Installation Guide For PowerHouse Generators

Installation Guide For PowerHouse Generators
Installation Guide For PowerHouse Generators
DRAFT
Not For Release
Supplied By M+H Power System
This manual is for guidance only and does replace any federal or local laws. Please
contact a licensed installer for more details relevant to your installation in regards to this.
Version 0.2
Contents
1. Manuals
2. Wiring Diagram for Controller
3. Visual Inspection
4. Unpacking Crate
5. Exhaust
6. Positioning of Generator
7. Expansion bottle install
8. Fuel System
9. Pre Starting Checks
10. Cranking Battery
11. Controller
12. Starting Generator
13. Servicing Requirements & Parts
14. Generator Do’s and Don’ts
15. Warranty Statement
2
Manuals
Please read and understand and all the manuals and supporting
documentation in regards to this generator. Some of these are shown below:
3
K3
NO VOLTS
REMOTE START
BATTERY
12VDC
+
-
K3
12V
REMOTE
START
4
30A
C/B
5
9
10
FUEL LEVEL
(OPTIONAL)
FUSE
3
OIL PRESSURE
W
4
ENGINE TEMPERATURE
K1
+B
G
8
REMOTE START
EMERGENCY
STOP
7
START RELAY
F4
6
FUEL SOLENOID VALVE
50
1
"W" SPEED INPUT
2
ALTERNATOR TYPE
BOSCH, MARELLI, LUCAS
30
CRANK MOTOR
GLOW PLUGS
OFF
RUN
START
Wiring Diagram for Controller
PDM1
KEYSWITCH
11
15/54
+D
K2
K1
Visual Inspection
Before going to site please ensure unit is complete and free from shipping
damage. Unit should come as pictured below:
Please ensure all accessories are included as shown in picture below
(including hoses):
Once this is done unit can then be shipped direct to site for installation. Once
there please complete this inspection again before commencing work.
5
Unpacking the Crate
Please take care when unpacking generator as not to damage unit and
controller. Please note: use suitable size tools and equipment to ensure the
unit is not damaged. On completion the unit should look like this or similar.
When removing generator from base please use correct lifting eye or correct
lifting pockets to ensure unit is removed safely. Also please give unit a quick
visual inspection to ensure no obvious sign of damage to unit.
6
Exhaust System
Please remove the U bolts nuts from end of exhaust located at the radiator
end.
Remove the metal insert from the end of the flexible exhaust and slide in the
exhaust pipe end to ensure the 45 degree angle is facing down to stop water
penetration into the system. Tighten up U bolts ensuring the flexible exhaust
is not crushed and tightly holding on to the inserted exhaust pipe.
7
Positioning Of the Generator
When considering where to position generator please ensure genset is
located away from flammable materials.
Have easy access all round to enable work to be carried out easily in the
future (for maintenance).
Also note that the wall of the building needs a hole cut in it to ensure venting
of the radiator. This hole needs to be slightly larger than the radiator and the
cowling mounted on the inside wall. The genset can then be fitted into the
cowling to ensure hot air is released out of the building. Please also ensure
vermin trap (wire mesh is fitted to outside of building).
Also note the exhaust has been mounted along the top of the radiator to vent
all the hot exhaust gases out of the room. Please drill a hole capable of
putting the exhaust through. Ensure exhaust is facing down to stop water
from getting into the engine i.e. 45 degree angle is facing down.
Please ensure all holes in the wall are sealed around the edges and the
sealing material is heat retardant, especially around the exhaust system hole.
Once final position of the unit has been decided place the vibration pads
underneath the skid as shown below:
Also ensure adequate ventilation around the unit to ensure air flow. In an
ideal situation this would be cross ventilation to enable engine to breathe.
The generator room needs to be kept clean and tidy, be free from heavy dirt
and dust to ensure a long life span of the electronic components fitted to the
unit.
8
Setting up Water Expansion Bottle
Radiator bottle and hose
Fit hose to radiator as below just below cap.
9
Attach cable tie to hold the hose in position. Ensure hose is not crushed but
held tightly in place.
Fit water bottle to side of radiator and attach hose to bottom of bottle and
fill to the max indicated level with recommended coolant.
Coolant levels also needs to be tested, this can be done at the radiator cap.
Ensure coolant can be touched by your finger; only do once the engine is
cold.
10
Fuel System
Remove bungs from fuel system located in pictures below prior to
commencing any work.
(Fuel in Bung)
(Fuel out Bung)
11
Place fuel line hose on bottom of tank. Ensure tap is turned off and clamp is
done up tight.
Fit other end of hose to fuel in. On generator located next to radiator and
yellow dipstick ensure hose clamp is held tight.
12
Place fuel return line. Hose on top of tank to generator return line located
above fuel filter ensure fuel filter is turned on as below (tap facing up) and
line connected with hose clamp held tightly.
Locate tank appropriately to room set up. The tank can be positioned as far
as the hose length can reach.
Once located ensure the fuel tank is turned off (Tap is facing across line)
unscrew the large cap on the tank and fill. Once finished filling, clean up
spillages then replace the cap on the tank Ensure hoses are tied together
when positioning tank and ensure that the hoses are not crushed. Run hoses
inside skid if needed to stop tripping hazard.
13
Turn fuel tap on. (Tap is facing in line with hose)
Fuel system now needs priming this is done by pushing down on the fuel
pump handle on the side of generator. This is located next to the fuel in point
next to the dipstick. (Yellow handle bottom left hand corner of picture). Also
the system will be a primed once there is sufficient fuel in the fuel filter and
the system is pressured. (10 or so depressions)
14
Pre Starting Checks
Please ensure that the unit is filled with the appropriate amount of oil this
can be checked via the dipstick (Yellow handle) located next to the priming
pump. The level should read halfway between minimum and maximum. If
not the unit will need topping up with appropriately graded oil. (10w – 40
Castrol)
Coolant levels also needs to be tested, this can be done at the radiator cap.
Ensure coolant can be touched by your finger; only do once the engine is
cold (Castrol Coolant)
Also ensure all clamps, bolts and nuts are tight fitting.
15
Crank Battery
Insert battery into cradle.
Fit and tighten battery terminals to battery posts and place cables on
terminals. Ensure the Red goes to positive (+), black to negative (-).
16
Controller
The TEM6- DE controller is one of the most versatile controllers on the
market and comes complete with a series of programmable interfaces.
The TEM6-DE (Complete Unit) has been sourced to enable you ease and
efficient use of the diesel. It comes complete with a 12v positive output and
also a dry contact for use with nearly all inverters out there in the market
place (two wire start). Also the unit can be spilt down in many different parts
the PDM1 is the engine management component and the TEM 3 is the user
interface.
17
TEM 3
It is a measurement instrument to convey the following information to the
user.
With only one button interface the select as indicated in the blue area.
Volts (V), Amps (A), Frequency (HZ), Working Hours (H)
Measurements can be seen in two different ways.
Manually, By means of the key “Select Mis”
In this case, by pressing the key repeatedly, you go on with the selection.
The selected measurement, besides appearing on the display, is also
emphasized by the lighting of the respective Led.
Automatically
In this way the various measurements automatically move in sequence on
the display with a 3 second scanning. If you want to stop the scanning on the
desired measurement, you only have to press the key “Select Mis”
To switch between Manual – Automatic mode is done by keeping the key
“Select Mis” pressed for 3 seconds to go from manual to automatic and once
from Automatic to Manual
18
PDM 1
The PDM 1 component of the controller is the engine management part of
the system. This will protect the engine from operating outside its normal
parameters.
Understanding this controller is very simple by a series off LED’s located
across the top line of the controller highlighted below this they are two more
just below this. In certain operations these light may be on or off. Ensure
you are familiar with these and what they indicate more details can be found
below regarding this or in the appropriate manual.
1.
2.
3.
4.
5.
6.
7.
8.
Under speed or Over speed engine out off tolerance. Led off in
normal running
Over temperature. Led off in normal operation
Fuel switched off in normal operation
Oil low pressure. Led off in normal operation
Alternator failure Led
Supply LED constantly switched on at power up
Glow plug pre heat
P1 & P2 programming buttons
19
This controller features are as follows:
•
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•
•
•
•
•
Only one mains supply from 7 to 30 V Dc
Programmable relay into 5 different ways
General Alarm
Glow Plug Pre-Heating
Allows remote Start – Stop
Magnet for stopping
Over speed and low speed survey
Protection from Polarity Reverse
Programmable up to 5 attempts to start
Working temperature range -20 to +60 Degrees
The next part of the controller package is the key switch, audible alarm and
also the emergency stop.
The emergency stop is located on the top right hand side of the controller
and is the big red button pressing this will cause the generator to stop
instantly and will also inhibit the engine to restart while depressed. Once
reset the generator will return to normal operation. This should be the first
point of call when checking the unit will not start.
The buzzer will sound once the unit has gone into fault conditions.
The key start is also located just below this part of the unit please refer to the
Pre Starting Checks and also the Manual Starting Generator sections
before turning the key.
20
Manual Starting Generator
Manual start of the generator can be done by the use of the key switch on
front of the unit.
Ensure emergency stop button is out before attempting to start unit.
This unit can be started by slowly turning the key slowly through start and
then holding in the run position for a few seconds. These may take a few
attempts when starting engine for the first time or after long periods of idle
times. We recommend this unit gets run for ten minutes every 2 weeks. Also
water and oil levels checked as per Pre Starting Checks above in this
manual.
To stop unit either hit emergency stop button or turn key to off position. If
emergency stop button is pressed ensure button is released after unit has
stopped.
21
Servicing Requirements
Servicing of this unit is required as below for the use continued good
running of the unit and also for warranty purposes.
22
Parts
Please find below a list of the spare parts to complete the service. Please
adhere to the intervals as stated above.
23
What to Do and Not to Do
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Keep the generator outside. Never use it indoors. (unless properly
installed inside building).
Install a battery-operated carbon monoxide alarm.
Keep the generator dry. Do not use in wet conditions. To protect from
moisture, operate it on a dry surface and with adequate ventilation.
Dry your hands if wet before touching the generator.
Never try to power the house wiring by plugging the generator into a
wall outlet, a practice known as "backfeeding". This is an extremely
dangerous practice that presents an electrocution risk. It also bypasses
some of the built-in household circuit protection devices unless done
properlly.
If you must connect the generator to the house wiring to power
appliances, get a licensed electrical contractor to do it in
accordance with Australian Standards AS/NZS 3000 Electrical
Installations.
Avoid creating a fire hazard. Store fuel for your generator in properly
labelled non-glass safety containers, out of the home and away from
fuel-burning / heat appliances.
Before refueling the generator, turn it off and let it cool down. Fuel
spilt on hot engine parts could ignite.
When running generator on hand ensure all load connection devices
are removed.
When performing service work ensure emergency stop button is
pressed.
Do not smoke in or around generator
Do not run generator on light loads for prolonged periods of time, the
generator needs at least 50% loading to prevent damage.
Familise yourself with all paperwork / manuals available to you.
Ensure emergency button is out prior to starting generator.
Contact installer For More Details
24
Warranty and Statement of Guarantee
The manufacturer Main Scope of supply
Yanmar Engines
Sincro generators
Heavy duty skid frames with forklift holes and centre lifting frame
Generator direct coupled to engine flywheel housing with 6 mounting
feet
Battery leads and holds down clamps
Engine oil, radiator coolant, bolts, industrial paint
Main circuit breaker with Clipsal enclosure wired to alternator output
terminals
Control panel mounted panel frame
Anti vibration rubber
Fuel tanks
Labour and load test
Statement of Guarantee
The Equipment shall be assembled to ensure satisfactory operation
in which continuity of service is the first consideration, and to facilitate
inspection, cleaning and repairs. The equipment shall also be built to
ensure satisfactory operation under atmospheric conditions prevailing
in Australia and local Countries
The generating sets shall incorporate every reasonable precaution
and provision for the safe working and reliable running of the
equipment.
The generators shall function without undue vibration. Components,
connections and cabling shall be assembled and arranged to
minimize the risk of any damage.
Consideration needs to be given to the importance of the correct
installation of the generating sets and should be done in accordance
with the M+H Manual
Inherent problems do exist when using machinery, therefore warranty
is reliant upon the installer and the operator, reading and
understanding the information provided by M+H
25
Warranty
Defects liability period shall commence on date of delivery of
equipment being, 12 months or first 1000 hours, whichever occurs
first.
On a warranty claim, equipment will be required for inspection by the
Manufacturer or a qualified Power Generation Service Agent, all
costs for removal and freight to be covered by Owner
The manufacturer will cover parts and labour applicable to scope of
supply. [Backed up by the manufacturers warranty for there products]
26
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