How to Arrange Diesel Engine Room Forced ventilation - engine compartment When a remote radiator is installed, consideration must be given to engine compartment ventilation. First of all, the exhaust system in the engine compartment must be efficiently insulated so that heat radiation is minimal. NOTICE! Because of the risk for overheating the exhaust manifold and turbocharger may not be insulated, only the exhaust pipe and silencer. The best forced ventilation systems normally comprise two electrically-driven fans. One fan forces air into the compartment and is installed on the wall directly opposite the generator end. The other fan extracts air hot air from the engine compartment. This fan must be installed on the wall next to and above the engine. An air duct is required on the inlet side if the cooling air does not reach the generator/engine. The ducting leads air to the generator and over the engine to the extraction fan. If no air ducting is installed when the inlet fan is located high up, inlet cooling air will pass by the generator set and be drawn out by the extraction fan without cooling the engine. If there is space in the right place for a large air inlet opening, no fan is required to force air into the compartment. The extraction fan must have sufficient extraction capacity to overcome the air resistance through the inlet and outlet grilles and air ducts, if such are installed. If an extraction fan is used and combustion air is drawn from the engine compartment, negative pressure may occur. Engine compartment negative pressure can be checked using a plastic, water-filled Ushaped hose. One end is connected to the engine compartment and the other is exposed to atmospheric pressure (outside the engine compartment). Allow the engine to run at full throttle for at least 5 minutes in order to build up a characteristic low pressure in the compartment. Then measure the pressure difference equivalent to the water's surface differences in mm water column. The pressure difference must not exceed 10 mm (0.4") (0.8 mm Hg or 1 millibar). A low pressure of 20 mm (0.8") water gauge is acceptable on engines with remote radiators and without a fan. Crankcase breather Gases from the engine crank case must be led away from the engine compartment via a separate duct. The crankcase ventilation pipe may be extended to lead crankcase gases out of the engine compartment. This is especially important when the engine has an pusher fan, as the crank case gases would otherwise coat the radiator which would become dirty and clogged, thus reducing cooling capacity. Note; where there is a risk of freezing (ice plugs) this pipe must be heated or insulated. WARNING! Only start the engine in a well-ventilated area. If operating the engine in a closed area ensure that there is exhaust ventilation leading out of the work area to remove exhaust gases and crankcase ventilation emissions. NOTICE! Some engines are equipped with closed crankcase ventilation that does not require additional ventilation. Calculating required engine compartment ventilation When calculating engine compartment ventilation, consideration must be given to the following important factors: • Max engine compartment air temperature is 60 °C (140 °F), given that combustion air is drawn from outside the engine compartment. • The entire exhaust system and silencer in the engine compartment should preferably be insulated. • The exhaust manifold and turbocharger may not be insulated. • Max input air for the radiator cooling system. Refer to Sales Support Tool, Partner Network. The large volume of air moved by an engine-mounted cooling fan is usually sufficient to ventilate the engine compartment. When a remote radiator or water-cooled heat exchanger is installed, consideration must be given to engine compartment ventilation. The volume of air required to provide a given temperature increase in the engine compartment can be calculated as follows: Total heat transfer to air Airflow requirement =––––––––– + Required combustion air Air density x Tincrease x Constant Total heat transfer to air: Heat transfer from engine + generator and other heat-emitting equipment in the engine compartment( kW). Air density: Air density at different temperatures shown in the table below in kg/m3. Tincrease: Max. air temperature increase in the engine compartment, above ambient temperature. Constant: = 0.0167 Required combustion air: Engine air consumption in m3/min according to data in the Sales Support Tool, Partner Network. Air density °C 0 5 10 15 20 25 30 35 40 45 50 55 kg/m3 1.30 1.27 1.25 1.22 1.20 1.19 1.17 1.16 1.14 1.12 1.09 1.08 A Microsoft Excel application for calculating both engine compartment ventilation and exhaust system back pressure is available from AB Volvo Penta, Sales Engineering Industrial. Multi-engine installations In general, the same installation instructions apply to multi-engine installations as for single installations, and each unit must have its own engine bed and exhaust system. IMPORTANT! Exhaust gases from multi-engine installations may not be led together in a common system, as this can be very dangerous and cause engine damage. If the exhaust system in a multi-engine installation must be led together in a combined exhaust system, each engine must be equipped with a separate exhaust shut-off valve, so that exhaust gases are not able to enter an engine that may not be running. Also refer to “Multiple exhaust outlets” in the chapter Exhaust System page 75. Engine Mountings for Stationary and Semi-mobile Installation Frame-mounted engines The simplest mounting method is to bolt the engine and driven unit directly to the frame. It is necessary for the engine and driven component mounting inserts on the frame to be flat, square and parallel to one another. The frame must be designed so that the mounting inserts cannot be twisted in any way. The quality of the installation is greatly affected by the appearance of the frame. Vibration levels from the engine and its components can be influenced by changing the design of the frame. Engine bed types The engine support/bed to which the frame is attached is of great importance as it must be able to: • support the units' static weight and dynamic loads from balance forces in the engine. • be sufficiently stiff and stable so as not to distort and thereby affect engine and driven unit alignment. • absorb vibrations from driven units and prevent vibrations from being propagated to the engine bed and walls. Refer to the chapter about noise and sound dampening. For more: How to Design Diesel Generator Set Room
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Maintenance of Diesel Generator in Winter As a emergency standby power supply after power failure, diesel generator sets are in standby state in most cases. Once the power is cut off, whether the generator set can start and supply is the key of playing as an important role during power supply. Otherwise, it will lose its meaning as a backup power source. Therefore, in order to make sure that diesel generator can be started successfully during power cut, it is necessary to maintain diesel generators in daily use. Below are some tips for users to maintain diesel generator. 1. When the generator is in operation, all screens should be locked and the key shall be kept by hand. It is especially important not to leave the key in the lock. 2. Note that insulation tools should be used to ensure circuit safety when connecting or disconnecting the circuit. 3. Check engine starting motor batteries and wiring for metal objects. Clean up immediately. 4. Once the generator has a major fault, can press the control screen emergency stop button emergency shutdown. (this method is not advocated because frequent adoption can cause damage to the equipment.) 5. Before the generator stops, pay attention to load separation, let the diesel generator set idling for a period of time until the complete shutdown. In addition, the forced shutdown of the generator can easily cause damage to the unit by installing part of the unit with the stop valve, or by turning off the key switch of the control screen. 6. Generator monthly maintenance content: A. Clean up the dust on the surface of the unit, etc. B. Check whether the speed control rod is flexible and lubricate the connection points; C. Change cooling water, measure PH value before and after replacement (normal value is 7.5-9), and do a good record of measurement, if necessary, add drug treatment; D. Check the tension of fan and charger belts and adjust them if necessary E. If the generator is used in important occasions, the no-load test should be started for at least 10 minutes per week, and the half-hour test with load should be done every six months. Besides daily maintenance, how to keep diesel generator safe in winter or cold weather is also important. 1. Selection of diesel oil Carefully Light diesel oil with low freezing point and good ignition performance should be selected in winter, and the freezing point of diesel oil should be lower than the local minimum temperature of 7-10 ℃ in the current season. Because the low temperature in winter will reduce the flow of diesel oil, increase the viscosity that will lead to uneasy spray. As a result, it is easy to cause poor atomization due to the diesel can not be fully burned, resulting in the power of diesel generators decreased and waste. 2. Do not release water too early or release water without cooling water Before flameout should idle operation, waiting for cooling water temperature to 60 ℃, water is not hot and then rest assured. If the cooling water is released prematurely, the body will suddenly shrink and crack when the temperature is high. The residual water should be discharged thoroughly when discharging water to avoid the expansion of the body. 3. It is not suitable to start with open fire Do not remove the air filter, with cotton yarn dipping with diesel fuel ignited to make a fuse placed in the intake pipe to implement combustion booster. In the starting process, the dust-containing air of the outside world will inhale directly into the cylinder without filtration, forming abnormal wear of the piston, cylinder and other parts, and will also form the rough operation of diesel engine and harm the machine. 4. The engine should run at low speed for 3-5 minutes after starting in order to raise the temperature of the diesel engine, check the working condition of lubricating oil, check the normal operation before it can be put into normal operation. In the operation of the diesel engine, the service life of the valve assembly will be affected by reducing the sudden acceleration of the speed or stepping on the throttle to the maximum operation, otherwise the long time will affect the service life of the valve assembly. 5. Attention should be paid to body insulation Winter temperature is low, easy to make diesel engine operation cooling excessive. Therefore, heat preservation is the necessary measure to prolong the life of diesel generator in winter. In the northern region, diesel generators should be equipped with insulation cover and thermal insulation curtain and other cold-proof equipment in winter. 6. It is not advisable to bake oil bottom with open fire Avoid causing oil in the oil pan to degenerate, even scorch, smooth function decline or thorough loss, and then aggravate machine wear. Low freezing point oil should be used in winter, and the engine oil temperature can be raised by using water bath outside the machine to warm up the engine oil. Low voltage of diesel generator will affect the use of generator set, which is one of the common faults. This article will guide you to learn the factors that affect the voltage of generating set. 1. The unstable speed of the engine causes the unstable voltage of the generator set. 2. If the load on the generator set is too large, the voltage will be unstable. 3. The damage of the voltage regulator components of the generator causes the unit’s voltage instability. 4. The poor circulation of the fuel pipe of the genset causes the unstable speed of the engine, which causes voltage instability. We recommend you to use the following methods to check and handle the low voltage fault of diesel generator sets. 1. If the contact surface of generator brush is too small and the voltage caused by poor contact is too low, it is necessary to check whether it is caused by the commutator surface, if it is, at low speed, to polish the commutator surface with sand cloth, or to adjust the spring pressure. 2. When the generator set is used, the voltage is too low. It may also be that the diesel engine speed is too low. In this case, you need to check the diesel engine speed. You only need to adjust the prime mover speed to the rated value. 3. During the process of using diesel generator set, the unit voltage is too low because the resistance of the excitation circuit is too large, and the resistance of the magnetic field rheostat is reduced to increase the excitation current. For semiconductor excitation generator, check if the additional winding connector is broken or connected incorrectly. 4, check whether the generator exciter brush is in the neutral line position. It is recommended to adjust the electric brush to the correct position, or to replace the brush to solve the problem of low voltage. 5. Check if there is a short circuit or ground fault in the stator winding or excitation winding of the generator set, and check the fault and clear faults in time. 6. Some rectifier diodes are broken down. It is necessary to deal with in time. Check and replace the broken diodes. Starlight Power company mainly produces diesel generator set and has 43 years experience in power generating sets manufacturing. Main products include Volvo generator, Cummins generator, Perkins generator, Ricardo generator, and Yuchai diesel generator and so on. All our products are approved by CE/ISO. Gensets meet international applicable standard ISO 8528. According to customers’ requirements, we also provide installation, commissioning, training, and maintenance service. This is the final part of checking and adjusting Deutz 226B series diesel engine for delivery beginning. It mainly includes checking exhaust, turbocharging and inter-cooling system and electrical system. 3. 9. 2 Exhaust The three - cylinder or four - cylinder diesel engine adopts unitary exhaust manifold, and the six - cylinder engine adopts inserted exhaust manifold which is made up of two parts ( every part for three cylinders) and sealed with narrow width ring. The joint between exhaust manifold and cylinder head is sealed with stainless steel gasket, the convex surface of which should face to the cylinder head. The torque for tightening nut is 45 t 5Nm. The exhaust resistance of diesel engine should be as small as possible; therefore the exhaust manifold must have sufficient sufficient or area and with bends as few as possible, because the performance of engine will be influenced obviously if the exhaust resistance exceeds a certain value. The sum of the resistances of exhaust main and muffler should not be more than 7.5kPa for natural aspirated engine, and not he more than 5kPa for turbocharged engine. 3. 9. 3 Turbocharging and inter - cooling system Turbocharger: Both turbocharging models and the turbocharging inter - cooling models of the 226B series engine employ the radial flow exhaust turbocharger. See the accessory list for the those models. The oil lubricating and cooling the turbocharger flows into the turbocharger from the main oil passage then directly back into the crankcase. The exhaust turbocharger is a kind of running mechanism at its high speed and high temperature. The immediate halt when the engine is running at high speed and with large load is strictly forbidden. The right way is to decrease the load and the speed gradually and let the engine run idly for another 5 -10 minute so as to avoid any damage to the turbocharger bearing. After the turbocharger is disassembled, some clean engine oil should be put at the oil inlet during the mounting process. Charging air cooler (intercooler) The temperature will go up after the air goes through the turbocharger and gets pressured. The intercooler of the 226B turbocharging inter - cooling engine features: air - air cooling. Is used to lower the pressured intake air temperature. Air - air cooling intercooler ( delivered conforming with the contract) , generally speaking, is assembled together with the circulating water radiator, cooled by fan. The intercooler be placed at the hack of the radiator. The intercooler could also be placed in line with the radiator, determined by the overall fitting mechanism. The maximum acceptable flow resistance ( supercharger to intercooler/ intercooler to engines) then the pressured air from the supercharger is passing through the pressure pipe should be less than 2kPa. The flow resistance while going through the intercooler should be less than 5.0 - 5. 5 kPa. So the limit value of the total resistance when the pressured air is passing through pressure pipe and intercooler is 7. 0 - 7. 5 ( kPa) , 3. 10 Electrical system The system is consisted of starter, chargeable generator, control instrument and storage battery. The service voltage is 24V or 12V, subject to the choice of the customers. Starter: the starter is a DC motor controlled by electromagnetism. Without specific requirement, the rated power is 4kW or 6kW at the working voltage of 24V and 2. 7kW or 4kW at the working voltage of 12V. Generator: The generator is a kind of silicon rectifying generator equipped with transistor adjuster. The rated voltage is 28V or 14V. The generator is connected paralleled with the storage battery. The generator is self - excited when working. Flame preheating unit ( OPT) :the unit is a cold - starting auxiliary equipment used in cold weather and is composed by temperature sensor, solenoid valve,flame preheating plug, electronic control device and preheating indicator fitted to water outlet pipe ( principle diagram shown in fig27) . The fuel enters preheating plug from the low pressure fuel delivery pipe and is ignited by electric heating ,and the flame enters air inlet pipe and heats the air . The process is perform automatically by control system. The unit controls automatically the glowing time and flame preheating time of the preheating plug according to the ambient temperature. The drive can start the engine after the preheating indicator give out signal. The fuel filter of diesel engine can filter out the harmful impurities and moisture in the fuel system, protect the normal work of the engine, reduce wear and tear, avoid clogging and improve diesel engine life. Here, we are willing to share the basic working principle of diesel engine fuel filter. Basic Working Principle of Diesel Fuel Filter The purpose of any diesel fuel filter is to remove foreign particles as well as water. The use of a suitable filtration system on diesel engines is a must to avoid damage to closely fitted injection pump and injector components. Filter's ability varies between the type and manufacturer. On diesel engines primary and secondary filters are used. The primary filter is capable of removing dirt particles down to 30 microns and the secondary filter between 10 to 12 microns. Secondary filters are available between 3 and 5 microns, which are used in severe service operations. The primary filter is usually located between the tank and the supply pump, the FWS is one type of the primary filters. The secondary filter between the supply pump and the injection pump. Diesel fuel filter is referred to as full-flow filter, because all the fuel must pass through it before reaching the injection pump. Some filters use internal replaceable element inside a bowl or shell. These are commonly referred to as a shell and element design. Most fuel filters used today are of the spin-on type, which allow for faster change out since the complete filter is a throwaway. Besides, if the filter is installed on the pressure side of the boost pump it must have sufficient strength to handle pump pressure without bursting or leaking. The filter must be located well away from sources of heat, preferably outside of the engine compartment. Components The fuel filter of diesel engine is mainly composed of three parts: filter element, the shell and filter base (As shown in Figure 1). All models are universal except for the overflow valve 8 that has two structures. Choosing C0810A or C0810B filter should be on the basis of different models. For the 12 cylinder V type diesel genset, it should be installed in parallel with each one of C0810A and C0810B. The fuel is sent to the fuel filter mainly by the fuel pump. The impurities in the fuel will be cleared through the paper filter element. And then the fuel can enter the inner cavity of the filter cylinder. Through the collection chamber of the filter sea, it leads to the fuel injection pump. The filter holder is equipped with fuel return fitting and the overflow valve is also installed inside. When the fuel pressure in the fuel filter is more than 78kPa(0.8kgf/C㎡), the excess fuel will return back to the fuel tank from the fuel return fitting. When connecting the low pressure fuel line, you should connect it according to the arrow pointing direction on the socket to avoid connection error. The filter seat and the shell are connected by pull rod, and it is sealed by rubber ring. Due to there is a bleeder plug on the top of filter seat, users can release the screw to clear the air of the fuel filter in use. The fuel filter of the diesel engine is fixed on the engine body and bracket with two M8-6H screws. If users find that the fuel supply is not smooth, it is possible that the filter element is pluged. At the moment, you should dump the fuel oil. You can directly loosen the pull rod nut of diesel generator set, remove the shell, and take out the filter cartridge (As shown in Figure 2). After the filter element is dipped into gasoline or diesel oil, you can gently wash the dirt off with brush (As shown in Figure 3). If the filter cartridge is broken or hard to clean, it must be renewed. Then install it as shown in Figure 1 and inject the clean fuel. The basic working principle of fuel filter for diesel engine mentioned above is share by Jiangsu Starlight Electricity Equipment Co.,Ltd. Hope it is useful for all users. Besides, our company can provide a variety of specifications common from 3KW to 2500KW, automated, four-protection, automatic cut over, low noise and mobile and so on high quality, and the low energy consumption generator set so as to satisfy the customer all electric power demand. We can also satisfy the user different voltage, different frequency request, as well as many units and networking power supply system. What Should be Considered When Purchasing a Generator Set When purchasing a generator set, you should consider the genset purpose, performance, loading capacity & variation range, and automation. The detailed information are as follows: 1. Purpose: Diesel generator set is usually divided into three types including standby, commonly used and emergency diesel generator set. The requirement is different for different purposes. 2. Loading capacity: You should choose loading capacity and variation range according to the different uses so as to determine the genset capacity and standby capacity. 3. Automatic function: Whether it can be fulfiled with the mains automatic switch during a power failure. Avoid the traps when purchasing a diesel generator set. 1. Avoid the generator set price is lower than the market when buying a diesel generator set. In general, the low price units have problems more or less. Be alert whether it is a refurbished genset. 2. Specify the generator with accessories in the contract, such as tank, oil pipe, and storage battery (battery specification, capacity and quantity), etc. 3. Avoid purchasing the diesel genset (Commonly known as four protection) without protection. When buying, check whether the genset instrument is comprehensive and the units equip with a air switch or not. Besides, avoid buying such diesel engine which power is lower than the alternator for the unit configuration. Diesel engine power is equal or higher 10% than the generator power in the industry due to the mechanical loss. 4. Confusion relationship between KVA and KW. Take KVA as KW and exaggerate the power to sell to customers. Actually, KVA refers to apparent power, KW refers to the effective power. The relationship between them is 1KVA=0.8KW. Usually, imported units are expressed by KVA and the domestic electric equipments are expressed by KW. However, the bad manufacturers usually take standby power as normal power to sell to customers. They just talk about one power and ignore the relationship between normal power and standby power. Actually, standby power = 1.1 normal (Rated) power. Moreover, standby power can only be used for 1 hour in continuous operation for 12 hours. When you are going to buy a diesel generator set, you should inquire the salesman and know the generator unit is expressed by KVA or KW. What should consider before buying? 1. Before buying, be clear what power you want to buy, what size you want to buy, the diesel generator set you want to buy is for industrial or home use, and what brand of generator set you wnat to buy, etc. 2. Inquire the salesman whether the diesel generator set is made by manufacturer not from the brokers or distributors. This is quite important since some bad manufacturers pretend to be genuine manufacturers and sale the diesel generators to customers. So it is necessary to go to their factory to observe and study, check whether it is real. 3. Besides, it is important to know about the warranty duration. In general, the warranty typically ranges from one year to five years depending on the generator set type. The warranty for residential and industrial genset is different. 4. Whatever types of generator set you are going to buy, you should know about the brand and history of the generator set. For example, Cummins, Volvo, Perkins, etc. Any diesel generator set can't be independently accomplished by an enterprise. Only by having a comprehensive understanding of the genset including diesel engine, generator, control cabinet and brand, can you evaluate the unit level synthetically. Indeed, there are many factors you should consider when buying a diesel generator set. The above important factors are provided by Jiangsu Starlight Electricity Equipment Co.,Ltd. Hope it can help you. Our company is one of earlier diesel generator and generator manufacturers in China. Starlight shall follow the philosophy to meet customer's demands and offer customers the genunine spare parts, technical consulting and installation guide, make equipment commissioning free of charge, rebuild generation set and train the person. Cooling System of Cummins NTA Series Engine Chong Qing-Cummins engines have small volume. light weight, low fuel consumption, high power and reliable work, and the spare parts supply and maintenance is convenient. The engines adopt electronic governor, with protection functions such as alarm and automatic parking for too high temperature in the cooling water, too low oil pressure or too speed. This article will guide you to learn the details of CCEC Cummins NTA Series engine’s lubricating system, cooling system and air system. Interested? Then continue reading. Lubricating System Chong Qing-Cummins engines are pressure lubricated, pressure is supplied by a gear-type, lubricating oil pump located in oil pan or on side of the engine. A pressure regulator is mounted in the lubricating oil pump to control lubricating oil pressure. Filters and screens are provided in lubricating oil system to remove foreign material from circulation and prevent damage to bearings or mating surfaces. A by-pass valve is provided in full-flow oil filter head as insurance against interruption of oil flow by a dirty or clogged element. Maximum cleansing and filtration is achieved through use of both by-pass and full-flow, lubricating oil filters. Full-flow filters are standard on all engines; by-pass filters are used on all turbocharged models and optionally on all other engines. Turbochargers are lubricated and cooled by same lubricating oil used for engine lubrication. Fuel pumps and injectors are lubricated by fuel oil. N/NT(A) Engines Oil is drawn into the pump through an external oil line connected to the oil pan sump. A screen in the sump filters the oil. Oil is drawn from the pan by the pump, out through a full-flow or compo filter and circulates back into the block. The filter may be mounted directly to the oil cooler or remote mounted. External lines are used for remote mounting arrangements. An oil header drilled length of block, fuel pump side, delivers oil to moving parts within the engine. Oil pipes carry oil from the camshaft to upper rocker housings and drillings through the block, crankshaft, connecting rods, and rocker levers complete the oil circulating passages. Another oil header drilled the length of the block on exhaust manifold sode, supplies oil to six spray nozzles used for piston cooling. Cooling System Water is circulated by a centrifugal water pump mounted either in or on the front of the engine belt driven from the accessory drive or crankshaft. Water circulates around wet-type cylinder liners, through the cylinder heads and around the injector sleeves. The injector sleeves, in which the injectors are mounted, are designed for fast dissipation of heat. The engine has a thermostat or thermostats to control the engine operating temperature. The engine coolant is cooled in a heat exchanger or keel coder. Sea water is circulated through heat exchanger by the raw waler pump, mounted on front of engine, and discharge through connections on the heat exchanger. The Fleetguard Water Filter is standard on Chong Qing-Cummins Engines. The filter by-passes a small amount of coolant from the system via a filtering and treating element which must be replaced periodically. NTA Aftercooled Engine Water flows from the heat exchanger into the cavity of the water pump, where the water flow splits. One portion circulates to the cylinder block water header around wet type cylinder liners, through the cylinder head and around the injector sleeves, upwards to the water manifold, to the thermostat housing. At the rear of the block water header, the water is directed to the after-cooler. Water flows forward through the aftercooler to the water crossover to the thermostat housing. The second portion of water flows from the cavity of the water pump housing through the oil cooler and tubing to the rear of the water manifold forward to the thermostat housing, to control engine temperature. Cooling Systems of Cummins generator set 1) Air inlet should be set on the ends or both sides of generators, with the area 2.2 times greater than the tank area. 2) The air outlet area should be 1.5 times of water tank area, and the shutters and wind wall should be installed at the air outlets. 3) Flexible duct flanges are used to connect to the water tank, so as to absorb displacement and vibration of the units and prevent the spread of noise. 4) Hot air must be vented to the outside of the chamber through the air duct, and the duct area should be smoothly transitted from small to large values. If there are curves in the air ducts, the guide plate must be installed in order to reduce the pressure loss. 5) When the environment temperature is higher than the design temperature, we should consider using it by reducing the power. Air System The diesel engine requires hundreds of gallons of air for every gallon of fuel that it burns. For the engine to operate efficiently, it must breathe freely; intake and exhaust systems must not be restricted. The intake air should always be touted through an air cleaner. The cleaner may be mounted on the engine or equipment and may be either oil path, paper element or composite type depending upon engine application. Air is routed from the air cleaner directly to the intake air manifold. NTA Aftercooler An aftercooler (or intercooler as it is sometimes called) is a device in the engine intake system designed to reduce intake air temperature and preheat intake air temperature. The aftercooler consists of a housing, used as a portion of the engine intake air manifold, with an internal core. The core is made of tubes through which engine coolant circulates. Air is cooled or heated by passing over the core prior to going into the engine combustion chambers. Therefore, improved combustion results from better control of the intake air temperature cooling or warming as applied by the aftercooler. Turbocharger The turbocharger forces additional air into the combustion chambers so the engine can burn more fuel and develop more horsepower than if it were naturally aspirated. In some cases the turbocharger is used for the engine to retain efficiency (balanced fuel to air ratio) at altitudes above sea level. The turbocharger consists of a turbine wheel and a centrifugal blower, or compressor wheel, separately encased but mounted on and rotating with a common shaft. The power to drive the turbine wheel – which in turn drives the compressor – is obtained from the energy of the engine exhaust gases. The rotating speed of the turbine changes as the energy level of gas changes; therefore, the engine is supplied with enough air to burn fuel for its load requirements. The turbocharger is lubricated and cooled by engine lubricating oil. Panel Mounted Governor Control Adjustments The panel mounted governor control has four potentiometers for making system adjustments. These components are mounted on the control which is located inside the engine instrument panel or generator control panel. NOTE: When a two bearing generator or a single bearing generator with a flexible drive between the flex discs and shaft (eg. Kohler 4T10 generators. Models 230ROZ, 250 ROZ and 275ROZ) is installed, use a remote mounted control. If the engine is not stable after the gain adjustment is made, install a jumper wire between terminals A and B. The gain control is a one-turn potentiometer. It is used to adjust the sensitivity of the governor. A clockwise rotation of the potentiometer dial will shorten the response time of the governor to load changes. Refer to the glossary for the gain drescription. The droop control is a one-turn potentiometer. It is adjustable for zero % (isochronous) to five % speed droop. Counterclockwise rotation will decrease the speed droop. The idle speed controi is a 20-turn potentiometer for adjusting the idle speed. A clockwise rotation will increase the idle speed. The run speed control is a 20 turn potentiometer for setting the desired no-load governed speed. A clockwise rotation will increase the run speed. An idle-run switch, located on the engine instrument panel, allows the selection of the idle or run mode. Also located on the engine instrument panel is the Speed Adjust potentiometer which is used for fine speed ajustment after Run Speed, Droop, and Gain have been set. The panel mounted governor control wiring. Caution: Measure the voltage on the engine control circuit board terminal strip and not on the control terminal strip. If two terminals on the control terminal strip are shorted, it can damage the control unit. Preliminary Adjustments The idle speed potentiometer adjustment. 1. Turn the screw counterclockwise 20 turns. 2. Turn the screw clockwise 10 turns. 3. This will set the idle speed potentiometer to its mid position. The run speed potentiometer adjustment. This will set the run speed potentiometer to its mid position. (Firs and second points are same to idle speed.) Turn the gain potentiometer adjustment to midposition or 50. The droop potentiometer adjustment. 1. Turn the potentiometer fully counterclockwise for isochronous operation. 2. Turn the potentiometer to approximately 40 for 3 percent droop. 3. Turn the potentiometer to approximately 80 for 5 percent droop. Adjust any remote speed potentiometers to the center of their adjustment range. Governed Speed Adjustment Place the idle-run switch on the engine instrument panel in the idle position. NOTE: Open the main line circuit breaker while the engine is at idle. Start the engine. Adjust the idle speed potentiometer the governor control until the engine i:s running at 600 to 650 RPM. Adjust the run speed potentiometer on the governor control until the no load speed is correct. NOTE: Close the main line circuit breaker. Droop Adjustment Isochronous Operation For isochronous operation, the droop potentiometer must be turned fully counterclockwise and will not require any further adjustment. Gain Adjustment Close the main line circuit breaker and apply approximately 1/4 of the rated load. Make sure the engine speed is constant. If the engine speed is constant, turn the GAIN potentiometer clockwise slowly until the engine speed is not constant. 1. Slowly turn the potentiometer counterclockwise until a constant speed is achieved. 2. Turn the potentiometer counterclockwise an additional 1/2 division. Fine Speed Adjustment After the gain adjustment is made, the full load governed engine speed may require a minor adjustment to equal the desired speed (i.e. 60 Hz, 1800 RPM or 50 Hz, 1500 RPM). Use the SPEED ADJUST potentiometer on the engine instrument panel for fine speed adjustments of less than ±100 RPM. System Adjustment Remote Mounted Governor Control Follow the panel mounted governor control instructions for setting the governed speed, idle, droop and gain on the remote mounted control. The wiring for the remote mounted control is shown. Caution: Do not attach the battery negative to Terminal Number 11. The control circuitry will be damaged. NOTE: When a two bearing generator or a single bearing generator with a flexible drive between the flexible drive between the flex discs and shaft (eg. Kohler 4T10 generators, Models 230ROZ, 250 ROZ and 275 ROZ) is used, install a jumper between terminals A and B. This jumper provides additional stability in the governor control. The oscillation frequency of the coupling between the engine and the generator can cause the governor control to react to this oscillation in addition to a change in engine speed. Caution: Measure the voltage of the panel mounted governor control on the printed circuit board terminal strip. Do not measure the voltage on the control terminal strip. Notes For Auto-Synchronizer 1. The "Gain Range" is changed by adding a jumper between Terminals 6 and 14. No jumper 6 to 14: Auto-Synchronizer is set for fast responding engines. With jumper 6 to 14: Auto-Synchronizer is set for slow responding engines. 2. a. Closing a contact or jumpering 11 to 12 allows the Auto-Synchronizer to perform as a sync check relay only, with circuit breaker contact output but no control on the incoming generator. b. Closing a contact between 12 to 13 allows the Auto-Synchronizer to perform as a speed matching unit. The speed and phase of the incoming generator are controlled and contact is closed to drive circuit breaker. Once the circuit breaker is closed, the contact between 12 and 13 should be opened. c. Open contacts or no jumper 11 to 12 or 12 to 13 allows the Auto-Synchronizer to still sense any error but it does not provide any control or contact closures. 3. Phasing of voltage potential to the Auto-Syncrhonizer is necessary to keep each signal in its correct phase relationship. If the generator voltage is not the same as the voltage rating of the Auto-Synchronizer, step-down transformers are required. Correct phasing of the transformer leads is necessary. Step-down transformers require a nominal 10 VA/PHASE for the GEN. input to the Auto-Synchronizer and 7 VA/PHASE for the BUS input to the Auto-Synchronizer. Volvo engine is equipped with a 2-pole electrical system and an alternator. System voltage is 24V. WARNING! Always stop the engine and break the current using the main switches before working on the engine. Main switch IMPORTANT! Never disconnect the current with the main switches when the engine is running, the alternator and electronics could be damaged. The main switches must never be switched off before the engine has stopped. If the circuit between the alternator and the battery is disconnected when the engine is running, the alternator and electronics can be damaged. For the same reason the charging circuits must never be re-connected with the engine running. Electrical Connections Check that electrical connections are dry, free from oxide, and that they are securely tightened. Battery, Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries. Always use protective goggles and gloves. If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, flush immediately with plenty of water and obtain medical assistance without delay. Connecting and disconnecting the battery Connecting 1 Connect the + cable (red) to the + pole on the battery. 2 Connect the – cable (black) to the – pole on the battery. Disconnecting 1 Remove the – cable (black). 2 Remove the + cable (red). Cleaning Keep the batteries clean and dry. Contamination and oxide on the batteries and battery poles can cause stray currents, voltage drop and discharge, especially in wet weather. Remove oxidation from the battery poles and terminals, using a brass brush. Tighten the terminals securely and grease them with terminal grease or petroleum jelly. Filling The electrolyte level should be 5–10 mm (0.2– 0.4”) above the cell plates in the battery. Top up with distilled water as required. After filling, the battery should be charged for at least 30 minutes by running the engine at idle. Some maintenance-free batteries have special instructions, which must be followed. Battery, Charging WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries. Always use protective goggles and gloves. If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, flush immediately with plenty of water and obtain medical assistance without delay. IMPORTANT! Observe the instruction manual for the battery charger carefully. To avoid the risk of electrochemical corrosion when an external charger is connected, the battery cables should be removed from the batteries before the charger is connected. Always switch off the charging current before the charging clips are removed. • Charge batteries if they have become discharged. During charging, unscrew the cell plugs but leave them in the plug holes. Ventilate well, especially if the batteries are charged in an enclosed space. • If the engine is not used for a longer period of time, the batteries should be fully charged, then possibly trickle charged. Refer to the battery manufacturer’s recommendations). Batteries are damaged by being left discharged, and can also freeze and burst more easily in cold weather. • Special instructions apply to boost charging. Boost charging can shorten battery life, and should therefore be avoided. Storage To prevent the engine and other equipment from being harmed during long (2 months or more) periods out of service, it must be conserved. Because it is of utmost importance that the conservation be performed correctly, we have compiled a checklist covering the most important points. Before taking the engine out of service for long periods, it should be checked by a Volvo Penta dealer for possible need of overhaul or repair. CAUTION! Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance and service operations in a safe and correct manner. WARNING! Conservations oils can be flammable and dangerous to inhale. Ensure good ventilation. Use a protective face mask when spraying. IMPORTANT! Remember the following must be considered when cleaning with a high-pressure water jet: Never point high pressure water jets directly at seals, rubber hoses or electrical components. Never use the high-pressure function when washing the engine. • For up to 8 month’s stoppage: Change the oil and oil filter on the engine, then run the engine until warm. More than 8 month's stoppage: Conserve the lubrication and fuel systems with conservation oil. Refer to the section Conservation of the lubrication and fuel systems for more than 8 months’ stoppage. • Make sure the coolant has adequate antifreeze properties. Top up as necessary. Alternatively, you can drain the coolant (also drain the coolant filter). • Drain any water and contamination from the fuel filters and fuel tank. Fill the fuel tank completely, to avoid condensation. • Disconnect the battery cables, clean and charge the batteries. Trickle charge the batteries while the equipment is in storage. A poorly charged battery can freeze and burst. • Clean the outside of the engine. Do not use a high pressure washer for engine cleaning. Touch up paint damage with Volvo Penta original paint. • Check and rust-proof any control cables. • Put a note on the engine with the date, type of conservation and the conservation oil used. • Cover the air filter, exhaust pipe and engine if necessary. Bringing out of storage • Remove any covers from the engine, air filter and exhaust pipe. • Fill the engine with the correct grade of oil into the engine, as necessary, refer to Technical Data, Lubrication System. Install a new oil filter if the filter was not changed during conservation. • Install new fuel filters and bleed the fuel system. • Check the drive belt(s). • Check the condition of all rubber hoses, and retighten the hose clamps. • Close the drain taps and install any drain plugs. • Check the coolant level. Top up as necessary. • Connect the fully charged batteries. • Start the engine and warm it up at fast idle with no load. • Check that no oil, fuel or coolant leakage occurs. Diesel generator battery is the power supply equipment for starting electrical machinery operation. When the diesel engine is started, it is required that the battery can supply low voltage and high current (200~600A) for starting electrical machinery in a short time. When the diesel engine is in low speed or parking, the voltage output by generator is insufficient or stops working, the storage battery can supply the electric current for the electrical equipment of the diesel engine. What is the function of the Battery? The Battery is the storage device for the energy supplied by the battery chargers. It stores this energy by converting the electrical energy to chemical energy and then to electrical energy. It supplies power to the cranking motor to start the engine. It supplies the extra power necessary when the engine's electrical load exceeds the supply from the charging system. It also acts as a voltage stabilizer in the electrical system, where it evens out voltage spikes and prevents them from damaging other components in the electrical system. It can be seen that the storage battery plays an important role in diesel generator. For the battery maintenance, how much do you know? 1. When the storage battery is in use, it must be installed firmly. Make sure the wiring clip keeps a good contact with the battery terminal. To avoid oxidation of the wiring terminal, its surface should be covered with a thin layer of butter. 2. In general, the wiring terminal of the storage battery is marked with “+” or “-“ symbol. If there is no marking, you can use the multimeter to measure the polarity of the battery. 3. The starting time of diesel engine is not allowed to exceed 10 seconds. Besides, the interval time must be controlled more than 2 minutes when booting second time. Avoid the battery continuous discharge time is too long that will make the pole plate out of shape due to overheating, which will result in short circuit or active material shedding and reduce the capacity of the storage battery. 4. Inspect the exhaust hole on the sealing cover which must be kept unblocked at any time to prevent blocking to cause the battery burst. 5. Regularly inspect the battery electrolyte level, generally, it is higher than the pole plate top surface 10-15mm. If you find it is abnormal, you should adjust to use dilute sulphuric acid or distilled water. (River water, well water and concentrated sulfuric acid are not allowed to use.) 6. Keep the battery surface clean. If there is dust or acid liquor, you should timely clean it with distilled water or pure water. 7. When the battery is used for a long time, the internal electrolyte is missing, you should timely add distilled water inside the battery to prevent pole plate oxidation, otherwise, it will influence battery capacity. 8. When the diesel engine is not working for a long time, you should periodically start the engine to charge the battery or charge the battery with a special charger. 9. When the battery is charged, the sealing cover should be screwed off. The positive and negative electrodes of the charger should be respectively connected with the positive and negative electrodes of the battery. Generally, the charging method of the battery is divided into two types: constant current charging and constant voltage charging. 10. When using the battery in cold area, you should pay attention to thermal insulation. In addition, you should properly increase electrolyte specific gravity to prevent freezing. When the ambient temperature is below -40°C, the electrolyte density should be increased to 1.30-1.32 (The measured value at 20°C).
12. If you find the battery separator and battery cover are damaged, it shall be repaired or replaced by a professional unit. |
作者
dieselgenerator 存档
July 2022
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