Generator Installation Rules and Precautions

Preparation before the unit starts:

1. Check the oil level of lubricating oil, coolant level and fuel quantity;
2. Check whether there is oil leakage or water leakage in each pipeline and joint of the oil supply, lubrication, cooling and other systems of the diesel engine;
3. Check whether the electrical circuit has potential leakage such as broken skin, whether the electrical circuit of the ground wire is loose, and whether the connection between the unit and the foundation is firm;
4. If the ambient temperature is lower than zero, a certain proportion of antifreeze must be added to the engine radiator;
5. When the diesel generator set is started for the first time or restarted after being stopped for a long time, the air in the fuel system should be exhausted by the hand pump first.

Start up:

1. After closing the insurance in the control box, press the start button and press the button for 3~5s. If the start is unsuccessful, wait for about 20s to start again. If multiple starts are unsuccessful, stop the starting operation, remove the battery voltage or oil circuit and other fault factors, and start again;
2. The oil pressure should be observed when starting up. If the oil pressure is not displayed or is very low, it should be stopped immediately for inspection.
run:
1. After the unit is started, check the parameters of the control box module; oil pressure, water temperature, voltage, frequency, etc.;
2. Under normal circumstances, the speed of the unit will directly reach the rated speed after the unit is started; for units with idle speed requirements, the idle speed time is generally 3~5min, and the idle speed time is not too long, otherwise it may burn out the related components of the generator;
3. Check the oil circuit, water circuit and electrical leakage of the unit;
4. Check the fastening of each connection of the unit to see if there is looseness and severe vibration;
5. Observe whether the various protection and monitoring devices of the unit are normal;
6. When the speed reaches the rated speed and the parameters of no-load operation are stable, switch on the power supply;
7. Check whether the parameters of the control panel are within the allowable range, and check the vibration of the unit again, whether there are three leaks and other faults;
8. Overloading is strictly prohibited when the unit is running.

Normal shutdown:

The brake must be opened before shutdown. Generally, it needs to run for 3~5min to stop after unloading.
Emergency stop:
1. When an abnormal situation occurs in the operation of the generator parts, it must be stopped immediately;
2. During emergency stop, press the emergency stop button or push the fuel injection pump stop control handle to the stop position quickly.

Maintenance matters:

1. The replacement time of the diesel filter element is 300H; the replacement time of the air filter element is every 400H; the replacement time of the oil filter element is 50H for the first time, and 250H after that.
2. The first oil replacement time is 50H, and the normal oil replacement time is every 250H.
Operating procedures
1. Before starting, check whether the fuel volume of the fuel tank is sufficient, and there is no oil leakage at each oil pipe and joint; whether the water volume of the cooling system is sufficient, clean, and free of leakage, and whether the fan belt is properly tightened. Check that the internal combustion engine and the transmission part of the generator should be connected reliably, the wires of the output line are well insulated, and the instruments are complete and effective.
2. After starting, it should be operated at low speed for 3 to 5 minutes, and the operation can be started only after the temperature and oil pressure wheel are normal. The generator should have no abnormal noise during the speed-up, the brushes on the slip ring and the commutator are in good contact, and there should be no jumping and sparking. After the operation is stable and the frequency and voltage reach the rated value, the power can be supplied to the outside.
3. When abnormal noise, odor, sharp rise in water temperature and sharp drop in oil pressure occur during operation, stop the machine immediately to check and troubleshoot.
4. The power factor of the generator shall not exceed 0.95 of the late phase (lag). The variation range of the frequency value shall not exceed 0.5HZ.
5. Before shutdown, cut off the main switch of each power supply shunt, gradually reduce the load, then cut off the main switch of the generator power supply, return the excitation rheostat to the maximum resistance position, reduce the voltage to the minimum value, and then cut off the excitation switch and the neutral The grounding switch is turned on, and finally the internal combustion engine is stopped. 

Proper use and maintenance of the generator set can extend the life of the generator set:

Preparations before starting:

1. The computer room operators should abide by the safety operation rules, wear work clothes and insulating shoes, and the crew members should have a clear division of labor;
2. Check whether the anti-railing cover of the flywheel and generator is in good condition;
3. Check the gearboxes, clutches, governors, oil levels, and fasteners, etc., and confirm that they are in good condition and the oil and water temperature is not lower than 20 degrees before starting;
4. Set the gates of each system pipeline in the "working" position;
5. Check the link bolts of the transmission mechanism and fasten them well;
6. Check whether the clutch handle pressure is normal and whether the overspeed safety device is positioned;
7. Check whether the pressure of the gas cylinder is normal and whether the overspeed safety device is positioned;
8. Open the drain valve of the air pump;
9. Check whether the circulating engine water pump, oil pump and fuel pump are normal;
10. Set the excitation resistance to the maximum resistance position, and disconnect the power transmission switch.

Start and run operations:

1. For the unit that has been shut down for more than 24 hours, the test valve must be opened first, and the oil pump must be started. For units that have been shut down for more than 7 days, the insulation resistance of the exciter and operating circuit should be measured, which must meet the requirements;
2. Start the fuel pump, release the air in the pipeline, and observe whether the voltage is within the specified range. If it is normal, the official start-up can be carried out;
3. Check whether the voltage of the starting power supply meets the requirements. If the voltage is normal, press the start button and release it after the diesel engine runs normally;
4. After the diesel engine is running, observe the indicated value of the oil pressure gauge. When it rises above the specified value, stop the oil pump, close the drain valve of the scavenging pump, and thread the front clutch screw;
5. When the generator starts, it is considered that the generator and all electrical equipment are charged, and the human body should not touch the live parts;
6. After the generator is started, the speed of the diesel engine should be gradually increased, and the inspection before power transmission should be carried out;
7. Gradually adjust the speed of the diesel engine, but pay attention to observe whether the generator is running normally when adjusting. When normal, the brushes on the collector ring and the commutator should have no jumping, no sparks, and no abnormal noise;
8. Adjust the output voltage and frequency of the generator, the voltage value should be stable and reach 380v+-10v, and the frequency should reach 50Hz+-0.5Hz

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