30027340 1 Removing and installing cylin der head cover Note Cover the engine beneath the cylinder head with cloths to collect emerging oil Remove screws Remove cylinder head cover Clean mating faces Check condition of profile gasket and re place if required T 5 Fit cylinder head cover and tighten screws with torque wrench to the specified tightening torque screw with twin 8 Preload torque 10 Nm collar 6 Tighten screws with torque wrench to the specified tightening torque Name sie E77 CNN Screw with twin M8 Tightening torque 20 Nm collar 105 Page s Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Fuel System Fuel system Venting Preconditions Engine is stopped and starting disabled hres Fuels are combustible Risk of fire and explosion A Avoid open flames electrical sparks and ignition sources Do not smoke Venting fuel system 1 Unlock fuel priming pump screw out han die 2 2 Loosen nut 1 on banjo union N
94. e front panel the engine will run for the pre set cooling down period then stop The generator should stay in the standby mode If not check that there is not a signal present on the Remote start input 10 8 Initiate an automatic start by supplying the remote start signal if configured The start sequence will commence and the engine will run up to operational speed Once the generator is available a load transfer will take place if configured the Generator will accept the load If not check the wiring to the Generator Contactor Coil if used Check the Warming timer has timed out 10 9 Remove the remote start signal The return sequence will begin After the pre set time the generator is unloaded The generator will then run for the pre set cooling down period then shutdown into its standby mode 10 10 Set the modules internal clock calendar to ensure correct operation of the scheduler and event logging functions For details of this procedure see section entitled Front Panel Configuration Editing the date and nme 10 11 1f despite repeated checking of the connections between the 7000 series controller and the customer s system satisfactory operation cannot be achieved then the customer is requested to contact the factory for further advice on 57 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com 7 25 Fault Finding SYMPTOM POSSIBLE REM
95. e pipe are absorbed by the engine without damaging any elements The use of flexible element also demands the placement of flanges in the exhaust pipe independent of the generator Therefore the pipelines must be fixed to the walls or ceiling of the engine room with supports that can bear the weight of the pipe to the engine outlet so that it does not rest on the parts of the engine collector turbo blower and allow its expansion When dealing with very long pipes it is necessary to insert expansion joints made of sealed flexible elements When establishing the trajectory of the exhaust pipe itis necessary that the pipe is not near the engine air filters in order to prevent the machine from drawing in hot air Otherwise it will be necessary to insulate it Whenever there are several generators it is advisable that all exhausts do not converge on a common pipe as there can be problems when some generators are in operation and others are not The produced exhaust gases can penetrate in the conduits of the sets that are not in operation and may cause damage 91 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com A Exhaust pipes measurement for Standard otatic Generators The engine s exhaust backpressure has a remarkable influence on the produced power and on the thermal charge Excessive backpressure values measured at the e
96. e system designer to print an insert card detailing DigtsinputA the LED function Sample showing operation of the LED 7 13 Warnings Actwation Delay Os User Configured Close to Activate Indication Away Battery Charger On Insert Card Ten Lit Battery Charger On Warnings are non critical alarm conditions and do not affect the operation of the generator system the serve to draw the operators attention to an undesirable condition Example In the event of an alarm the LCD will jump to the alarms page and shutdowns scroll through all active warnings and By default warning alarms are self resetting when the fault condilion is removed However enabling all warnings are latched will cause warning alarms to latch until reset manually configuration suite in conjunction with a compatible PC 41 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 This is enabled using the 7000 series www hipowersystems com Display Reason CHARGE FAILURE The auxiliary charge alternator voltage is low as measured from the W L terminal BATTERY UNDER The DC supply has fallen below the low volts setting level for the duration of the VOLTAGE low battery volts timer BATTERY OVER VOLTAGE The DC supply has risen above the high volts setting level for the duration of the high battery volts timer FAIL TO STOP module has detect
97. e the oldest entry in the log Hence the log will always contain the most recent shutdown alarms The module logs the alarm along with the date and time of the event or engine running hours if configured to do SO If the module is configured and connected to send SMS text To view the event log repeatedly press the next page button until the LCD screen displays the Event log Press down toview the next most recent shutdown alarm Continuing to press down o cycles through the past alarms after which the display shows the most recent alarm and the cycle begins again To exit the event log and return to viewing the instruments press the next button to select the next instrumentation page 32 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com 7 6 Controls Stop Reset This button places the module into its Stop Reset mode This will clear any alarm conditions for which the triggering criteria have been removed If the engine is running and the module is in Stop mode the module will automatically instruct the changeover device to unload the generator Close Generator becomes inactive if used The fuel supply de energises and the engine comes to a standstill Should a remote start signal be present while operating in this mode a remote start will not occur Manual This mode allows manual control of the genera
98. e your generator is being used Do not smoke while refueling Do not refuel near sparks or an open flame Clean up fluid spills and contaminated material accordance with local regulations WARNING Ensure that all personnel operating servicing maintaining or working near this equipment are wearing appropriate Personal Protective Equipment PPE including eye and ear protection and are fully aware of the emergency procedures in case of any accidents WARNING Generators emit noise Ensure appropriate ear protection is worn at all times Maximum A weighted emissions levels may reach 104 db 1 4 Maintenance Hazards Service and maintenance procedures must be carried out by experienced qualified engineers familiar with the procedures and the equipment Before any intrusive procedures are carried out ensure that the engine is inhibited and the generator is electrically isolated All electrical equipment can be dangerous if not operated correctly Always service and maintain the generator in accordance with this 9 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com manual Always use genuine replacement parts N WARNING Hot engine and exhaust system can cause severe injury Do not touch hot engine parts Do not perform service or maintenance on generator until cool to the touch WARNING R
99. ecial tools Material Spare parts Designation Use Drive belt Fan drive Drive belt replace ment Remove protective cover from cooler Remove fan Loosen securing screws 3 Screw out tension nut 1 as far as neces sary to allow drive belt removal Check belt pulley on cooler bearing mount and crankshaft for contamination and clean if necessary Bue qu em Note When placing the drive belt in the grooves no force must be applied 6 Fit new drive belt The fan bearing mount must be in contact with the retainer 2 to allow belt tension Ing 02800172 B Adjust and check drive belt tension 9 Install fan 10 Install protective cover Battery charging generator and engine coolant pump Drive belt replacement Remove protective cover 2 Remove drive belt from fan drive Page 119 3 Remove brace 2 4 Use appropriate tool to release the auto matic belt tensioner at hexagon 3 and take off drive belt 1 Note When placing the drive belt in the grooves no force must be applied Fit new drive belt 1 and unioad ten sioner 6 Install drive belt on fan drive m i nstall protective cover zd 02800104b 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 121 www hipowersystems com Engine coolant pump drive Drive belt replacement engine with mechanical belt tensioner Remove protective cover 2 Remo
100. ed a condition that indicates that the engine is running when it has been instructed to stop Anote Fail to Stop could indicate a faulty oil pressure sensor or switch If the engine is at rest check oil sensor wiring and configuration FUEL USAGE Indicates the amount of fuel measured by the fuel level sensor is in excess of the Fuel Usage alarm settings This often indicates a fuel leak or potential fuel theft 5 AUXILIARY INPUTS Auxiliary inputs can be user configured and will display the message as written by the user LOW FUEL LEVEL The level detected by the fuel level sensor is below the low fuel level setting CAN ECU ERROR The engine ECU has detected a warning alarm and has informed the DSE module of this situation The exact error is also indicated on the module s display kW OVERLOAD The measured Total kW is above the setting of the kW overload warning alarm EARTH FAULT The measured Earth Fault Current has been in excess of the earth fault trip and DSE7300 series V2 0 or has surpassed the IDMT curve of the Earth Fault alarm above NEGATIVE PHASE Indicates out of balance current loading of the generator SEQUENCE sometimes also called Negative Sequence Current or Symmetry Fault DSE7000 series V2 0 or MAINTENANCE DUE Indicates that the maintenance alarm has triggered A visit is required by the 05 7000 series V2 1 Generator service company LOAD
101. eriodic Maintenance 80 15 SAFETY REGULATIONS 15 1 G rneral SarelV precautions usosctesut este taU ocu 15 2 Safety at delivery storage and 5 Page www hipowersystems com 15 3 Safety during installation and initial startup 81 15 4 Safety during 82 15 5 Safety during 82 Engine cooling circuit cece ceccccseeeceeeeeeeeceeeeseeeneeeseaeeseueeneueeneeeeseeeens 83 LUD ATION CNC UT TT 83 WC CNC UU TEES 83 EST CUO WU 83 gt Electric startup system 83 gt Synchronous generator sicectssdisinoctinindeunusatsousduaiaesmecidameuaantaabicucticnnieunes 84 S CONOP e in ee eee ere 84 15 6 Environmental Salely eE AaS 84 15 7 Safety stickers and 84 16 INADEQUATE USE WARNINGS 84 17 WORKING CONDITIONS 2 2 tcs
102. ery maintenance o During the supply of inhibitors or antifreeze products o During the replacement or supply of lubricant oil hot engine oil can cause scalds during emptying Allow the oil to cool below 60 C Wear protective helmets when operating in an area with suspended loads or equipment at head level Always wear safety footwear and tight clothes When working with parts that may be live always make sure that your hands and feet are dry We recommend the use of insulating flooring to perform maneuvers Wet clothes must be replaced immediately Keep used rags in containers that are anti flammable or indicated for such effect Do not leave rags on the engine When starting up an engine that has been repaired take precautions in order to prevent air suction in case there 15 an excess in revolutions during the start up Always keeps the engine clean removing eventual oil stains gas oil and or other cooling liquids Never start up the engine when the fan speed regulator lever has been dismantled Do not carry out tasks that need the presence of several people if you are alone especially when moving or operating parts such as switches section switches fuses and or other live devices Engine cooling circuit Never add coolant to a hot engine allow the engine to cool down first Periodically check the level of the coolant and if necessary add product until the appropriate level is reached Only use liquids tha
103. es in relation to the temperature and air pressure within the installation paying special attention to the HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 CHART 4 humidity value with respect to the maximum temperature The maximum and minimum temperatures of the cooling water only in those generators that are equipped with water water interchangers under special request instead of a radiator Any other environmental conditions that may require special solutions or shorter maintenance cycles such as o Dusty and or sandy environments o Maritime environments o Environments with the possibility of chemical pollution o Environments with existence of radiations o Operating conditions with the presence of great vibration e g earthquake prone areas or subject to external vibrations caused by nearby machines When the effective conditions not specified in the contractual base the power of the generator is interpreted according to the otandard conditions for Diesel engines as established If the effective environmental conditions change subsequently it will be necessary to contact HIMOINSA in order to calculate the new power losses and to carry out the necessary calibrations For Diesel engines these deratings are determined by the manufacturers of the respective engine In order to become familiar with them contact the technical department at HIM
104. et the re quired drive belt tension 3 Tighten screws 1 and locknut 3 4 Check drive belt tension for compliance with specifications 02800118b 118 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Drive belt Condition check Preconditions Engine is stopped and starting disabled Checking condition 21300118c LEER Fading mm Drive belt singular cracks None Drive belt B Cracks on entire circumference Fit new part gt Page 119 Drive belt C Chunking Drive belt Fouling by oil overheating 119 HIPOWER Systems Inc 16002 W 110th Street Lenexa TELE Fax 913 495 5575 www hipowe rsystems com Drive belt Tension check Preconditions Engine is stopped and starting disabled special tools Material Spare parts Designation Use Belt tension tester 500 1400 N Y20097430 1 Belt tension tester 1300 3 100 Y20097431 1 Fan drive Belt tension check 1 Remove protective cover 2 Set belt tension tester onto the drive belt in the middle between the belt pulleys ar rowed 3 Using pushbutton press vertically on top side of drive belt exerting even pressure until spring disengages noticeably 4 Do not press any further otherwise the dis play value will be falsified 5 Take off tension tester without changing the position of the display arm 6 Read off measure
105. form the operator of this status This feature is provided to assist the system designer in meeting specifications for Warning only Protections Disabled Run to Destruction War mode or other similar wording When configuring this feature in the PC software the system designer chooses to make the feature either permanently active or only active upon operation of an external switch The system designer provides this switch not DSE so its location will vary depending upon manufacturer however it normally takes the form of a key operated switch to prevent inadvertent activation Depending upon configuration a warning alarm may be generated when the switch is operated The feature is configurable in the PC configuration software for the module Writing a configuration to the controller that has Protections Disabled configured results in a warning message appearing on the PC screen for the user to acknowledge before the controllers configuration is changed This prevents inadvertent activation of the feature 7 11 1 Indications Warning Alarms Under Indication or Warning alarms e he module operations is unaffected by the Protections Disabled feature See sections entitled Indications and Warnings elsewhere in this document 7 11 2 Shutdown Electrical Trip Alarms An OTE The EMERGENCY STOP input and shutdown alarm continues to operate even when Protections Disabled has been activated Under Shutdown or Electri
106. formation without notice All rights especially copying and distribution rights are reserved Copyright 2010 by Himoinsa Power systems No part of this publication may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission from Himoinsa Power Systems This manual is provided to assist in the maintenance and operation of the generator and is not to be used in any manner detrimental to the interests of Himoinsa Power systems Information in this manual represents components installed when product was manufactured based upon the best available information Modifications made subsequent to initial delivery are not included Always verify the parts required with Himoinsa Power Systems lf you have any questions please contact our Parts and Service Department Do not operate generator without an Operators Manual Treat the Operators Manual as part of the generator Replace the Operators Manual if it is lost damaged or becomes unreadable All personnel that will be operating maintaining and working around the generator must review these documents before interacting with the generator If you have any safety concerns or questions that are not covered by this manual please contact Himoinsa Power Systems at 1 913 495 5557 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause c
107. g attempts the start sequence will be terminated and Fail to Start NN fault will be illuminated When the engine fires the starter motor is disengaged and locked out at 20 Hz measured from the Alternator output After the starter motor has disengaged the Safety On timer is activated which is fixed at 10 seconds allowing Oil Pressure High Engine Temperature Under speed and Charge Fail to stabilise without triggering the fault Selecting STOP O de energises the FUEL SOLENOID bringing the generator to a stop 5 1 2 Automatic Mode of Operation To initiate a start sequence in AUTO turn the key to the position The start sequence is initiated when the remote start input is activated After a fixed 5 second start delay Preheating will occur fixed at 10s indicated by the LEU the Fuel Solenoid is energised then one second later the Starter Motor is engaged The engine is cranked for a 10 second period If the engine fails to fire during this cranking attempt then the starter motor is disengaged for a 10 second rest period Should this sequence continue beyond the 3 starting attempts the start sequence will be terminated and Fail to Start uml fault will be illuminated When the engine fires the starter motor is disengaged and locked out at 20 Hz measured from the Alternator output After the starter motor has disengaged the Safety On timer is activated allowing Oil Pressure High Engine Temperature Under speed
108. ge the display shows the Alarms page to draw the operator s attention to the alarm condition 28 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com 7 4 1 Status This is the home page the page that is displayed when no other page has been selected and the page that is automatically displayed after a period of inactivity LCD Page Timer of the module control buttons This page is configurable using the DSE Configuration Suite Software Factory setting of Status screen showing engine stopped and engine running The contents of this display may vary depending upon configuration by the generator manufacturer supplier The display above was achieved with the factory settings shown below in the DSE Configuration suite software Configurable Status Screens Home Page Home Page Mode Displayed Pages Page 1 Summary screen 2 NotUsed NotUsed Page 3 NotUsed v Page8 Not Used Page 4 Not Used Page9 NotUsed Page 5 NotUsed 10 NotUsed The following sections detail instrumentation pages accessible using the scroll left and right buttons regardless of what pages are configured to be displayed on the status screen 29 Page KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 4 2 Engine Contains instrumentation gathered about the engine itself so
109. gish recovery on load switching 1 Check governor response Refer to generating set manual Check DWELL setting 69 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 8 Alternator Maintenance WARNING Service and fault finding procedures present hazards which can result in injury or death Only personnel qualified to perform electrical and mechanical service should carry out these procedures Ensure engine starting circuits are disabled before commencing service or maintenance procedures Isolate any anti condensation heater supply As part of routine maintenance procedures periodic attention to winding condition particularly when generators have been idle for a long period and bearings is recommended When generators are fitted with air filters regular inspection and filter maintenance is required 11 8 1 Winding Condition Warning Service and fault finding procedures present hazards which can result in injury or death Only personnel qualified to perform electrical and mechanical service should carry out these procedures Ensure engine starting circuits are disabled before commencing service or maintenance procedures Isolate any anti condensation heater supply 11 8 2 Guidance Of Typical Insulation Resistance IR Values The following is offered as general information about IR values and is aimed at
110. h red reset button and then the green button to start 6 Check for correct voltage adjust with voltage adjustment dial labeled if necessary Move safety lock to left to release and back to right to lock For more information please see laminated instructions in manual box 14 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 3 2 Portable Power Quick Start Manual 3110 Portable Power m Quick Start Manual generating sets Quick overview of Rental set operations and functions e JOHN DEERE GENERATING SETS 35 to 460 KVA Before using generator set PLEASE read these easy steps on operation Q Check all fluid levels before running the generator set Turn on the battery cut off switch located by the engine starter housing To start the unit turn key to the AUTO position then push the green button marked with a to start Engine will preheat for 10 seconds if equipped with glow plugs before starting Engine diagnostic switch can be used to power up the gauges while fueling unit DO NOT turn on when running generator set Q Check the selector switch for correct operating voltage DO NOT CHANGE POSITION OF SELECTOR WHILE GENERA TOR IS RUNNING it s located on the generator end box on the front end To access it open the left hand door by the vented panel Q This generator is equipped with a DSE 3110 control p
111. hin acceptable 95 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Once the batteries are settled and cool check that the level of liquid is between the maximum and 20 BEFORE OPERATION minimum levels These operations must be performed in the following situations e Before the startup e After the installation of the set e After a general check e f maintenance operations have been carried out set has been idle for a long time these operations make sure the set cannot be started Water level in the radiator In case the radiator needs water it must be refilled with a mix containing at least 50 of coolant liquid corrosion inhibitor Paraflu Il type and the rest with clean water Oil lubricant level in the crankcase The type of oil to be used is ACEA ES API CF4 MIL L2104E F for supercharged engines and ACEA E2 API CJ4 MIL L2104E F for aspirated engines Fill up the crankcase with oil up to the top mark of the graduated dipstick but without exceeding it With the cool engine and after a short time in operation recheck the lubricant oil and if necessary add the amount that is missing Fuel tank level If the fuel level is below the minimum required for the startup of the generator it is necessary to add fuel until the tank is full Electrical regulations Before starting up the generator all electrical
112. ht and check that the insulation of the wires is satisfactory We recommend connecting first the positive pole to the battery and next the negative pole usually grounding in order to prevent the formation of electrical arches www hipowersystems com Synchronous Generator e Do not manipulate the generator when it is in operation Before manipulating set the generator to the position of LOCK e Ensure the air intakes for the ventilation of the generator are clean and in some models lubricate the bearings Also make sure that the tightness and the position of the electrical connections are correct Control panel e Before operating the control panel disconnect the power input and set the generator to the position of LOCK e Electrical control panels as all electrical devices are damp and dusty Verify that the anti condensation heaters if available are in good working order and that the air ventilation intakes are clean e Periodically check that the bolts that fix electrical connections are securely screwed 15 6 Environmental safety Do not start a G S in closed premises where there is no exhaust installation with outlets Exhaust gases are harmful and may be lethal e Follow the rules and other regulations concerning acoustic installations e Replace the exhaust and or silencer of the engine if the humming level is louder than the allowed by the respective regulation e Maintenance operations oil rep
113. ight will be turned off 23 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 6 10 Fault Icons ICON DESCRIPTION I gt AUXILIARY INPUTS Auxiliary inputs can be user configured and will display the message as written by the user The engine has not fired after the preset number of start attempts The module has detected a condition that indicates that the engine is running when it has been instructed to stop FAIL TO STOP A NOTE Fail to Stop could indicate a faulty oil pressure sensor If engine is at rest check oil sensor wiring and configuration OW OIL PRESSURE The module detects that the engine oil pressure has fallen below the low oil pressure pre alarm setting level after the Safety On timer has expired ENGINE HIGH The module detects that the engine coolant temperature has exceeded the high TEMPERATURE engine temperature pre alarm setting level after the Safety On timer has expired The engine speed has fallen below the underspeed pre alarm setting Eo The engine speed has risen above the overspeed pre alarm setting The auxiliary charge alternator voltage is low as measured from the W L terminal The level detected by the fuel level sensor is below the low fuel level setting BATTERY UNDER VOLTAGE BATTERY The DC supply has fallen below or risen above the low high volts setting level OVER VOLTAGE GENERATOR UNDER The generato
114. il Level Sensor pressure sensor Oil Temperature Sensor Top Dead Center Panel Peripheral Interface Module Pulse Width Modulation Pressure xyz Redundancy Lost society of Automotive Engineers sensor Defect stop engine light system Identifier synchronous Reference Sensor safety System Security Shutdown Turbocharger Boost Sensor Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Throttle Position Sensor Timing Reference Sensor Temperature xyz Voltage Power Driver Unit Uberdruckventil Pressure relief valve Bottom Dead Center nozzle turbine Variable speed governor Vehicle Speed Sensor Tool Catalog Monitors ail level Monitors oil pressure Monitors oil temperature Control panel Modulated signal Pressure measuring point xyz Alarm Redundant CAM bus failure US standardization organization Alarm Sensor failure tst function Warning lamp stop engine and rectify fault 2nd function Read out fault codes TDC cylinder 1 Safety system alarm Monitors charge air pressure Alarm Sensor comparison fault Temperature measuring point xyz Supply voltage of solenoid valve final stages Zuordnung Kategorie Parameter Assign Number assigned to a parameter that describes the ment Category Parameter 126 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax function and assignment 913 495 5575 www hipowersystems c
115. in a place which must be as protected against weather conditions dust etc as possible For temporary installations the generator can rest on a well levelled surface For long time installations it is advisable to build a concrete base 89 Page e Generator room For the correct installation of a generator in closed premises the size of the room must allow o regular operation of the generator o An easy access to its components for maintenance and possible repairs o possibility of introducing the generator using the available means of transport The door through which the generator will be introduced must be centered so that the set remains centered once it is inside and there is no need of moving it o The existence of holes that allow oil replacement o installation of the exhaust pipe with the minimum possible number of pipe elbows o generator to be placed in the middle of the premises with respect to perimeter walls in order to facilitate access o layout of the command panel in case it is an automatic set to be in a position that allows the operator to have complete visibility over the instruments when operating it The recommended room dimensions are displayed in the following pictures HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com ENCLOSED GENERATOR Generating set Contro
116. ion one or more levels of maintenance alarm may occur based upon a configurable schedule There are three maintenance alarms in the DSE7200 DSE7300 series V3 and above and one level of maintenance alarm in prior versions Example 1 Screen capture from DSE Configuration Suite Software showing the configuration of Maintenance Alarm 1 and Maintenance Alarm 2 When activated the maintenance alarm can be either a warning set continues to run or shutdown running the set is not possible Resetting the maintenance alarm is normally actioned by the site service engineer after performing the required maintenance The method of reset is either by Maintenance Alarm Maintenance alarm 1 Enable Description Maintenance alam 1 Action Waning Engine run hours Enable alarm on due dete Niantersance mierv l Maintenance alarm 2 Enable J Desernptian Maintenance anm 2 Warning Engine run hours 250 I Enable alarm on due dale mil arnal mora Activating a input that has been configured to maintenance x reset where x is the number of the maintenance alarm 1 to 3 Pressing the maintenance reset button in the DSE Configuration Suite Maintenance section Example 2 Screen capture from DSE Configuration Suite Software showing the configuration of a digital input for Reset Maintenance Alarm 1 Screen capture from DSE Configuration Suite Software showing the M
117. ions and noise abatement characteristics If it is the one supplied by HIMOINSA the length must be multiplied by a coefficient of safety so that the total length to be considered due to backpressure will be L22xl If it has been provided by another supplier it is recommended to check the value of backpressure derived from the silencer with the supplier Example The exhaust pipe consists of the following parts 5 metres of straight pipe stretches Two pipe elbows type a Three pipe elbows type c A 1m long silencer If the inner diameter of the engine exhaust is 80mm the total length of the exhaust pipe is calculated as follows a for the inner diameter 80mm according to the chart 1 2m b total length of the elbows type is 1X 1 1 1 2 1 2 as there are two pipe elbows 2 x 1 2 2 4m the total length of the pipe elbows type c is 5 X 1 5 x 1 2 6m as there are three pipe elbows 3 x 6 18m d the total length of the exhaust silencer is L 2X 1 2X1 2m e the total length of the exhaust pipe is 5 2 4 18 2 27 4metres LATT T T AA m m B E LI LI NESS WE LLL ING TT NENNT mci bl tN lt ho 101 TONGA lm CCCILONSNNNS HEN _ bh AAR TELE
118. isk of severed digits or limbs Generator can be started from a remote switch Disconnect the negative battery cable from generator battery before performing service or maintenance on generator set WARNING Electrical shock can cause injury or death Ensure that all personnel operating servicing maintaining or working near this equipment are fully aware of the emergency procedures in case of accidents WARNING Do not handle Permanent Magnet Generators PMGs if you have mechanically implanted devices ie pacemakers WARNING Service and fault finding procedures present hazards which can result in injury or death Only personnel qualified to perform electrical and mechanical service should carry out these procedures Ensure engine starting circuits are disabled before commencing service or maintenance procedures Isolate any anti condensation heater supply California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects other reproductive harm Battery posts terminals and related accessories contain lead and leads compounds chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling 10 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com
119. ities from the bottom of the tank or mixed air Thorough cleaning of the used pipes Avoid abrupt variations in the tube section and the use of elbows with wide angles in pipes Electrical connections The generators are ready for user connections When making the connections you must comply with the conditions specified in the diagrams enclosed with the generator Generator of manual intervention The user cables must be connected to the line terminals which for standard static generators are located inside the electrical panel on the rail terminals or at the bottom of the magneto thermal switch either inside 94 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com the panel or in the molded box check values in case a sudden start or power input may the electrical diagrams included in the damage the engine manual of the panel For soundproof sets the connection to the grounding terminals is easily accessible as they are prepared for such effect and protected with a methacrylate sheet Generator for automatic intervention The cables that come from the generator the external power supply and user shall be connected to their respective terminals located in the command panel The power cables of the generator shall be connected directly to alternator terminals of the generator The connection to auxiliary services between the
120. l it locks in place Lubricant Value Standard Cover Tightening torque Engine ail 35 Nm Replace other engine oil filters in the same way Check oil level 113 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com Coolant Circuit General High lemperature Circuit Engine coolant Level check Preconditions Engine is stopped and starting disabled Fluids and Lubricants Specifications A001063 are available WARHING Coolant is hot and under pressure Risk of injury and scalding A Let the engine cool down Wear protective clothing gloves and goggles safety mask Coolantlevel check at filler neck 1 Tum breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape i Continue to turn breather valve counter clockwise and remove Check coolant level coolant must be vist ble at the lower edge of the cast in eye or at the marking plate 4 Top up with treated coolant as necessary 5 Check breather valve visual inspection and clean if necessary Place breather valve on filler neck and close 01400308b Coolantlevel check by means of level sensor l switch on engine control system and check readings on the display 2 Topup with treated coolant as necessary Engine coolant Change special tools Material Spare parts
121. l panel Air intake gap Air outlet tunnel Cable wire way Access door Reinforced concrete base Exhaust pipe Flexible pipe 10 Exhaust silencer May vary depending on the function of the outlet section of the model see plans of the specific model to be installed The dimensions showed are in millimeters OPEN SET GENERATOR Generating set Control panel Air intake gap Air outlet tunnel Cable wire way Access door Reinforced concrete base Exhaust pipe Flexible pipe 10 Exhaust silencer May vary depending on the function of the outlet section of the model see plans of the specific model to be installed The dimensions showed in millimeters The basic elements to be considered are e Foundations Exhaust installations Ventilation Fuel installation Electrical connections Grounding Heating Foundations The foundations must be calculated and dimensioned by experts in civil engineering They must prevent the transmission of vibrations and noise to other parts of the building The surface on which the set will be placed must be leveled in order to allow its correct operation For cleaning reasons it is 90 Mag 2100 Dim Carroceria N SSS M MAS ae IRARAAARAAA r 8000 4 Dimensiones Grupo SECCI
122. lacements fuel tank cleaning radiator cleaning washing battery batteries replacements etc storage and waste disposals will be carried out according to the existing regulations in the country where they are being used 15 7 Safety stickers and information There are some safety stickers and information all over the generator Next you can find a brief explanation of their locations and information on each of them PICTURE LOCATION INFORMATION A Located on the connections from the alternator to They warn of the danger in case an alien object collides with the timing belts or with the components in motion that they connect n the engine Whenever there are timing belts or do transmission shafts UBICACI N INFORMACI N Located on the parts of the genset that heat up They indicate those areas which must not be touched during operation while the set is in operation or shortly after having Placed on the coolant tank cap They warn of the precautionary measures to be taken when opening this cap The liquid is hot and may spout and cause scald on bonnet and next to the lifting eye It indicates poini by which the set must be lifted 1 order to move it Located next to the fuel cap Depending on the It indicates the location of the fuel tank Tank filling model it can be either on the bedplate or next to the engine Located on both sides of the bedplate skids It indicates the advisable area to move
123. lap Inlet valve A Exhaust valve BS B 05500472c 2 055004426 Checking valve clearance at two crankshaft positions Check position of piston in cylinder 1 f the rocker arms are unloaded on cylinder the piston is in firing TDC f the rocker arms are under load on cylinder the piston 15 in overlap Check valve clearance with cold engine Inlet 0 3 0 05 mm Exhaust 0 6 0 05 mm Check all valve clearances in two crankshaft positions firing and overlap of cylinder 1 as per diagram Use feeler gauge to determine the distance between valve bridge and rocker arm If the deviation from the reference value exceeds 0 1 mm adjust valve clearance 103 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com Adjusting valve clearance 1 Loosen locknut 1 and unscrew adjusting screw 2 by a few threads 2 Insert feeler gauge between valve bridge and rocker arm 3 3 Readjust adjusting screw 2 so that the feeler gauge Just passes through the gap 4 Tighten locknut 1 to specified torque using a torque wrench holding adjusting screw 2 firm with Al len key 5 mm 10 1 Tightening torque 43 Nm 4 Nm 5 Check if the feeler gauge just passes through between valve bridge and rocker arm 3 Result If not a
124. lected in Action High current shutdown is a latching alarm and stops the Generator Remove the fault then press Stop Reset Q to reset the module High current electrical trip is a latching alarm and removes the generator from the load before stopping the Generator after the off load Cooling timer Remove the fault then press Stop Reset Q to reset the module The higher the overload the faster the trip The speed of the trip is dependent upon the fixed formula T5t L Ix 1 Where Tis the tripping time m seconds la 15 the actual current of the most highly loaded line L1 or L2 or L3 ly is the delayed over current trip point tis the time multiplier setting and also represents the tapping time in seconds at twice full load when I4 ty 21 Factory settings for the IDMT Alarm when used on a brushless alternator are as follows screen capture from the DSE Configuration Suite PC software Owertcurrent Alarm Warning y DRT Alarm Time Mulbipluer Sti These settings provide for normal running of the generator up to 100 full load If full load is surpassed the Immediate Warning alarm is triggered the set continues to run The effect of an overload on the generator is that the alternator windings begin to overheat the aim of the alarm is to prevent the windings being overload heated too much The amount of time that the set can be safely overloaded is governed by how high the overload condi
125. me of which may be obtained using the CAN or other electronic engine link Engine Speed Oil Pressure Coolant Temperature Engine Battery Volts Run Time Oil Temperature Coolant Pressure Inlet Temperature Exhaust Temperature Fuel Temperature Turbo Pressure Fuel Pressure Fuel Consumption Fuel Used Fuel Level Auxiliary Sensors If fitted and configured Engine Maintenance Due If configured Engine ECU Link When connected to suitably configured and compatible engine ECU For details of supported engines see Electronic Engines and DSE wiring DSE Part number 057 004 Depending upon configuration and instrument function some of the instrumentation items may include a tick 2 icon beside them This denotes a further function is available detailed in the operation section of this document Example The tick icon denotes that manual fuel pump control is enabled in this system Press and hold to start the fuel transfer pump release to stop the pump This is further detailed in the section entitled operation elsewhere in this document 30 HIPOWER Systems Inc 16002 W 140th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 4 3 Generator Contains electrical values of the generator alternator measured or derived from the module s voltage and current inputs Generator Voltage ph N Generator Voltage ph ph Generator F
126. nator When charge intake capacity constitutes an important requirement the must 3 3 clearly specify it and must provide HIMOINSA with all the necessary information related to the different loads to feed it s possible distribution in groups and the connection sequence The former is necessary to obtain the best dimensions of the generator and to prevent low profit oversized generators or dangerously downsized ones Start up of asynchronous engines The start up of asynchronous engines by means of a generator set poses some problems as engines with squirrel cage motors have start up voltages that are 8 times higher than the normal intensity of the generator larr 2 8 x In and a low power factor In these conditions the current that is absorbed by the asynchronous engine or by the engines that start simultaneously during the start up must not exceed the maximum current that the generator can produce in short times taking into account a tolerable fall in voltage and without exceeding overheat limits In order to avoid this excessive oversize of the generator the following systems can be used Several engines distribute them in several groups each according a pre set sequence at time intervals of 30 60 seconds One engine whenever the operating machine that is fitted allows it by using a startup system with reduced voltage star triangle or self transformer or for higher powers
127. nce N WARNING Hot engine and exhaust system can cause severe injury Do not touch hot engine parts Do not perform service or maintenance on generator until cool to the touch N WARNING Risk of severed digits or limbs Generator can be started from a remote switch Disconnect the negative battery cable from generator battery before performing service or maintenance on generator set N WARNING Electrical shock can cause injury or death Ensure that all personnel operating servicing maintaining or working near this equipment are fully aware of the emergency procedures in case of accidents Maintenance must be performed on a regular basis to ensure the generator set performs properly and to extend the life of the generator set Generator set routine maintenance will depend on the installed location environment and application for which the generator set is used Consider these factors when planning the maintenance schedule otand by generator sets installed in a clean and dry location will require at least a visual inspection once a month otand by generator sets installed in a dusty damp or humid locations will require inspections and maintenance more frequently Refer to the engine manufacturer s manual for the scheduled maintenance on the engine Refer to the alternator manufacturer s manual for the scheduled maintenance on the alternator otandby generator set must be exercised at least
128. ng In Test Mode When in test mode the set will not start automatically To begin the starting sequence press the button 7 9 2 Starting Sequence The set begins to crank If the unit has been configured for CAN compatible ECU s will receive the start command via CAN If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made Should this sequence continue beyond the set number of attempts the start sequence will be terminated and the display shows Fail to Start When the engine fires the starter motor is disengaged Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel Selected by PC using the 7000 series configuration software Additionally rising oil pressure can be used disconnect the starter motor but cannot detect underspeed or overspeed Anote If the unit has been configured for CAN speed sensing is via CAN After the starter motor has disengaged the Safety On timer activates allowing Oil Pressure High Engine Temperature Under speed Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault 38 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com
129. ngine oil 100 Nm 4 Replace engine oil filter gt Page 108 Filling with new oil Open 1 on cylinder head cover Fill with oil Oil filling capacity gt Technical data Close cap 1 on cylinder head cover Check engine oil level ROM 112 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 495 5575 www hipowersystems com WARNING Oil Filtration Cooling Engine oil filter Replacement Preconditions Mi Engine is stopped and starting disabled special tools Material Spare parts Designation Uze Torque wrench 10 60 Mm F30510423 1 F30027340 1 Socket 37 mm F30006 120 1 Engine oil Oil filter element Spare Parts Catalog Hot oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing engine oul filter Unscrew the oil filter covers 1 approx 3 to 4 revolutions Wait 10 minutes until the oil has drained from the filter housings Remove cover 1 with oil filter element 3 and remove oil filter element 3 by press ing on the bottom edge from the side Check condition of sealing ring 2 on cov er Replace sealing ring 2 if damaged Coat sealing ring Z with oil Insert new oil filter element 3 in cover T and press in unti
130. oil pressure stop high water temperature in the engine stop and the user installed emergency stop switch which is usually outside the premises Check the correct ventilation of the premises so that the exhaust gases can be released to the atmosphere to the exterior of the premises and verify that they are in a safe position away from doors windows and air intakes Check that pipes and silencers are installed in a correct way They must have expansion joints and be protected against accidental contact Make sure there are no losses or leaks in the oil and fuel pipes Before the starting up make sure the generator set has the right amount of lubricant oil cooling liquid and fuel oingle out the position of the fire extinguishers and other protective and emergency devices and learn how they work oingle out the sources of dangers such as fuel leaks lubricant oil acid solutions condensed drippings high pressures and other dangers Check that the set is clean and the surrounding area and escape routes are clear and free of obstacles Check that there are no obstructions on grilles intakes and outlets Check that there are staff members working at other nearby sets and that those tasks are not dangerous and may affect the operation of the system 15 4 Safety during operation Do not allow people or animals to access the operating area of the G S Do not touch the generator set especially wires and connections to the
131. ol and protection controller Specific handbooks and electric diagram are supplied belong each control panel 19 INSTALLATION 19 1 Important warnings When the generator is delivered it is advisable to check that the received material matches the order and to compare it with the delivery note that is enclosed with the set Also check that the material is not damaged Proceed to open the packaging In case any flaws are detected you must contact the shipping company immediately in order to report the incident to the insurance company Himoinsa specifies that all deliveries are made at the customer s complete risk During the operations prior to the installation of the automatically driven generators or when connecting the electrical connections or in order to avoid unfortunate startups etc the following precaution measures must be taken Battery batteries must be disconnected The control panel switch must be set to the OFF position Safety rules for diesel G S The engine room and installations of the set foundations air intake gas exhaust must match the Safety rules that exist in the country where the generator will be installed Installation For stationary generators two types of installation can be considered Outdoors assembly Indoors assembly 19 2 Outdoor installations The generators which are assembled outdoors excluding soundproof sets that are intended for such applications must be located
132. om
133. once per month at a minimum of 7096 load for one hour 60 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 10 2 Lubrication and Maintenance Service Interval Chart Standard Applications NEN Lubrication and Maintenance Service Intervals Daily 500 Hour 12 2000 Hour 24 As Month Month Required Check Fuel Filter Water Bow J Fuel Filter Water Bowl Check Air Cleaner Dust Unloader Valve amp Restriction peine Indicator Gauge S _ Service Fire Extinguisher po Check Engine Mounts Service Check Manual Belt Tensioner and Bet Wear J o So oe Too ooo To Change Engine Oil And Replace Oil Fiter fo o _____ Check Crankcase Ven System Check Air Intake Hoses Connections amp System Jo o oo To Replace Fuel Fiter Elements o o po e po Check Automatic Belt Tensioner and Bet Wear To Check Engine Electrical Ground Connection o _____ Check Cooling System oo po po e Jo e Coolant Solution Analysis Add SCAs as required Pressure Test Cooling System Check Engine Speeds e e Flush and Refill Cooling System Test Thermostats oo oo S poe T Check and Adjust Engine Valve Clearance f 1 Add Coola Replace Air Cleaner Elements o o o po Jo Poe Replace Fan and Alternator Bets oo o Jo o o E TS S r
134. ore Size 2 Number of bearings 1 or 2 The product is an AVR controlled separately excited by a shaft driven pilot exciter synchronous ac generator or a self excited shunt arrangement Designed for incorporation into a generating set A generating set is defined as machinery in European directives 11 2 Serial Number Location Each generator has a unique serial number stamped into theupper section of the drive end of the frame The serial number is also shown on the nameplate Two other labels are located inside the terminal box both fixed inside of the terminal box one on the sheet metal work and the other on the main frame of the generator Neither of these two labels is considered to be permanently fixed 11 3 Rating Plate The generator has been supplied with self adhesive rating plate label to enable fitting after final assembly and painting Stick the nameplate to the outside of the non drive end of the terminal box The surface in the area where a label is to be stuck must be flat clean and any paint finish must be fully dry before attempting to attach label Recommended method for attaching label is peel and fold back sufficient of the backing paper to expose some 20 mm of label adhesive along the edge which is to be located against the sheet metal protrusions Once this first section of label has been carefully located and stuck into position progressively peel off the backing paper and smooth down
135. ories on the engine near the engine or in the area where the generator set is located Do not leave any flammable liquids or rags soaked in flammable liquids near the generator set electrical devices or any other parts of the electrical installation including lamps Take extreme caution to avoid risks of fulguration make sure there is a grounding installation and that it has been fitted according to the regulations Place a sign stating DO NOT PERFORM MANOUVERS in all sectioning parts that www hipowersystems com separate the areas of the installation where you are to work Install all the necessary protective measures required for safety in the parts that complete the installation Insulate all connections and wires that are disconnected Do not leave any terminals of the generator sets unprotected Plug all connection points concerning the generator set and its accessories into the grounding installation Verify and make sure the electrical power connections and the auxiliary services connections are correctly made Check that the cyclical direction of the phases matches the one of the power supply Isolate the position of the emergency stop switches quick stop fuel valves switches and other incidental emergency systems existing in the installation Verify the perfect functionality of the stop devices of the set especially those in the following devices in case they are standard supplies overspeed stop low
136. ote Catch emerging fuel with a suitable cloth 3 Operate the pump with the handle 2 until bubble free fuel emerges 4 Tighten nut 1 on banjo union 5 Lock fuel priming pump screw in han dle 2 106 KS 66219 Ph 913 495 5557 Fax 91 www hipowersystems com Fuel Filter Fuel filter Replacement Preconditions Engine is stopped and starting disabled special tools Material Spare parts Designation Use Filter wrench F30379 104 1 Engine oil Easy change filter gt Spare Parts Catalog 1 Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Replacing fuel filter Remove easy change filter using the filter wrench 2 lean sealing surface on filter head 3 Slightly lubricate sea on the easy change filter 4 Screw on easy change filter by hand until the seal makes contact and then tighten by hand 08300469b 107 c 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Fuel prefilter Replacement Preconditions V Engine is stopped and starting disabled WA System is not under pressure special tools Material Spare parts Designation Use Filter wrench F30379104 1 Engine oil Easy change filter Spare Parts Catalog 1 WARNING Fuels are combustible Risk of fire and explosion
137. page using the buttons and locate FUEL LEVEL 2 is shown on the module display to indicate that this feature is available e Press and hold the button to energise the transfer pump The pump starts two seconds after the button is pressed e Release the button to de energise the transfer pump 7 8 5 Manual Speed Control Speed Control is only available on suitably configured systems with V3 or higher control modules Consult your set supplier for further advice e Navigate to instruments page using the buttons and locate ENGINE SPEED 2 is shown on the module display to indicate that this feature is available e Press the Vv button to enter edit mode e Press or down to change the engine speed e Press the button again to exit the editor and leave the engine running at the newly selected speed 37 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 8 6 Stopping Sequence In manual mode the set will continue to run until either The stop button is pressed The set will immediately stop The auto button X is pressed The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence 7 9 Test Mode Test mode will start the set and transfer the load to the generator to provide a Test on load function 7 9 1 Waiti
138. please refer to the manufacturer For safety reasons in those premises where there are sets in continuous operation or in those areas where the room temperature is high it is advisable to use an auxiliary extractor fan that has enough power to achieve suitable ventilation Such extractor fan must be located on top of the room as close to the radiator as possible Fuel installation Generator sets supplied by HIMOINSA include a complete fuel installation since the fuel tank is located on the bedplate of the generator The fuel tank is connected through flexible tubes in order to guarantee their operating durability depending on the model For longer durability and in order to satisfy special demands it is necessary to use a special tank that is fitted separately It will be necessary to connect the engine to the new tank and previously perform the placing of the flexible connections and new suitable pipes that must be firmly fixed The new fuel tank must be located according to the following criteria so that the engine injection pump is able to draw in fuel from the new tank e Closer than 20m from the engine in case they are both at the same level Less than 5m deep The usual connections are e For fuel injections the engine injection pump e For fuel excess returns from the injection pump e For drain return of the injectors The pipes must not have any welds They can be made of steel iron or cast iron
139. providing guidance about the typical IR values for generators from new through to the point of refurbishment Generators In Service It is known that a generator will give reliable service with an IR value of just 1 0 MO For a relatively new generator to be so low it must have been subjected to inappropriate operating or storage conditions Any temporarily reduction in IR values can be restored to expected values by following one of the drying out procedures 11 8 3 Winding Condition Assessment The AVR should be disconnected and the Resistance Temperature Detector R T D leads grounded during this test NOTICE The AVR must be disconnected and the resistance Temperature Detector R T D leads grounded during this test The condition of the windings can be assessed by measurement of insulation resistance IR between phase to phase and phase to earth Measurement of winding insulation should be carried out 1 As part of a periodic maintenance plan 2 After prolonged periods of shutdown 3 When low insulation is suspected e g damp or wet windings Care should be taken when dealing with windings that are suspected of being excessively damp or dirty The initial measurement of the IR Insulation Resistance should be established using a low voltage 500V megger type instrument If manually powered the handle should initially be turned slowly so that the full test voltage will not be applied and only applied fo
140. r long enough to very quickly assess the situation if low values are suspected or immediately indicated Full megger tests or any other form of high voltage test should not be applied until the windings have been dried out and if necessary cleaned 11 9 Replacement Parts Contact your Himoinsa Power System dealer or distributor to order parts Have your genset serial and model number when ordering parts 70 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 SPECIFICATIONS JOHN DEERE 12 1 Generator Set Models 71 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 2 UL 2200 Generator Set Models 72 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 3 Engine Models 12 3 1 4024TF281 3 4 in 86 mm x 4 1 in 105 mm Prime 43 82 Standby 49 36 553 0 251 kg 12 3 2 4045TF280 4 19 in 106 mm x 5 0 in 127 mm Prime 76 57 Standby 85 63 Prime 409 302 Standby 453 334 73 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 12 3 3 4045HF 280 Bore amp Stroke 4 19 in 106 mm x 5 0 in 127 mm Prime 90 67 Standby 99 74 12 3 4 4045
141. r output voltage has fallen below the pre set pre alarm setting after VOLTAGE the Safety On timer has expired The generator output voltage has risen above the pre set pre alarm setting zl GENERATOR UNDER The generator output frequency has fallen below the pre set pre alarm setting after FREQUENCY the Safety On timer has expired Y The generator output frequency has risen above the pre set pre alarm setting CAN ECU WARNING CAN The engine ECU has detected an alarm CHECK ENGINE LIGHT ECU SHUTDOWN Contact Engine Manufacturer for support CAN DATA FAIL The module is configured for CAN operation and does not detect data on the engine Can datalink Ss L I The emergency stop button has been depressed This a failsafe normally closed to battery positive input and will immediately stop the set should the signal be removed Removal of the battery positive supply from the emergency stop input will also EMERGENCY STOP remove DC supply from the Fuel and Start outputs of the controller A NOTE The Emergency Stop Positive signal must be present otherwise the unit will shutdown MAGNETIC PICKUP Pulses are no longer being detected from the magnetic pickup probe 31 10 xxx 01 FAILURE magnetic pickup version only INTERNAL MEMORY ERROR Either the configuration file or engine file memory is corrupted Contact your supplier for assistance 24 Page HIPOWER Systems Inc 16002 W 110th Street
142. rator output voltage has risen above the pre set pre alarm setting VOLTAGE GENERATOR UNDER The generator output voltage has fallen below the pre set pre alarm setting after VOLTAGE the Safety On timer has expired The engine ECU has detected a warning alarm and has informed the DSE module of this situation The exact error is also indicated on the module s display 42 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com If the module is configured for CAN and receives an error message from the engine control unit CAN ECU Warning is shown on the module s display and a warning alarm is generated 7 14 High Current Warning Alarm GENERATOR HIGH CURRENT if the module detects a generator output current in excess of the pre set trip a warning alarm initiate The module shows Alarm Warning High Current If this high current condition continues for an excess period then the alarm escalates to a shutdown condition For further details of the high current alarm please see High Current Shutdown Alarm By default High Current Warning Alarm is self resetting when the overcurrent condition is removed However enabling all warnings are latched will cause the alarm to latch until reset manually This is enabled using the 7000 series configuration suite in conjunction with a compatible PC 43 HIPOWER Systems Inc 16002 W 110th Street Lenexa
143. rature fault operates after engine has fired Shutdown fault operates Warning fault operates Fail lo Start is activated after pre Check wiring of fuel solenoid Check fuel Check battery supply Check battery set number of attempts to start supply i is present on the Fuel output of the module Check the speed sensing ignal is present on the 7000 series module s inputs Refer to engine manual Continuous starting of generator Check that there is no signal present on the Remote Start input Check when in AUTO configured polarity is correct Check the mains supply is available and within configured limits DSE7220 DSE7320 only Generator fails to start on receipt Check Start Delay timer has timed out of Remote Start signal Check signal is on Remote Start input Confirm correct configuration of input is configured to be used as Remote Start Check that the oil pressure switch or sensor is indicating low oil pressure to the controller Depending upon configuration then set will not start if oil pressure is not low Pre heat inoperative Check wiring to engine heater plugs Check battery supply Check battery supply is present on the Pre heat output of module Check pre heat configuration is correct starter motor inoperative Check wiring to starter solenoid Check battery supply Check battery supply is present on the Starter output of module Ensure that the Emergency Stop input is at Positive Ensure oil pressure switch or sensor
144. requency Generator Current Generator Earth Current Generator Load kW Generator Load kVA Generator Power Factor Generator Load kVAr Generator Load kWh kVAh kVArh Generator Phase Sequence Dual Mutual Status Available The set is running and available Inhibited The set is prevented from running by the other controller Master The master set will call for the slave when the timer hrs mins expires Slave The master will call for the slave until the timer hrs mins expires 31 Page www hipowersystems com 7 5 Viewing the Event Log The DSE7000 series modules maintain a log of past alarms and or selected status changes The log size has been increased in the module over past module updates and is always subject to change At the time of writing the 7300 series log is capable of storing the last 250 log entries Under default factory settings the event log only includes shutdown and electrical trip alarms logged The event log does not contain Warning alarms however this is configurable by the system designer using the DSE Configuration Suite software Event Log Display Options 9 Date and ti Module display Engine yt run Logging Options Log the following events to the event log Power up Shutdown alarms Mains fail v Electrical trip alarms Mains Return v Latched warnings ECU Shutdown alarms Unlatched warnings Once the log is full any subsequent shutdown alarms will overwrit
145. rocedure cannot be performed away from the DSE factory 52 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 22 1 Editing a Parameter Enter the editor as described above c0 Press the left or right buttons to cycle to the section you wish to view change Press the up or down buttons to select the parameter you wish to view change within the currently selected section To edit the parameter press to enter edit mode The parameter begins to flash to indicate that you are editing the value Press the o up or down buttons to change the parameter to the required value Press to save the value The parameter ceases flashing to indicate that it has been saved To exit the editor at any time press and hold the v button ANOTE The PIN number is automatically reset when the editor is exited manually or automatically to ensure security NOTE More comprehensive module configuration is possible using the 7xxx series PC configuration software Please contact us for further details 53 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com 7 22 2 Adjustable Parameters Front Panel Configuration Editor Only available on DSE7220 DSE7320 AMF Modules oection Parameter as shown on display acon Settings c
146. rpose 1 2 EX It is totally forbidden to use any other lifting points located over the engine alternator or other components If the G S is damaged for any reason during its transportation storage and or mounting it must not be started up before being verified by our specialized personnel If you want to store the Tower until its utilization it is highly recommendable to have a warehouse properly protected against any chemical agents that may damage its components e Unpacking must be carried out carefully avoiding causing any damages to the goods during such operation especially when using levers saws or any other metallic tools 15 3 Safety during installation and initial start up 81 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 The installation of the generator set and its respective accessories must be carried out by specialized personnel In the event of any difficulties during the installation consult with the Technical Department at Himoinsa You must be familiar with the emergency procedures concerning the installation to be followed Always wear a safety helmet footwear and safety gloves protective goggles and dry tight clothes Do not modify the original protections located on all rotary parts on display hot surfaces air intakes belts and live parts Do not leave dismantled parts tools or any other access
147. rr a Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in 20 b During engine break in change the oil and filter for the first time before 100 hours of operation c If the recommended engine oils John Deere PLUS 50 ACEA E7 or ACEA E6 are not used the oil and filter change interval is reduced see DIESEL ENGINE OIL AND FILTER INTERVALS chart If diesel fuel with a sulfur content greater than 0 05 is used the oil and filter change interval is also reduce d If John Deere COOL GARD is used the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive the flushing interval may be extended to 5000 hours or 60 months whichever occurs first 61 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 10 3 Lubrication and Maintenance Service Interval Chart Standby Applications Lubrication and Maintenance Service Intervals 2 500 Hour 12 2000 Hour 24 Weeks Month Month WAR Operate Engine at Rated Speed and 50 70 Load a Minimum of 30 Minutes Check Engine Oil and Coolant Level Check Fuel Filter Water Bowl Fuel Filter Water Bowl Check Air Cleaner Dust Unloader Valve amp Restriction Indicator Mum t eae a
148. run on load For further details please see the more detailed description of Test operation elsewhere in this manual 5 7 1 2 START This button is only active in STOP RESET Q or MANUAL mode Pressing this button in manual or test mode will start the engine and run off load manual or on load test Pressing this button in STOP RESET mode will turn on the CAN engine ECU when correctly configured and fitted to a compatible engine ECU Mute Lamp Test This button silences the audible alarm if it is sounding and illuminates all of the LEDs as a lamp test feature When correctly configured and fitted to a compatible engine ECU pressing this button in STOP RESET mode after pressing the START button to power the ECU will cancel any passive alarms on the engine ECU 33 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com Transfer to generator Allows the operator to transfer the load to the generator when in Manual mode only Open generator DSE7210 DSE7310 only Allows the operator to open the generator when in Manual mode only Transfer to mains DSE7220 DSE7320 only Allows the operator to transfer the load to the mains when in Manual mode only Menu navigation Used for navigating the instrumentation event log and configuration screens For further details please see the more detailed description of these items elsewhere in
149. se to the unstable region 66 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 5 4 Type MX321 AVR The following jumper connections on the AVR should be checked to ensure they are correctly set for the generating set application MX321 jumper connections Frequency selection terminals 4 pole 50Hz operation Link 2 3 4 pole 60Hz operation Link 1 3 otability selection terminals UC22 Link A B Stability selection terminals UC27 Link B C Excitation Interruption Link K1 K2 1 Volts 2 Indicator led l limit 4 UFRO 5 Frequency selector 6 Dip 7 rms 8 Dwell 9 Stability 10 Over v 11 Exc trip 12 Stability selector 13 Droop 14 Trim 15 Link over 550kW iG RIP wx s 6 lo gt 6Pi60Hz T 4PI50Hz 1A 4Pi60Hz Ge 5 19 OR go uyy 90 o lel eo ere so e IP all e Te o 9 Initial Start Up On completion of generating set assembly and before starting the generating set ensure that all of the engine manufacturer s pre running procedures have been completed and that adjustment of the engine governor is such that the generator will not be subjected to speeds in excess of 125 of the rated speed Overspeeding the generator during initial setting of the speed governor can result in damage to the generator rota
150. sible 2nd function Read out fault codes Monitors coolant level Current measured value Monitors coolant pressure Monitors coolant temperature Engine control system made by Detroit Diesel Diagnostic lines Diagnostic unit At the same time identifier of German standards DIN Deutsche Industrie Norm Alarm Default CAN bus failure Oxidation catalyst before the diesel particulate filter Diagnostic unit Electronic control unit of the DDEC system Engine governor 124 Page 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 www hipowersystems com Abbre Meaning Explanation viation EDM EE PROM EFPA EGR EIL ESCM SPE EUI FO FPS FRS FTS FWCP GND HP HI HIHI HT IDM Ila IN 50 KGS KS L1 L2 LED CAC LO LOLO 156 LSU LT MCR N A LP NN HIPOWER Systems Inc Engine Data Module Electrically Erasable Programmable Read Only Memory Electronic Foot Pedal Assembly Exhaust Gas Recirculation Engine Ident Label Engine Monitoring Unit Extreme Site Condition Management Spare Parts Catalog Electronic Unit Injector Frequency Output Fuel Pressure Sensor Fuel Differential Pressure Sensor Fuel Temperature Sensor Fire Water Control Panel Ground High pressure High High High High Temperature Interface Data Module Initiale Injektorgleichstellung Injector International Organization for Standardiza tion Kraftgegenseite Kraftseite Limit 1
151. st silencer is usually attached to the stretch of pipe that remains inside the room where the generator is located Whenever possible it can be separated from the generator The silencer used in industrial applications performs a 15 to 20 decibels noise reduction In order to reduce the noise caused by the resonances of gas pulses in pipes the position of the silencer can be altered by reducing the length of the tube that goes into the engine For example for a 10m long pipe the optimal position would be half way through the distance in relation to the outlet In the cases of private installations such as hospitals or residential areas where a higher noise reduction is required special silencers can be used with a reduction of 25 to 30 decibels and whenever possible using special quiet chambers The ventilation of the engine room where the G S is installed is of vital importance for a correct operation and durability of the generator The engine room must have the following features Allow the dissipation of the heat produced when the generator is in operation by irradiation and convection Guarantee the correct supply airflow and in the right amount for the engine combustion Allow the engine cooling by means of the radiator keeping the operating room temperature within the safety limits in order to guarantee a good aspiration of the supply air A good ventilation solution applicable to most cases is the one indi
152. t are recommended in the use and maintenance handbook Remove the radiator cap gently The cooling conduits are usually pressurized and therefore the hot liquid may spout if pressure is released very quickly Periodically check the tightness and level of wearing of pump belts fan Lubrication circuit Periodically check the level of the oil in the crankcase with a cool engine and add oil whenever necessary according to the directions found in the use and maintenance handbook Do not smoke or light fires during the oil supply Fuel circuit Do not smoke or light fires during the fuel supply Do not smoke during the fuel replacement and be careful not to spill fuel on the generator set Exhaust circuit Watch the exhaust circuit and in the event that any eventual gas leaks are detected repair immediately These are possible fire Sources Warning very hot surfaces Pre assembled installation parts are protected against accidental contacts The installer must insulate and or protect any other additional parts gas evacuation pipes the silencer which is supplied separately etc Electric start system 83 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 Disconnect the negative pole from the battery batteries before operating the engine in order to prevent the automatic start system of the engine from starting while being operated Keep joints tig
153. tandby 3309 2440 77 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 13 SPECIFICATIONS YANMAR 13 4 Engine Models 13 1 1 ATNV84T 3 31 in 84 mm x 3 54 in 90 mm 13 1 2 4TNV88 3 46 in 88 mm x 3 54 in 90 mm 78 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 13 1 3 4TNV98 Engine Type In line 4 Cylinder Diesel Engine Bore amp Stroke 3 31 in 84 mm x 3 54 in 90 mm Displacement 203 cu in 3 32 L Compression Ratio 18 5 1 Combustion System Direct Injection Cooling System Liquid Cooled 13 1 4 ATNV98T 3 86 in 98 mm x 4 33 in 110 mm 79 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 14 PERIODIC MAINTENANCE YANMAR O Check X Replace Contact your authorized Yanmar dealer or distributor oystem Check Item Daily Every 50 Every 250 Every 500 Hours Check and refill engine coolant Check and clean radiator fins Cooling Check and adjust System cooling fan V belt O 1st time O 2nd and after Drain flush and refill cooling system with new X or every year whichever comes first coolant Adjust intake exhaust Cylinder valve clearance Head Lap intake exhaust valve seats Electrical
154. th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowe rsystems com Appendix A Abbreviations Abbre viation A D AFRS EGR AL ANSI EIC ATS BR CAN CDC CEL CCT CLS CM CPS CR CTS DDEC DDL DDR Dia Sys DIN DL DOC DPF DT ECM ECU HIPOWER Systems Inc Analoz Digital Advanced Diesel Engine Controller Air Filter Restriction Sensor Exhaust Gas Recirculation Alarm American National Standards Institute Exhaust turbocharger exhaust turbocharg ing Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubri cants Specifications Controller Area Network Calibration Drift Compensation stop engine light Circuit Coolant level sensor Current Measurement Coolant pressure sensor Common Rail Coolant temperature sensor Detroit Diese Electronic Controls Diagnostic Data Link Diagnostic Data Reader Electronic dialog system Deutsches Institut f r Normung e V Default Lost Diesel Oxidation Catalyst Diesel Particulate Filter Diagnostic Tool Electronic Control Module Engine Control Unit Transformer transforms sensor voltages into numer ic values Engine management system Association of American standardization organiza tions MTU Publication A01061 Data bus system bus standard Drift correction setting with DiaSys in engine gover nor st function Warning lamp rectify fault as soon as pos
155. the set by means of a fork lift truck E Located next to the oil fill dipstick and oil fill cap Indicates the location of the oil fill dipstick UBICACI N INFORMACION Next to the derivations of the grounding protections They are the parts by means of which the genset is protected against possible electric shocks Next to the protective thermal magnetic switches They protect the genset against possible overcurrent it E of the genset that may occur during charge On the emergency n It indicates the location of the emergency stop button which allows the simultaneous stop of the genset AL Located on the control panel They warn of electric shock hazard Always located on the thermal magnetic switch They Mages the prohibition of manipulating the enset when the switch is on 16 INADEQUATE USE WARNINGS The Generator Set that HIMOINSA supplies is aimed at the production of electrical energy according to the conditions and environmental and operating limits established agreed this contract All amendments of such conditions and limits must be notified directly to the manufacturer or made via authorised workshops in order to achieve an optimal performance and if necessary to perform modifications and or new calibrations of the generator The Generator Set is a machine that transforms potential thermal energy contained in the fuel into electrical energy and is aimed at supplying distribution
156. this manual When the engine has stopped it is possible to send configuration files to the module from DSE Configuration Suite PC software and to enter the Front Panel Editor to change parameters Any latched alarms that have been cleared will be reset when STOP mode is entered The engine will not be started when in STOP mode If remote start signals are given the input is ignored until AUTO mode is entered When configured to do so When left in STOP mode for five minutes with no presses of the fascia buttons the module enters low power mode To wake the module press the button or any other fascia control button Miscellaneous Options Jan Enable fast loading feature ep mode configuration Enable sleep moda T Inthe DSE Configuration _ Suite Software Enable manual fuel pump control 7 6 1 ECU Override Anote ECU Override function is only applicable to the CAN variant of the 6100 series controller Auore Depending upon system design the ECU may be powered or unpowered when the module is in STOP mode ECU override is only applicable if the ECU is unpowered when in STOP mode When the ECU powered down as is normal when in STOP mode it is not possible to read the diagnostic trouble codes or instrumentation Additionally it is not possible to use the engine manufacturers configuration tools 34 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219
157. ting components Voltage Set Up The voltage is factory set as per the rating plate If necessary adjust the voltage to the no load level as required To adjust the voltage remove the AVR access cover plate use the insulated tool supplied Stability Set Up The STABILITY control potentiometer is pre set and should not normally require adjustment If adjustment is necessary proceed as follows Run the generating set on no load and check that speed is correct and stable Turn the STABILITY control potentiometer clockwise then turn slowly anti clockwise until the generator voltage starts to become unstable Note The correct setting is slightly clockwise from this position i e where the machine volts are stable but close to the unstable region 11 6 Electrical Protection It is the responsibility of the end user and contractors sub contractors to ensure that the overall system protection meets the needs of any inspectorate local electricity authority or safety rules pertaining to the site location WARNING Incorrect installation and or protective systems can result in injury and or equipment damage Installers must be qualified to perform electrical installation work Adequate electrical protection must be provided so that there will be no danger to personnel danger of fire or damage to the generator under fault conditions 67 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph
158. tion is 47 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 91 3 495 5575 www hipowersystems com 7 18 ROCOF Vector Shift When configured to run in parallel with the mains utility supply the module monitors for ROCOF Vector shift trips according to the module s configuration settings This is included within the module and will detect failure of the mains supply during parallel operation with the generator This protection operates only when in parallel with the mains supply and is disabled at all Should either of these alarms operate the module will perform a controlled shutdown electrical trip of the generator This operation must be manually reset 1 Press button The engine will stop if it is still running and the alarm is cleared 2 Activate digital input configured to Clear ROCOF Vector shift if this has been provided 3 Press and button together and hold for 5 seconds The ROCOF Vector shift instrument is displayed and all peak hold values are reset clearing the ROCOF Vector shift alarm For details on activating and configuring the ROCOF Vector shift protection you are referred to the 8600 configuration software manual 48 HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 7 19 Maintenance Alarm Depending upon module configurat
159. tor functions Once in Manual mode the module will respond to the start button start the engine and run off load If the engine is running off load in the Manual mode and a remote start signal becomes present the module will automatically instruct the changeover device to place the generator on load Close Generator becomes active if used Upon removal of the remote start signal the generator remains on load until either selection of the STOP RESET or AUTO modes For further details please see the more detailed description of Manual operation elsewhere in this manual Auto This button places the module into its Automatic mode This mode allows the module to control the function of the generator automatically The module will monitor the remote start input and mains supply status and once a start request is made the set will be automatically started and placed on load Upon removal of the starting signal the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary The module will then await the next start event For further details please see the more detailed description of Auto operation elsewhere in this manual 5 7 1 1 TEST DSE7220 DSE7320 ONLY This button places the module into its Test mode This allows an on load test of the generator Once in Test mode the module will respond to the start V button start the engine and
160. utton to save the change before moving to another item or exiting the fascia editor Ensure the generator available LED is lit Check that the output configuration is correct to drive the load switch device and that all connections are correct Remember that the set will not take load in manual mode unless a remote start on load input is oresent or the close generator button is pressed Check that the CT primary CT secondary and VT ratio settings are correct for the application Check that the CTs are wired correctly with regards to the direction of current flow p1 p2 and 51 52 and additionally ensure that CTs are connected to the correct phase errors will occur if CT1 is connected to phase 2 Remember to consider the power factor le kW kVA x powerfactor The 7000 series controller is true RMS measuring so gives more accurate display when compared with an averaging meter such as an analogue panel meter or some lower specified digital multimeters Accuracy of the controller is better than 196 of full scale le Gen volts full scale Anote The above fault finding is provided as a guide check list only As the module can be configured to provide a wide range of different features always refer to the source of your module configuration if in doubt 59 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 10 ROUTINE MAINTENANCE 10 1 Maintena
161. ve drive belt from fan drive Page 119 3 Slacken off screws 1 and lacknut 3 amp Release adjusting screw 2 on mechanical belt tensioner 4 and take off drive Note When placing the drive belt in the grooves no force must be applied 9 Fit new drive belt 5 and tighten adjusting screw 2 on mechanical helt tensioner to set the required tensior 6 Install drive belt on fan drive protective cover 02800175 Wiring General for Engine Gearbox Unit Engine wiring Check Preconditions Engine is stopped and starting disabled special tools Material Spare parts Isopropyl alcohol 00058037 1 Checking engine wiring Check securing screws of cable clamps on engine and tighten loose threaded connections Ensure that cables are fixed in their clamps and cannot swing freely Check that cable clamps are firm tighten loose cable clamps Replace faulty cable clamps Visually inspect the following electrical line components for damage Connector housing Contacts Sockets Cables and terminals Plug in contacts Result Contact Service if cable conductors are damaged c RON Note Close male connectors that are not plugged in with the protective cap supplied 6 Clean dirty connector housings sockets and contacts using isopropyl alcohol Ensure that all sensor connectors are securely engaged 122 Page KS 66219 Ph 913 495 5557 Fax 91 www hipowers
162. w of Rental set operations and functions e YANMAR GENERATING SETS 25 to 50 Before using generator set PLEASE read these easy steps on operation Check all fluid levels before running the generator set Q Turn on the battery cut off switch located below the battery charging alternator Red Handle Rotate clockwise to vertical position To start the unit turn key to the AUTO position then push the green button marked with a hand to start it Engine will preheat for 10 seconds before cranking Q Engine diagnostic switch can be used to power up the gauges while fueling unit DO NOT turn on when running generator set Q Check the selector switch for the correct operating voltage DO NOT CHANGE POSITION OF SELECTOR WHILE GENE RATOR IS RUNNING The switch is located on the front end of the generator box To access it open the left hand door by the vented panel Q This generator is equipped with a DSE 702 control panel The illustration below shows all funtions and safety DEEP SEA ELECTRONICS Engine diagnostic switch amp Panel power switch Model 702 HC DSE 702 Control Panel Technical details 1 Over speed 2 Over crank 3 Low oil pressure 4 Battery charge fault 5 Over temperature 6 Glow plugs 7 Hour meter 8 Start button 3 9 Auto start position 8 10 Key power switch Q Selector switch HIMOINSA POWER SYSTEMS INC 16210 W 110 St Lenexa KS 66219 USA
163. w the operators attention to the alarm condition Page order Engine Speed Generator Volts Generator Frequency Engine Run Time Battery Volts 20 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 6 4 Controls Stop Reset This button places the module into its Stop Reset mode This will clear any alarm conditions for which the triggering criteria have been removed If the engine is running and the module is in Stop mode the module will automatically instruct the changeover device to unload the generator Close Generator becomes inactive if used The fuel supply de energizes and the engine comes to a standstill Should a remote start signal be present while operating in this mode a remote start will not occur Auto This button places the module into its Automatic mode This mode allows the module to control the function of the generator automatically The module will monitor the remote start input and once a start request is made the set will be automatically started and laced on load Upon removal of the starting signal the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary The module will then await the next start event Start Pressing this button in auto mode will start the engine and run off load Pressing this button in ST
164. with a clean cloth The adhesive will achieve a permanent bond in 24 hours A factory fitted metal nameplate is available for the generator only Do not lift the complete generating set by the generator lifting points When lifting the generator use a spreader bar to ensure that the angle on the lifting chains are vertical to the lifting position on the generator 4100 Kg MAX 63 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 www hipowersystems com 11 5 Automatic Voltage Regulators To make AVR selections and adjustments remove the AVR cover and refer to the appropriate section depending upon type of AVR fitted Reference to the generator nameplate will indicate AVR type Most of the AVR adjustments are factory set in positions which will give satisfactory performance during initial running tests Subsequent adjustment may be required to achieve optimum performance of the set under operating conditions 11 5 1 Type AS440 1 Z2 linked for normal remove for auxiliary winding 2 Output Voltage adjustment 3 Hand trimmer link when not used 4 Low voltage selection 110v 5 Droop adjustment 6 To optimise analogue input sensitivity 7 Excitement trip cut off adjustment 8 Stability control 9 UFRO adjustment 10 Stability section 11 Frequency section Stability Selection No Power range Response B D lt 100kW Slow A C
165. www hipowersystems com Do not operate generator set with safety guard s removed Seek medical attention immediately if your skin contacts high pressure fuel 1 2 Installation And Transporting Hazards WARNING Crushing hazard Generator set is heavy Use properly rated lifting devices to move generator set Never enter the area under a raised generator set WARNING The generator lifting points are designed to lift the generator only Do not lift the complete generating set by the generator lifting points WARNING Incorrect installation and or protective systems can result in injury and or equipment damage Installers must be qualified to perform electrical installation work 1 3 Operational Hazards WARNING Risk of death or serious injury Do not operate work on or around this machine while under the influence of alcohol drugs or if feeling ill WARNING Carbon monoxide hazard Do not operate the generator in an enclosed building or confined area Avoid actions or areas that expose you and others to carbon monoxide WARNING Entanglement hazard Loose fitting clothing and long hair can be come entangled in moving or rotating parts Do not wear loose fitting clothing Long hair must be tied back or netted Remove neck ties Do not operate generator with a guard removed or access panel removed You must adhere to local codes and regulations wher
166. xhaust collector outlet for turbocharged engines and at the turbine outlet in case of supercharged engines cause reductions in power rise in temperature of exhaust gases fumes high fuel consumption cooling water overheat lubricant degradation and the ensuing consequences on the engine parts The limits that must not be exceeded referred to the delivery conditions of maximum power at full throttle in HIMOINSA genets must be consulted in the factory ouch limits can be observed considering the dimensions that are suitable for the exhaust installation that is the diameter of the pipe and type of silencer The pipes must be as short as possible and with as few pipe elbows as possible Whenever these are essential they must be used with a very wide angle of curvature from 2 5 to 3 times the diameter of the pipe Solutions with bends of angles lower than 2 5 times the diameter pose difficulties so they must be avoided In order to calculate the total length of the pipe which is crucial for the exhaust s backpressure the following considerations must be taken into account The rectified length of the pipe elbows must be determined according to the chart and pictures Interior diameter of the exhaust gt gt ppe uom T eise usur pos 12 vr 22 2 The backpressure values due to the exhaust silencers may vary within a wide range depending on the type of building dimens
167. y collapse 1 Check sensing leads to AVR 2 Refer to Separate Excitation Test Procedure Voltage unstable either on no load or with load 1 Check speed stability 2 Check STAB setting Refer to Load Testing section for procedure Low voltage on load 1 Check speed 2 If correct check UFRO setting Excessive voltage speed dip on load switching 1 Check governor response Refer to generating set manual Check DIP setting Sluggish recovery on load switching 1 Check governor response Refer to generating set manual 11 7 6 MX321 AVR No voltage build up when starting set 1 Check link K1 K2 on auxiliary terminals Follow Separate Excitation Test Procedure to check machine and AVR Voltage very slow to build up 1 Check setting of ramp potentiometer Loss of voltage when set running 1 First stop and restart set If no voltage or voltage collapses after short time follow Separate Excitation Test Procedure Generator voltage high followed by collapse 1 Check sensing leads to AVR 2 Refer to Separate Excitation Test Procedure Voltage unstable either on no load or with load 1 Check speed stability 2 Check STAB setting Refer to Load Testing section for procedure Low voltage on load 1 Check speed 2 If correct check UFRO setting Excessive voltage speed dip on load switching 1 Check governor response Refer to generating set manual Check DIP setting Slug
168. y for a limited number of hours per year performing the maintenance intervals described by the manufacturer and in the specified environmental conditions Prime Power PRP is the maximum power available for a cycle with variable power that the generator set can produce for a limited number of hours per year performing the maintenance intervals described by the manufacturer and in the specified environmental conditions The average power produced for a period of 24 hours must not exceed 80 of the PRP A 10 overload is allowed for 1 hour out of 12 operating hours Stand By Power SBY is the maximum power which in the established environmental conditions the generator can produce for a maximum period 86 Page HIPOWER Systems Inc 16002 W 110th Street Lenexa KS 66219 Ph 913 495 5557 Fax 913 495 5575 of 500 hours per year The load factor must not exceed 90 of the SBY Overloads are not allowed Rate HIMOINSA generators are prepared to work at 1 500 rpm or 1 800 rpm at a rate of 50 or 60 Hz respectively Low power engines are equipped with a mechanical rpm regulator installed in the injection pump this is normally adjusted so that motionlessness is 5 and therefore the output rate is 52 5 Hz with no load and 50 Hz at full load In static conditions the mechanical rpm regulator usually provides an accuracy of 0 596 Voltage The voltage regulator is usually ELECTRONIC with features that
169. ystems com Accessories for Electronic Engine Governor Control System Engine governor and connectors Cleaning Preconditions Engine is stopped and starting disabled special tools Material Spare parts Isopropyl alcohol X00058037 1 Note Always use test connectors to enter the connectors Never use test leads for this purpose Otherwise the contacts could be bent Engine governor and connectors Cleaning 1 Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connectors on the engine governor Note Seal unused connectors with the supplied protective cap 1 Release the latch and pull off connectors 2 Clean connector housings connector socket housings and all contacts with isopropyl alcohol 3 When connectors sockets and all contacts are dry Fit connectors and lock them Engine governor Checking plug connections Preconditions Engine is stopped and starting disabled Checking engine governor plug connections Check firm seating of all connectors on the engine governor Ensure that the clips 1 are engaged 2 Check firm seating of all screws 2 on en gine governor cable clamps Make sure that cable clamps are not defective 123 Page HIPOWER Systems Inc 16002 W 110

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