Hyundai Diesel Generator. Manual - part 4

User manual

The  following  fuel  oil  specification  is  typical.  For  a
specific  engine  refer  to  manufacturers’  data  sheets
for fuel oil details.
Fuel Recommended Physical Properties Feature
Viscosity

1.3 to 5.8 centistrokes (1.3 to 5.8mm per second) at 40°C (104°F)
(ASTM D445)

Cetane Number

40 Minimum above 0°C (32°F) ~45 Minimum below 0°C (32°F)
(ASTM D613)

Sulphur Content

Not to exceed 0.5 mass percent* (ASTM D129 or 1552)

Active Sulfur Copper Strip Corrosion

Not to exceed No. 2 rating after three hours at 50°C (122°F)
(ASTM D130)

Water and Sediment

Not to exceed .05 volume percent (ASTM D1796)

Carbon Residue

Not to exceed 0.35 mass percent on 10 volume percent
residuum (ASTM D524 or D189)

Density

42 to 30° API gravity at 60°F (0.816 to 0.876 g/cc at 15°C).
(ASTM D287)

Cloud Point

6°C (10°F) below lowest ambient temperature at which the fuel
is expected to operate(ASTM D97)

Ash

Not to exceed 0.02 mass percent (0.05 mass percent with
lubricating oil blending) (ASTM D482)

Distillation

The distillation curve must be smooth and continuous (ASTM
D86)

Acid Number

Not to exceed 0.1 Mg KOH per 100 ML (ASTM D664)

Lubricity

3100 grams or greater scuffing BOCLE test or Wear Scar
Diameter (WSD) less than .45mm at 60°C (WSD less than .38mm
at 25°C) as measured with the HFRR method.

Diesel Fuel Property Definition
Ash  ‐  Mineral  residue  in  fuel.  High  ash  content  leads
to  excessive  oxide  build  up  in  the  cylinder  and/  or
injector.
Cetane  Number  ‐  Ignitability  of  fuel.  The  lower  the
cetan  number,  the  harder  it  is  to  start  and  run  the
engine. Low cetane fuels ignite later and burn slower.
This  could  lead  to  explosive  detonation  by  having
excessive fuel in the chamber at the time of ignition.
In cold weather or with prolonged low loads, a higher
cetane number is desirable.
Sulphur ‐ Amount of sulphur residue in the fuel . The
sulphur  combines  with  the  moisture  formed  during
combustion to form sulphuric acid.
Viscosity  ‐  Influences  the  size  of  the  atomized
droplets during injection. Improper viscosity will lead
to detonation, power loss and excessive smoke. Fuels
that  meet  the  requirements  of  ASTM  or  2.0  diesel
fuels are satisfactory with fuel systems.

2.8.2

Fuel tank

Our generator sets provide base frame style fuel tank
for  customer.  The  base  frame  style  fuel  tank  is
installed  with  fuel  tank,  fuel  pipes  and  fuel  level
indicator.  This  fuel  supply  system  does  not  need
customer to make other installations. Customers only
need to add fuel to the base frame.
Users  who  intend  to  self  manufacture  the  fuel  tank
shall  use  stainless  steel  or  steel  plate  to  make  the
backup  tank,  do  not  make  painting  or  galvanization
inside  of  the  fuel  tank  so  that  to  avoid  the  possible
chemical  reaction  between  these  kind  of  materials
and diesel, which may generate the material harmful
to  the  generator  set  and  decrease  the  quality,  Merit
Rating  and  combustion  efficiency  of  diesel.  In
addition, the configuration of fuel tank assembly shall
be as follows:
◆Air ventilation pipe above fuel tank surface
◆Manhole on the top surface of fuel tank
◆Watch window for fuel level
◆Discharge valve at the bottom of fuel tank
◆Ground cable between fuel adding hole and fuel tank
◆Separate  panel  with  holes  between  fuel  supply  area

and fuel return area, so that to reduce heat exchange

◆The end of fuel supply pipe shall be 50mm above the

bottom of base frame so that to avoid the deposit
and water at the bottom of fuel tank being sucked
into fuel supply pipe.

◆Part of the generator sets’ fuel level shall be higher

than the position of fuel injector, so that to avoid fuel
return from fuel injector, which cause start difficulty.

2.7.2

Installation of fuel tank

◆ The position of the fuel tank shall ensure the

maximum suction fuel head is no less than 2 meters.
Suction fuel head of the fuel transfer pump shall be
calculated from the bottom of the fuel tank.

◆The position of the fuel tank shall ensure maximum

return fuel head no less than 1.5 meters. Return fuel
head shall be calculated from the top of the base
frame.

◆The arrangement of the fuel pipe shall avoid the fuel

being affected from the heat elimination from
generator set too much.

◆The maximum temperature of the fuel before fuel

pump shall be lower than 60 degree Celsius.

◆No leakage of fuel and air is allowed in the fuel inlet

and fuel return pipe. This is very important.

◆Hose need to be used to connect generator set with

fuel transfer pipe. If the generator set use soft
connection (through vibration reduction unit), hose
shall be used.

◆When engine’s fuel inlet pipe is above 6 meters and

User manual

below 10 meters, this fuel inlet pipe’s inside diameter
shall  be  at  least  20%  bigger  than  that  of  the  hose
installed  in  this  engine.  Fuel  return  pipe  shall  be
connected  to  the  top  of  fuel  tank.  Don’t  directly
connect it to fuel inlet pipe.

2.7.3

Fuel consumption

The content of diesel plays a very critical role in diesel
engine’s  performance,  life  expectancy  and  the
content  of  discharged  material.  In  order  to  achieve
the  rated  power,  fuel  economy  and  specified
emission  standard,  only  the  fuel  which  refer  to
international  standard  or  national  standard  can  be
used.
The  parameters  of  diesel  fuel  include  low
temperature feature, sulphur content, specific gravity,
water  content  and  foreign  material  content  shall  be
the first priority when user need to choose the quality
of the fuel. Different quality of fuel will directly affect
diesel generator set’s start, lubricating, output power,
discharge, and fuel filter change cycle etc.
Specific  requirement  for  fuel  please  refer  to  engine
operation manual which attached with the generator
set.

Warning:
!  When  you  intend  to  add  fuel  into  the  fuel  tank,

please make sure the generator set has been stopped.
Only  after  the  added  fuel  become  static  for  some
time,  this  generator  set  can  be  started  again.  This
way  to  avoid  the  foreign  material  in  the  diesel  fuel
being  sucked  to  fuel  supply  hose,  which  will  cause
fuel  filter  stuck  and  fail  to  supply  engine  with
sufficient  fuel,  and  in  turn  decrease  the  output
power.

! The malfunction caused by bad quality of fuel does

not belong to the scope of warranty.

2.8

Control system

Our  diesel  generator  sets  has  been  furnished  with
control  panel.  All  of  the  control  panels  choose
imported digital meter as the core of control system
for the generator sets.
◆ Digital  control  panel:  the  generator  set  can  be

controlled locally by manual, and also can be started
or stopped by remote control (controlled by external
signal line) users are required to correctly connect the
signal line to this control panel.(details see the
control panel operation manual)

◆Automatic transfer panel (optional): is the automatic

transfer switch for transfer between generator set
and mains.(details refer to control panel operation
manual)

2.9

Battery

Our  generator  set  standard  configuration  provides
start  battery  as  accessory  parts.  According  to  user’s
different  requirements,  our  company  can  provide
two types of batteries, that is high efficient plumbous
acid battery and maintenance free battery.
If  maintenance  free  battery  is  used,  users  only  need
to connect cables for the battery.
If  plumbous  acid  battery  is  used,  before  being  used,
users  need  to  use  standard  battery  to  electrolyze
primary  liquid.  Untighten  the  battery  cover,  slowly
pour electrolyte into the battery until the electrolyte
level  reach  the  indicating  line  in  the  internal  polar
plates(not allow to exceed this line), then take off the
lable  from  the  battery  cover’s  air  hole  and  close  the
cover. After the electrolyte being added, please don’t
use  it  immediately,  keep  the  battery  in  static  status
for  thirty  to  sixty  minutes.  In  low  temperature
environment,  this  time  period  need  to  be  extended
(use  battery  charger  to  charge  battery  when
necessary)
Users  can  use  the  standard  connecting  cable
attached  with  the  generator  set,  the  red  color  shall
be  connected  to  positive  polar,  black  (or  blue)  to
negative  polar,  correctly  connect  to  the  generator
set’s start motor . Most of the diesel generator sets’
cables  have  been  connected  to  the  engines  before
shipment.

The  energy  storage  capacity  of  the  start  battery  will
determine  if  the  diesel  engine  generator  set  can
smoothly  start  in  a  specified  period.  During  the
process  of  generator  sets  running,  the  charging
alternator  installed  in  the  engine  will  continuously
charge battery to start battery.

Warning:
! Please ensure the connection for positive and

negative polar is correct. Wrong connection will
cause malfunction! (Wrong connection will surely
cause damage to the charging alternator)

! When generator set is running, battery cables are not

allowed to be cut down!

User manual

2.10

Electrical Connection

Only  full  qualified  and  experienced  electrical
technicians  should  carry  out  electrical  installation,
service and repair work.

Warning:
!  Make  electrical  connections  in  compliance  with

relevant electrical codes, standards or other
requirements.

2.10.1

Cabling

Due  to  movement  of  generating  sets  on  their
vibration mounts, the electrical connection to the set
should  be  made  with  flexible  cable.  The  cable  must
be  suitable  for  the  output  voltage  of  the  generating
set  and  the  rated  current  of  the  set.  In  determining
the  size,  allowances  should  be  made  for  ambient
temperature.  Method  of  installation,  proximity  of
other cables, etc. All connections should be carefully
checked for integrity.
Current carrying capacity of power cables that will be
given  in  APPENDIX  A.  On  the  other  hand,  there  is  a
one more important point while cable cross sections
are being selected. If the distance between load and
generator  is  too  length,  voltage  falling  at  the  load
side  can  be  too  much  at  the  transient  current
duration.  The  voltage  drop  across  a  cable  can  be
determined as follows:



1000

)

Xsin

Rcos

ΔU









ΔU    Voltage drop (V)
L      Length of conductors (m)
I      Rated current (A)
R    Resistance (Ω/km to VDE 0102)
X    Reactance (Ω/km to VDE 0102)

Refer to APPENDIX E Cable Current load standard.

2.10.2

Grounding / Earthing Requirements

The  frame  of  the  generating  set  must  be  connected
to  an  earth  ground.  Since  the  set  is  mounted  on
vibration  isolators,  the  ground  connection  must  be
flexible  to  avoid  possible  breakage  due  to  vibration.
Ground  connection  cables  or  straps  should  have  at
least  full  load  current  carrying  capacity  and  meet
applicable regulations.

2.10.3

Insulation Test

Before  starting  the  generating  set  after  installation,
test  the  insulation  resistance  of  the  windings.  The
Automatic  Voltage  Regulator  (AVR)  should  be
disconnected  and  the  rotating  diodes  either  shorted

out  with  temporary  links  or  disconnected.  Any
control wiring must also be disconnected.
A 500 V Megger or similar instrument should be used.
Disconnect  any  earthing  conductor  connected
between  neutral  and  earth  and  megger  an  output
terminal to earth.
The insulation resistance should be in excess of 1MΩ
to earth. Should the insulation resistance be less than
1MΩ winding must be dried out.

2.11

Power distribution system

Our diesel engine generator set use three phase five
line  system  for  power  distribution.  That  is,  three
phase  live  wires,  one  neutral  line,  one  ground  line.
The  neutral  line  and  the  ground  line  are  not
connected.  Users  can  choose  three  phase  four  lines
for power distribution according to requirement that
is  to  connect  the  neutral  line  to  the  ground  (base
frame), so that to solve the problem of feint that the
neutral line sometimes is electriferous.

Note:
HYUNDAI  Power  series  diesel  engine  generator  sets
require  users  to  safely  connect  generator  sets  and
base frames to the ground, please refer to the ground
label for connecting point.

User manual

Operation

3.1

Inspect Before Operation

After  finished  installation,  our  diesel  engine
generator  set  can  be  put  into  use.  Each  time  before
starting  the  generator  set,  following  items  shall  be
checked without fail:
◆If  there  is  foreign  material  exists  in  the  surface  of

generator set or in the ambient environment which
may hamper the generator set’s operation.

◆If the air inlet and ventilation path in the generator

set working room is expedite.

◆If the anti‐freeze level is normal.
◆If the air filter indicator works well
◆If the lubricant level is within the specified range
◆If the fuel valve is open, if the fuel has been supplied

to the engine normally.

◆If the cable has been connected to the battery in a

correct way.

◆Check if the load equipment has been well prepared.

When the generator set directly connects to the load,
the air switch shall be cut off before start.

Warning:
Operators

shall

establish

good

operation

(maintenance) procedure, this is the precondition for
generator set’s smooth running in long time period.

3.2

Generator set’s running

3.2.1

Pre‐heat

For the generator set which is installed with
pre‐heater, operators need to decide if pre‐heating is
needed before start the generator set according to
environment temperature. The control panel which is
installed with pre‐heat switch can instruct the engine
to start the pre‐heater so that to achieve the purpose
of pre‐heating.

3.2.2

Connect to power

Turn the air switch in the control panel from “OFF” to
“ON”,  watch  the  panel  until  the  background  light
turn  on,  that  means  the  control  panel  has  been
successfully  connected  to  the  power.  At  the  same
time  make  sure  the  fuel  pipes  are  open,  and  the
speed  governor  or  the  control  unit  in  the  electronic
fuel injection generator set is under working status.

3.2.3

Start

Part  of  the  generator  set  control  panel  has  been
furnished with idle speed / full speed transfer switch,
users can choose if the engine need to be started in
idle speed or in one time full speed. Usually the time
period  for  idle  speed  shall  not  exceed  five  minutes.
Do  not  run  the  generator  set  in  idle  speed  in  a  long
time period.
Press  on  the  start  button,  the  duration  shall  not
exceed 30 seconds, engine will be started by the start
motor. As soon as the engine be started successfully,
you  can  release  the  start  button  and  the  generator
set will enter into running status.

Suggestion:
In order to extend the life expectancy of start battery
and start motor, the duration for one time start shall
be controlled within 5 to 10 seconds. If one time start
fails,  stop  for  some  time  and  begin  the  second  time
start procedure.

For  the  control  panels  which  are  installed  with
self‐start(or

communication)

instrument,

the

generator  set  pre‐heating,  start‐up  period  and
starting  times  have  been  controlled  by  the  program
(this  program  can  be  set  and  modified  by  user).
Operation  procedure  please  refers  to  operation
manual.
When  the  generator  set  control  panel  has
malfunction(s),  timely  overhauling  is  needed  before
Re‐start the control panel.

Warning:
For any start up which is made through force, not by
control panel, the malfunction caused by it do not
belong to the scope of warranty.

3.2.4

Running

When  the  generator  set  begins  full  speed  running,
and  the  alternator’s  voltage  and  frequency  becomes
normal  and  stable,  operators  can  put  the  generator
set into normal running.
During the generator set’s running period, operators
shall often watch and check the parameters such as if
the  generator  set  is  running  normally,  if  the  control
panel instrument is indicating the right position, if the
control panel has pre‐warning indication, and the fuel
level in the base frame etc, and make record for the
parameters. (see attach file)

3.2.5

Emergency stop

In case the generator set was found to have severe

Content .. 2 3 4 5 ..