Hyundai Diesel Generator. Manual - part 2

User manual

General Introduction

1.1

Brief Introduction

HYUNDAI  series  diesel  engine  generator  sets  is  the
core  products  of  HYUNDAI  Power  Equipment
Manufacturing  Co.,Ltd.  Thanks  to  their  good
performance,  the  generator  sets  are  widely  used  in
the  fields  of  construction,  communication,  banking
business,  mining,  leasing  industry  and  other  special
sites. As what you are expecting, HYUNDAI generator
sets endeavor to meet your needs for the concept of
individual  design  through  the  excellent  features  of
more  safe,  more  reliable  and  more  clean.  The
generator  sets  provided  by  HYUNDAI  Power  is
reliable and professional. The advantage of low noise
level,  energy  conservation,  and  stable  performance
has made a credible assurance for many enterprises.
Our  generator  sets  supply  the  following  power
service:
Continuous service
Used as main power supply to generate electricity for
several purposes: motion force, lighting, heating etc.
The generator sets can continue running and allow 10%
over load for 1 hour per 12 hours under variable load,
which is used for remote area.
Standby service
Used  as  standby  power  supply  to  provide  continue
electric power for non‐invariable loads. The generator
set  is  suitable  for  the  area  where  must  ensure
continue  power  supply,  such  as  hospitals,  industrial
facilities, airports etc. Keep the generator set standby
state  at  any  time  and  start  to  run  when  the  mains
supply is abnormal.
Emergency service
Used  as  auxiliary  power  supply  to  solve  energy
interruptions  that  may  cause  serious  problems  to
people,  physical  and  /or  financial  damage  or  to  face
consumption  peaks.  The  generator  set  can  start  in
short  order  to  provide  steady  electric  power  for  the
loads when the mains supply happen abnormity, and
switch  to  stop  after  the  mains  supply  becomes
normal.  Generally  the  generator  set  continues
working for several hours.

1.2

Generator Set Main Parts Specifications

NO NAME

1 CONTROL PANEL

2 BUSBAR PANEL

3 LIFTING LUG

4 BASEFRAME FUEL TANK

5 ENGINE

6 BATTERY

7 RADIATOR

8 ALTERNATOR

9 FUEL DRAIN OUTLET

10 FUEL LEVEL SENSOR\

11 ABSORBER

1.3

Diesel Engine

According to different output power of the generator
sets, and combine with the advantage of each model
of diesel engine in a specific range of power output,
HYUNDAI Power chooses the engines with first class
performance and high reliability. And furthermore,
HYUNDAI Power pay special attention to the

User manual

technical advantage of engines in the aspects of
reducing exhaust gas, decrease fuel consumption
rate and good noise level control.

1.4

Alternator

All of the alternators chosen by HYUNDAI Power are
single  bearing  self‐excitation  brushless  alternators
with  the  attributes  of  international  top  brand.  By
citing  Stamford  alternator  as  an  example,  we  can
illustrate the features of our alternators as follows:
◆Four  polar  brushless  self‐excitation,  single  bearing,

insulation class is H and protection level is IP22.

◆Stators are wound to 2/3 pitch, which can effectively

eliminates triple and curbs waveform deformation of
output  voltage.  When  in  parallel  with  the  mains  or
other  generator  sets,  this  type  of  winding  can
effectively  avoid  excessive  neutral  currents  and
reduces inductive heat.

◆Before being assembled, rotors need to pass dynamic

balance testing. The improved damper reduces
voltage deviation and heat under unstable load.

◆The exciter rotor output is fed to the main rotor

through  a  three  phase  full  wave  bridge  rectifier,  the
rectifier  is  protected  by  a  surge  suppressor  against
surges  caused  by  short  circuit  or  out‐of‐phase
paralleling.

◆ Automatic voltage regulator has the feature of

automatic  load  curtailment  which  is  used  to  protect
the  engine,  and  make  it  possible  to  add  full  load  to
the  alternator  at  one  time.  Steady  state  voltage
adjusting  rate  can  reach  ±1%  (under  certain
requirements, steady state voltage adjusting rate can
meet  ±0.5%).    If  PMG  system  is  chosen,  the  motor
will  have  high  starting  capacity  and  the  ability  of
interference  rejection  for  the  deformed  voltage
waveform  fed  by  the  main  stator  generated  by
non‐linear  load(such  as  silicon  control  DC  electric
motor, UPS etc).

◆ Telephone influence factor TIF<50, telephone

harmonic wave factor THF<2%

，

the brushless style

and high quality AVR ensures low interference with
Radio.

1.5

Cooling System

The engine cooling system is water cooled. The water
cooled system is comprised of a radiator a pusher fan
and thermostat. The alternator has its own internal
fan to cool the alternator components.

1.6

Electrical System

The engine electrical system is 12 volt or 24 volts DC,
negative  ground/earth.  This  system  includes  an
electric  engine  starter,  a  battery  and  a  battery
charging  alternator.  For  DC  12  volts  electrical  system
one battery is given. For 24 volt system two lead‐acid
batteries  are  given.  Other  types  of  batteries  may  be

fitted if they were specified.

1.7

Coupling

Engine and alternator are firmly joined by a coupling
cone that guarantees the proper assembly coaxiality
Single‐support machines are also used a special
flexible disk is used in place of a flexible coupling.

1.8

Fuel Tank and Base Frame

The  engine  and  alternator  are  coupled  together  and
mounted on a heavy duty steel base frame. This base
frame  includes  a  fuel  tank  with  capacity  of
approximately 8 hours operation under variable loads.
The  tank  is  complete  with  filling  cap  and  fuel  level
gauge and is connected by flexible joints to the intake
piping  and  to  the  overflow  piping  containing  fuel
from  the  injector  drain.  Big  capacity  generator's  fuel
tank is separate from generator set.

1.9

Control Panel

All  models  of  HYUNDAI  Power  generator  sets  use
high grade control panel. The core of control panel is
an  imported  digital  diesel  engine  control  module,
which  has  been  facilitated  with  more  complex
functions  such  as  further  monitors,  demonstration,
people‐module  dialogue,  distance  communication
and protection etc.
HYUNDAI  Power  generator  set  control  panel  use
steel  plate  structure,  which  ensures  security  and
reliability, and the surface of it has been treated with
static  powder  painting.  The  outside  appearance  is
beautiful.  Special  lock  has  been  used  to  fix  it.  It  has
been designed for easy maintenance.

1.10

Optional for Canopy Generator Set

1.10.1

External antifreeze adding hole

Our generator sets has been facilitated with external
antifreeze  filling  hole.  When  user  intends  to  add
antifreeze,  He  only  needs  to  open  the  antifreeze
filling  hole  on  the  roof  of  canopy  and  the  radiator’s
pressure  valve  cap  to  directly  add  antifreeze  to  the
hole, and easily watch the anti‐freeze level.

1.10.2

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User manual

Installation

2.1

General Outline

Correct  installation  of  generator  set  is  the
precondition which ensure the normal working status
of the generator set. The working room for generator
set  shall  be  designed  specifically  to  meet  the
expected functions and maintenance operations, and
at the same time the design of generator set working
room  shall  conform  to  local  government’s  laws  and
regulations  on  architecture,  fire  protection  laws  and
other applicable regulations.

2.2

Transportation

During  the  period  of  shipment,  protection  shall  be
made  for  the  generator  set.  In  addition,  the
generator  set  shall  be  tightly  secured  in  the  loading
truck  so  that  to  avoid  any  vibration  during  shipment
which  will  cause  the  generator  set’s  components
loosen  and  even  damaged.  During  the  process  of
shipment  of  generator  set,  no  people  or  other
material  is  allowed  to  place  above  the generator  set
so  that  to  avoid  damage  to  generator  set  caused  by
weight.
When  loading  or  unloading  the  generator  set  to  the
truck, forklift or hoisting device shall be used to avoid
the generator set become tilted or fell to the ground,
which causes damage.
Lifting  holes  have  been  designed  on  the  common
base  frame  of  our  generator  sets.  Some  of  the
specifically  designed  generator  sets  has  been
facilitated  with  lifting  holes  on  the  roof  and  forklift
openings on the base frame etc. Users can transport
the generator set according to the guidance specified
on  the  specific  labels  sticked  on  the  generator  set.
Please do not use the lifting lugs on the engine or on
the alternator to hoist the whole generator set.

2.3

Design for Foundation

The foundation which used to install and fix the diesel
generator set is very important, it must conform to
the following requirement:
◆Have enough hardness and stability, so that to avoid

deformation, which will affect the concentricity of
diesel engine and alternator and other accessory
parts.

◆To support the weight of the whole generator set and

to absorb the dynamic impact caused by unbalanced
force and vibration during engine’s running period.

◆Generator set’s foundation is not allowed to connect

to other architecture’s foundation.

◆ The width and depth of foundation shall meet

requirement.

◆Ensure foundation’s levelness and smoothness.
◆If possible, waste discharge sink can be sued so that

the waste oil can be discharged in a timely manner.
Cable channel for generator power output cable need
to be reserved.

◆Normally, concrete foundation is reliable, simple and

preferable.  When  pouring  the  concrete  foundation,
please make sure the surface of concrete is flat, and
no  scratch  is  allowed.  Gradienter  or  similar
instruments  need  to  be  used  during  installation  of
generator set and its exhaust system.

The  design  of  foundation  can  refer  to  following
calculation  formula:  (below  is  the  diagram  for  diesel
generator set foundation)
1. Generator dimension length × width: L1×W1
2. Foundation dimension length × width: L2×W2
    L2 =L1+400 (mm)
    W2 =W1+400 (mm)
3. B=2×M/ (L2×W2×D)
    B: Thickness of foundation

M: Generator set weight

L2: Length of foundation

W2: Width of foundation

D: Density of Concrete (refer to 2322kg/m3)
(Foundation drawing Refer to APPENDIX A )

2.4

Design for Generator Set Working Room

The installation of generator set shall be designed, so
that  to  meet  the  demand  of  planned  operation  and
maintenance. The complete installation shall conform
to  local  architecture  laws,  fire  protection  laws  and
other  applicable  regulations.  Except  the  above
matters,  there  are  other  matters  needs  your
attention as follows:
◆Ensure diesel engine generator set working room is

furnished with rainproof, sunscreen, and windproof.

◆Ensure diesel engine generator set working room has

good ventilation and good exhaust system, and the
area for ventilation is sufficient, and at the same time
use pipes to let out the hot air generated from the
radiator and prevent the hot air from returning.

◆Ensure the waste gas generated during generator set

running  period  can  be  discharged  to  outside  timely,
and try your best to reduce the adverse effect caused
to  environment.  The  silencer  and  exhaust  pipe  shall
be  supported  by  the  roof,  the  supporter  shall  allow
the  exhaust  pipe  to  expand.  It  is  not  permitted  to
install  the  exhaust  system  directly  on  the  generator
set.

◆ Enough space shall be reserved for the diesel

generator set for convenience of cooling, operation
and maintenance etc. Generally speaking, no foreign
material is allowed to be placed within the area of

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