KAWO丨DIESEL GENERATOR SET OPERATION MANUAL

KAWO POWER DIESEL GENERATOR SET OPERATION MANUAL

OPERATION PROCEDURES

2.1 Pre-operation Inspection

After the diesel generator set is installed, it can be put into power generation operation. Before each start-up, at least the following inspection items shall be carried out:

• Check if there are any obstacles on the surface and around the generator set;

• Check if the air inlet and exhaust passages of the machine room are unobstructed;

• Check if the coolant level in the water tank is normal;

• Check if the air filter indicator is normal;

• Check if the lubricating oil level is within the normal range;

• Check if the fuel valve is open and fuel is properly supplied to the engine;

• Check if the battery cables are connected correctly;

• Check if the power generation load equipment is ready. When the generator is directly connected to the load, the air switch must be disconnected before starting.

Establishing good operation (maintenance) procedures by operators is the basic guarantee for the long-term trouble-free operation of the generator set.

2.2 Operation of the Generator Set

2.2.1 Preheating

For generator sets equipped with a preheater, the operator can decide whether to preheat the unit according to the ambient temperature before starting. The control panel with a preheating button can control the engine starting heater to work to achieve the preheating purpose.

2.2.2 Power-on

Turn the key switch on the control panel from the "OFF" position to the "ON" position. When the instrument backlight on the panel is on, it indicates that the control panel is powered on. At the same time, the fuel supply of the unit is turned on, and the controller of the unit with an electronic speed regulator or an electronically controlled fuel injection system is also in the working state.

2.2.3 Starting

The control panel of some generator sets is equipped with an idle speed/full speed switch. Users can choose to start at idle speed or directly start at full speed according to actual needs.

Generally, the idle running time should not exceed 5 minutes; the unit should not be operated at idle speed for a long time.

Press the start button for a maximum duration of no more than 30 seconds. The engine will start under the drive of the starter motor. Once the start is successful, release the start button immediately and the unit will enter the running state.

For the control panel with an automatic start (or communication) instrument, the preheating, starting cycle and starting times of the unit are controlled by a program (the program can be set and modified by the user). For detailed operation, please refer to the Operation Manual Supplied with the Unit.

When a fault occurs in the control panel of the unit, it must be repaired in a timely manner before starting the unit.

Any act of forcibly starting the engine without going through the control panel will result in the loss of warranty service for the resulting consequences.

2.2.4 Operation

After the unit enters full-speed operation and the generator voltage and frequency are normal and stable, the operator can close the power generation air switch.

During the operation of the unit, the operator should also frequently observe and check whether the unit is running normally, whether there is any pre-alarm indication on the control panel, the fuel level in the fuel tank and other operating parameters, and record the operating parameters of the unit at regular intervals (see the example).

2.2.5 Emergency Stop

Once the operator finds a serious fault of the unit or a power distribution fault, the emergency stop button on the control panel can be pressed to stop the unit immediately.

Under normal circumstances, it is not recommended that users arbitrarily stop the unit by pressing the emergency stop button.

2.2.6 Normal Shutdown

Before the normal shutdown of the unit, first disconnect the load (open the power generation air switch), then let the unit run at no-load for a certain period of time (3-5 minutes) to allow the unit to cool down sufficiently before shutdown. (Do not perform the cooling operation at idle speed.)

For some units equipped with a shutdown valve, the operation of stopping the unit by turning the key switch on the control panel is invalid. The correct shutdown operation must be performed by pressing the shutdown button when the control panel is powered on.

The unit operation described in this chapter takes the standard configuration panel of the unit—the ordinary manual control panel—as an example. There are various configuration types of diesel generator set control panels: automatic start control panel, "three-remote" fully automatic control panel with communication function, parallel operation control panel (manual or automatic), etc. However, their basic operation (control) procedures are consistent and will not be listed one by one here. For the specific operation of the control panel, users should also refer to the supporting document: Control Panel Operation Manual.

2.3 Post-operation

After the unit is shut down, it is necessary to perform the following work:

• Check the unit for the "three leaks" phenomenon (lubricating oil leak, fuel leak, coolant leak);

• Close the fuel valve;

• Turn off the air inlet and exhaust facilities of the machine room;

• Open the generator output air switch;

• Turn off the power key switch of the control panel, remove the key and keep it properly;

• For long-term shutdown or unit maintenance, the negative cable of the unit's starting battery must be disconnected. If necessary, drain all the fuel and coolant.

For automatic start units, some of the above clauses are not applicable. The post-shutdown work of automatic start units is to keep them in the pre-start state (standby state) to be ready for emergency start at any time.

2.4 Operation Records

Users must keep operation records for each operation of the unit, and the form of operation records can be diversified. The basic content should include: the operation time of this time, the cumulative operation time of the unit, the readings of the engine oil pressure gauge and temperature gauge during operation, power generation voltage, frequency, maximum power (current), etc., the operation status of the unit, and whether the unit has any fault alarm/shutdown.

Only with correct and complete operation (maintenance) records can users obtain correct and comprehensive after-sales (warranty) service.

2.5 Notes

• When the engine temperature is very low, the idle running time of the unit should be appropriately extended; after the unit is warmed up, it is not allowed to operate the unit at idle speed for a long time, nor is it allowed to operate the unit continuously under no-load or light-load conditions. Such operation will cause serious carbon deposition and oil leakage in the engine turbocharger and exhaust system;

• Do not allow the unit to operate under overload for a long time, otherwise it will cause unit failure and reduce the service life of the unit;

• It is strictly prohibited to disassemble or replace parts on the unit while the unit is running;

• When adding coolant, use the same coolant as in the original cooling system. When opening the water filler cap, pay attention to whether there is high temperature to prevent steam or high-temperature coolant from spraying out and injuring people;

• Prevent burns when draining high-temperature lubricating oil;

• Must use fuel that meets national standards, otherwise it will cause failure of the engine fuel injection pump;

• For engines equipped with a turbocharger, it is not recommended that the unit bear more than 50% sudden load, otherwise it will cause large stalling of the unit; it is recommended that users adopt methods such as step-down and frequency conversion to control the start of large electrical equipment to reduce the large current impact on the unit during startup;

• For standby units or units that have not been operated for a long time, it is recommended to run the unit at least once a month to the working temperature, and run the unit at full load for about 4 hours at least once a year. This can burn off the carbon deposition in the engine exhaust system;

• For manually paralleled units, it is necessary to ensure synchronization (same frequency, same phase sequence, same phase, same voltage) before closing the switch; before shutdown, it is necessary to open the switch first and then shut down the unit, and someone must be on duty when the unit is in use to prevent shutdown due to single-unit failure.