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Unit structure and description
1.1 Description of diesel engine
Diesel engine is the source of power for generators. It is specially designed for generator sets. Its speed and power are matched with generators. When in use, carry out normal maintenance according to the requirements of "Diesel Engine Manual". The diesel engine will continue to be sustainable and reliable. To provide power.
1.2 Generator description
The alternator installed on the unit can be equipped with different models according to the needs of users. When in use, perform normal maintenance according to the data provided on the nameplate and the "generator manual". Under the condition of not overloading, the generator Can run continuously.
1.3 Control screen description
The control panel matched with the unit is designed with an advanced control system and adopts a dedicated program controller made of imported Hitachi chips. When the grid loses power, lacks phase, or undervoltage, it can automatically start the generator to make it Put into normal operation power supply. When the mains power supply is normal, the power supply can be automatically switched and the generator set can be automatically turned off, and it will enter the continuous standby state.
2. Working principle
The generator set is driven by a diesel engine, and the generator establishes a rated output voltage to supply power to the outside. The generator can continuously and stably output the rated voltage, and the main function is the control panel. When the control panel detects the power failure, phase loss, or undervoltage of the power grid, it will immediately output the first "additional control" signal, and control the unit to start automatically after a certain time delay. The second "additional control" signal is obtained, and the main switch is switched on to put it into operation and supply power. If the unit cannot be started once, it can be controlled for the second and third start. Each start time is about 5 seconds, and the time interval between two starts is about 8 seconds. If the unit fails to start after three starts, it will send out a "start failed" audible and visual alarm signal or although it has started, the voltage cannot be established and no closing signal will be sent. If the main switch is closed, when the following fault conditions occur, it will also send out an audible and visual alarm, and remember the fault point, and at the same time, it can automatically unload and stop to ensure the safety of the unit.
a When the cooling water temperature exceeds, it will open and shut down after 3 minutes.
b When the lubricating oil temperature exceeds, it will open and shut down after 3 minutes.
c When the diesel engine exceeds the rated speed by 112%-115%, it will be opened immediately, the speed will be reduced, and the machine will stop.
d When the diesel engine is under-speed, immediately open and stop.
e When the lubricating oil pressure is low, immediately open, reduce speed, and stop.
f When the generator is overcurrent, it will immediately open, reduce speed, and run at idle speed.
3. Operation
3.1 Preparation and inspection before use
3.1.1 Remove dust and dirt from the internal and external parts of the unit (including inside the control panel, instrument panel and generator carbon brushes, slip rings, etc.). The carbon brushes and slip rings are strictly prohibited for rubbing with oil. If there is paint, use O-size sandpaper to wipe off.
3.1.2 Check whether the fasteners of the unit are reliable, whether there are loose or missing parts, and eliminate abnormal phenomena.
3.1.3 Check whether the connecting wires of the electrical components in the control panel are firm, damaged, loose, or disconnected.
3.1.4 Use a 500V megohmmeter (250V megohmmeter if the rated voltage is lower than 100V) to check the insulated electrical groups between the independent electrical circuits of the unit to the ground and the circuits. During the measurement, each switch is in the on position and the semiconductor device. Capacitors, etc. should be removed or short-circuited. The measured resistance should not be less than 2M. If the generator is damp, it must be dried before operation.
3.l·5 Open the water tank filling cap and drain hole, add clean water to the water tank, and keep the water flowing out until there is no rust in the water flowing out, and then fill up the water tank. In winter, when the temperature is lower than 0, the water tank must be filled with antifreeze (fill according to the instructions of the freezing liquid to prevent the insulation system from malfunctioning and cause the mechanical parts of the unit to freeze and crack.)
3.1.6 Check the storage and contamination of the oil in the bottom case of the diesel engine. When the oil is insufficient, add it to the specified oil level, and replace it if it is deteriorated or dirty.
3. I. 7 According to the diesel engine manual, add enough fuel, open the fuel valve, and use the fuel transfer pump to remove the air from the fuel system.
3.1.8 Check whether there is oil and water leakage at the joints of the oil supply, lubrication and cooling systems of the diesel engine, and eliminate hidden dangers in time.
3.1.9 Check the battery connection and battery capacity. Tighten the wiring when it is loose. The battery should be charged when its capacity is insufficient (new batteries should be charged according to regulations).
3.1.10 Check whether the electrical meters are in good condition and whether the pointer points to the correct position, except for the frequency meter.
3.1.1 1. Check the cleanliness of the air filter, if it is dirty, clean it. ,
3.1.12 Connect one end of the cable or wire whose insulation grade and conductor cross-section meet the requirements to the motor terminal board and one end to the control panel. The phase sequence should be the same.
3.1.13 The unit should be grounded reliably, and the grounding wire should be connected to the grounding screw of the generator.
3.2 Mains power-on test
The mains is turned off and closed by the three-phase power switch and input to the control panel. After the mains indicator on the control panel is on, close the Kl, K2 switches in the control panel, and the oil and water heaters and charging devices are put into operation. When the oil temperature and water temperature rise to 25℃～35℃, the heater will automatically cut off, and it will automatically heat when the temperature falls below. After the mains input, the charger will automatically charge the battery pack automatically, observe the ammeter in the control panel, and adjust the charging rheostat to make the charging current reach about 1A.
Under the normal conditions mentioned above, carry out manual control test.
3.3 Manual control test
In order to ensure the safety of the control panel and the unit, at the beginning of the commissioning, the test is carried out from the manual program. That is, the SA2 switch is placed in manual gear, and the operation is carried out according to the operation method specified in the diesel engine manual, that is, according to the following steps.
a. Press the pre-sliding button to pre-lubricate all parts of the diesel engine (diesel engine with pre-sliding pump).
b. Press the start button to start the diesel engine and run at low speed for 15 minutes, and there should be no abnormalities, otherwise, it should be shut down for inspection.
c. Press the speed up button to adjust the output frequency of the unit to about 52HZ.
e. Press the closing button to supply power to the unit. At this time, pay attention to the working conditions of the unit and the control panel. If there is no abnormal condition, you can continue to run, otherwise it should be shut down for inspection.
f. Press the opening button before shutting down, and the unit will stop supplying power.
g. Press the deceleration button to gradually reduce the idling speed of the unit.
h. Press the stop button until the diesel engine stops steadily before releasing the button.
The newly installed unit and control panel must strictly implement the above procedures. After completing an action, you should pay attention to the operation of the unit, whether it is manual or automatic state, it can be stopped in an emergency.
3.4 Automatic control test
3.4.1 After the manual test, the unit and the control panel will perform an automatic test when everything is normal. That is, the SA2 switch is placed in automatic gear, and the mains power is artificially cut off. At this time, after a delay of 3 seconds, the control screen will automatically follow the working procedure. Namely: pre-slip, start, speed increase, closing, power supply, continuous operation.
During this period, if one of the five failures occurs, it will automatically alarm and stop, write it down, and automatically recall the point of failure.
3.4.2 When the unit is in normal operation, the mains power is artificially connected, and after the control panel receives the mains signal, it delays for 5 seconds and transfers to the shutdown procedure. Namely: after opening, decelerating, stopping, and opening, the unit will be unloaded and run at idle speed for a period of time (adjustable from 20 seconds to 4 minutes) and stop and reset, and prepare for the next power outage start state.
3.5 "Trial run" control test
After the "manual" and "automatic" tests are successful, a "trial run" test is carried out. That is, when the mains power is normal, the SA2 switch is placed in the "trial run" position, the unit will automatically start, increase the speed, and run normally, but it is impossible to close. After a period of operation, under all normal conditions, Set the SA2 switch to the "auto" position and press the "stop" button to reset the unit to stop and prepare for the next power outage to start.
4. Maintenance
(1) The diesel engine, generator and battery pack used in the unit should be regularly maintained. The automatic control system is mainly to ensure the emergency start of the unit, fast loading and unattended in a short time or several hours. Therefore, the unit can only be used when the diesel engine and the generator itself are fault-free, the heating, pre-slip system is normal, and the battery pack capacity is sufficient.
(2) The unit must be in a heating preparation state for a long time. Only when the room temperature is higher than 30℃ day and night, the heating system is allowed to not work, otherwise
The start-up success rate of the unit is low, or the diesel engine is working rough, which reduces the service life.
(3) The heating preparation state of the unit exceeds 5-7 days, and the alarm button must be manually pressed in the "manual" gear to test the sound and light alarm device to ensure that it is in good condition to avoid no alarm record after a failure. ’.
(4) The capacity of the battery shall not be less than 195Ah, and the electrolyte and the specific gravity of the electrolyte shall be supplemented and adjusted regularly. .
(5) The water and oil heaters are powered by the mains, and the insulation resistance value is measured once a month, that is, disconnect the K1 and K2 switches, and the measured resistance value is not less than 1M to ensure personal safety. A water temperature alarm occurs when the unit is in the heating preparation state, which is a temperature control failure and should be overhauled.
(6) If the unit fails and shuts down, after the operator learns the cause of the failure, he should turn the SA2 switch to the "manual" position and press the "reset" button to release the alarm. After troubleshooting, switch to the "automatic" gear to avoid repeated start and disease operation.
(7) In the case that the mains power is not cut off and the unit is not working within 7-10 days, it must be "trial run" once, that is, according to the provisions of 3.5. In order to prevent the unit from failing to work normally due to mechanical or control system failure during emergency conditions. During the "trial run", if a fault or abnormality is found, the fault shall be eliminated in time to ensure that the unit is on standby without any fault.
(8) The dedicated program controller in the control panel does not require special maintenance and should not be arbitrarily adjusted. If an abnormality occurs, please find out the reason and notify the factory for answers, or the factory will send personnel for repairs.
(9) During the operation, the operator must first understand the working principle, operate according to the above regulations, and must not operate in an unfamiliar situation. If the operator's misoperation has consequences, the factory can send personnel to assist in the repair. At the user's own risk.