Genset Installation Manual.

GENSETMANUAL Help Desk OWNER’S Call 1800 233 3344 020-6608 4608 Email : [email protected] Customer assistance is also available from our help desk 24 hrs.x 7 days a week) for all after sales assistance. Power, Performance, Peace of Mind KIRLOSKAR OIL ENGINES LIMITED L.K Road, Khadki, Pune 411 003, INDIA. Tel.: +91 (20) 2581 0341, 2581 5341 Fax : +91(20) 2581 3208, 25810209 www.kirloskar.com rtwfasdfafasfasf GENSET OWNER’S MANUAL KIRLOSKAR OIL ENGINES LIMITED KIRLOSKAR OIL ENGINES LIMITED I First Edition- April 2012I Issued by Customer Support Published on behalf of Customer Support, Kirloskar Oil Engines Limited, Khadki, Pune -411 003. INDIA All rights reserved. This Publication may not be produced in any form, in whole or in part, without our written permission. In view of continuous product updating and design changes, contents of this Manual are subject to change without prior notice. camshafts and connecting rods that are manufactured in-house. 1946 saw Kirloskar Oil Engines Limited (KOEL) taking shape. special purpose machines to achieve critical degrees of precision that international specifications demand. Of special mention are critical components like crankcases. KIRLOSKAR OIL ENGINES LIMITED I First Edition. and 2400 hp to 11000 hp. making sure that there's always the highest up-time for Kirloskar engines. investment in state-of-the-art manufacturing facilities with thoroughly perfected processes. Add on. Indore and Kolhapur. crankshafts. construction. A well spread out service network manned by about 3500+ Kirloskar trained engineers and technicians ensure prompt service and easy availability of genuine consumable and spare parts. including the role of prime movers for industrial. Such a wide acceptance has resulted in increase in demand for engines in all market segments. giving its customers a wide choice ranging from 3 hp to 800 hp. A powerhouse today. In 2007. Customer Support: Assurance through adequate product support is derived out of clear thought processes. A variety so large also makes these engines the backbone in many industries. in-house research. coupled with the most extensive service network in the country. with the number growing steadily. Recognition for this came as an ISO 14001 certification for Environment Management Systems in 1999. the belief that industry and environment can co-exist. And that means constant technology up-gradation. This practice towards achieving efficiency and performance is a mantra at all KOEL plants. Rajkot. agricultural. This rigorous internal quality pace easily makes sure that KOEL's processes meet all the standards that global specifications demand. Around 90% of Kirloskar engines are within 80 km of a Kirloskar Service Dealer. Service Engineers and Technicians have been stationed at 14 Kirloskar Area and Regional Offices. power generation and marine applications. every detail in these engines is carefully perfected.Kirloskar Engines: Prime Movers to the Indian Nation. KOEL also manufactures for its exclusive use. 342 Service Dealership outlets are operating efficiently to provide relentless service to customers.April 2012I Issued by Customer Support . starting from the main engine manufacturing plant at Pune to all the other units at Nashik. Being a leader is also about being driven by technology. it easily stands out as India's leading manufacturer of engines. On the other hand. Ahmednagar. engines ranging from 2400 hp to 11000 hp are also used for marine propulsion and auxiliary power on naval and coast guard ships. 210 Service Dealership locations provide 24-hour service as of December 2011. Kirloskar Service Managers. led to in-house development of the environmental-friendly engines produced using environmentalfriendly manufacturing facilities. The dealership locations and infrastructure is continuously assessed based on the Kirloskar engine population build-up in each territory and the customer's emerging service needs. Similarly. Manufactured in both air-cooled and liquid-cooled versions. ABS QE (USA) awarded KOEL Khadki plant the prestigious ISO-TS-16949-2002 and ISO 14001 certification for its Quality Management Systems. Out of these. All aimed at one goal: Deliver well thought-out quality products and services to the customers at competitive prices. SVO ( Straight Vegetable Oil ) and Natural Gas as per customer requirement. The installation of ERP was followed by net enabled business processes in 2000. 365 days a year. KIRLOSKAR OIL ENGINES LIMITED I First Edition. AGOEMs. Such a high. This exercise by itself is noted to be one of the most extensive installations of Oracle© in the manufacturing industry. Bio Gas. Suppliers and the Logistic Providers into a closely-knit digital community.April 2012I Issued by Customer Support . So whether it's the latest service information or parts availability. Kirloskar installed Oracle's Enterprise solutions in 1998. DG Genset the Specific Anecdote: We are recognized as one of the world’s leading generating set manufacturers. This networked Kirloskar Service Dealers. We have been instrumental in developing the latest technology driven products to suffice power requirements of every individual customer from different market segments. We also provide variety of alternative fuel gensets. Area Sales Offices. “ Kirloskar Green Genset “ is a major player globally. 24 hours a day. expect complete information access at the touch of a button. specialized in manufacturing of both air cooled & water cooled Engines / Diesel Gensets with power output covering from 5 kVA to 625kVA & 1800kVA to 6300 kVA. The company has also launched Oracle CRM (Oracle Customer Relationship Management) module in 2006 to serve customers pro-actively. which efficiently run on Bio Diesel. We provide reliable & high quality products at competitive cost.All-pervasive IT in Operations: Having forethought and foreseen the power of Information Technology (IT) to transform businesses. internet-led IT-focus has helped Kirloskar service its customers with a new-found efficiency. April 2012I Issued by Customer Support .Contents Topic Pages Introduction 1 Technical Specifications 2-6 Liquid cooled n n Air cooled n Sizing and load calculation Installing KGPI Genset for the best performance n Location 7 .Customer Support Network 29 KIRLOSKAR OIL ENGINES LIMITED I First Edition.27 Starting n Starting and Stopping KGPI Genset n Log Book n Maintenance Tips KGPI Genset Cleaning and Preservation 28 KGPI .23 and Room Layout Ø Location Ø Layout Ø Ventilation n Foundation n Unloading and Positioning n Exhaust System n Cooling System n Lub Oil System n Fuel System n Electrical System n Battery Starting and Stopping a New KGPI Genset n Before 24 . . KIRLOSKAR OIL ENGINES LIMITED I First Edition. in case of a customized or critical installation need. You are a proud owner of The Best & Preferred Nation’s own Kirloskar Green Power Ideas – Genset (KGPI Genset). Adequate information is compiled together. handy and user friendly. Once again thank you for showing your trust by selecting KGPI Genset. the installation and continuous maintenance of the set are the important factors. This booklet describes simple procedures that should be followed to get the best output from the generating set. this manual will be useful for installation to the end user to achieve desired performance of the KGPI Genset. If the installation and maintenance procedures are followed. Safe and optimum operation can only be possible if the generating set is properly operated and maintained. The details of this network are provided at the end of this booklet. Roof-top.Introduction Welcome to the family of Kirloskar Oil Engines Ltd. Utmost care is taken while manufacturing the generating set to ensure to deliver the best performance to the end user. etc. the generating set will deliver the output for prolonged time and will also ensure ð Better reliability ð Highest uptime ð Improved aesthetic ð Better working conditions Our Area offices and ‘Service Dealer’ network will be pleased to provide you the necessary support and guidance. About this manual This manual provides installations and commissioning general guidelines and recommendations for KGPI Genset. diagrams and tables. Basement. keeping in mind to make this manual crisp. However. We are sure. read the User Manual to become familiar with your generating set. Before operating the KGPI Genset. To get the best performance from the generating set.April 2012I Issued by Customer Support 1 . and Structural. The information is supported by different photographs.) have been considered while preparing the guidelines and recommendations. This product is designed to deliver full rated output with high degree of reliability. In this manual different types of installations (Free field. kindly consult Seller or Kirloskar Area Office. 3 (14) 2R1040 20.5 10 15 20 25 30 40 50 62.3 (127) 6R1080TA 113.5 (200) 6SL1500TA SrI 165 (224) 6SL1500TA SrII 184 (250) 6SL8800TA 228 (310) DV8 SrI 294 (400) DV8 SrII 346 (471) DV8 360 (490) DV10 448 (608) DV12 532 (723) DV12 SrI 552 (750) Engine Model Prime Power Genset rating at 0.5 82. – In view of continuous product updating and design changes. consult KOEL for available prime power.6 (28) 2R1040 20. Also refer to latest product catalogue for updates.5WS2 KG82. – Specific gravity of diesel is considered as 0. consult Seller or Kirloskar’s Area Office.845 (+5 % tolerance as per ISO 3046).6 (62) 4R1040T 61 (83) 4R1040TA 77.2 (56.8 pf (kVA) 7. – For site conditions other than standard operating conditions.5WS2 KG100WS KG100WS2 KG125WS2 KG140WS2 KG160WS2 KG180WS KG200WS KG250WS1 KG320WS3 KG380WS KG400WS2 KG500WS3 KG600WS2 KG 625WS Engine Power at 1500 rpm. 745 755 915 925 1020 1050 1520 1500 1900 1950 1950 2500 2700 3500 3550 3870 3950 4660 5650 5850 6000 6655 7500 7500 Note: – Genset ratings are as per ISO 8528 performance class G2.2 (105) 4K1080TA 92 (125 ) 6R1080T 93.Technical Specifications (General Guidelines) Overall Specifications of Kirloskar Green Silent Gensets Liquid (Radiator) cooled Silent Gensets Genset Model KG7. all above specifications and dimensions are subject to change without prior notice. – Single phase genset option available up to 30 kVA.April 2012I Issued by Customer Support . – For the site conditions other than standard operating conditions.kW (hp) EW14 10. – Prime Power Rating is the maximum power available continuously for a variable electrical load for unlimited number of hours per year under standard operating conditions. – All canopy dimensions have tolerance of + 50 mm.5 100 100 125 140 160 180 200 250 320 380 400 500 600 625 Overall Canopy Dimensions L x W x H (mm) 1725 x 845 x 1155 1725 x 845 x 1155 2050 x 950 x 1220 2050 x 950 x 1220 2380 x 950 x 1230 2380 x 950 x 1230 2650 x 1050 x 1605 3350 x 1190 x 1650 3240 x 1140 x 1585 3240 x 1140 x 1585 3200 x 1300 x 1805 3450 x 1300 x 1900 3450 x 1300 x 1900 4040 x 1540 x 1900 4040 x 1540 x 1900 4940 x 1700 x 2050 4940 x 1700 x 2050 4940 x 1700 x 2050 5700 x 2000 x 2555 5700 x 2000 x 2555 5700 x 2000 x 2555 6200 x 2000 x 2555 6660 x 2000 x 2705 6660 x 2000 x 2705 Approx. 2 KIRLOSKAR OIL ENGINES LIMITED I First Edition. – For E-Series fuel tank integral with base frame.9 (42) 4R1040 41.5WS KG10WS KG15WS4 KG20WS4 KG25WS5 KG30WS KG40WS KG50WS KG62.1) 4R1190 45.6 (28) 3R1040 30.9 (42) 3R1040 30. weight (with canopy) kg.5) 6K1080TA 164.2 (154) 6K1080TA SrI 127.5 (173.3 (14) EW14 10. 7 (16) 10 2070 x 820 x 1540 850 KG15AS4 HA294 SrIII 15.845 (+5 % tolerance as per ISO 3046). – For E-Series fuel tank integral with base frame. – For site conditions other than standard operating conditions. – All canopy dimensions have tolerance of + 50 mm.7 (16) 7. KIRLOSKAR OIL ENGINES LIMITED I First Edition. – Specific gravity of diesel is considered as 0.4 (10) 5 1600 x 820 x 1320 650 SEKG7. – In view of continuous product updating and design changes.April 2012I Issued by Customer Support 3 .8 pf (kVA) Overall Canopy Dimensions L x W x H (mm) Approx.2 (56) 45 3220 x 1100 x 1680 1580 KG50AS HA694 47.1 (20. consult Seller or Kirloskar’s Area Office. – Single phase genset option available up to 30 kVA.5) 15 1770 x 1050 x 1400 1220 KG25AS-C HA394 23. – Prime Power Rating is the maximum power available continuously for a variable electrical load for unlimited number of hours per year under standard operating conditions.6 (43) 30 3130 x 1100 x 1680 1440 KG40AS HA494T 41. Also refer to latest product catalogue for updates. – For the site conditions other than standard operating conditions. kW (hp) Prime Power Genset rating at 0. all above specifications and dimensions are subject to change without prior notice.8 (65) 50 3980 x 1240 x 1680 1870 KG70AS HA694T 61 (83) 70 3980 x 1240 x 1680 1920 Note: – Genset ratings are as per ISO 8528 performance class G2.2 (56) 40 3220 x 1100 x 1680 1580 KG45AS HA494T 41. weight (with canopy) kg.5 (32) 25 2030 x 1050 x 1400 1350 KG30AS HA494 31. SEKG5AS7 EA10 7.5AS5 EA16 11.5 2070 x 820 x 1320 850 SEKG10AS5 EA16 11. consult KOEL for available prime power.Technical Specifications (General Guidelines) Overall Specifications of Kirloskar Green Silent Gensets Air cooled Silent Gensets Genset Model Engine Model Engine Power at 1500 rpm. The relation between kW and kVA rating is kW = kVA x Power Factor kW = 1.Sizing of KGPI Genset (General Guidelines) Sizing of KGPI Genset To select the right Genset under a given set of circumstances. a generator is designed for a power factor of 0. It is also equally necessary to understand load characteristics and to make a load analysis. Normally. Power Factor is leading for capacitive load. Power Factor is lagging for inductive load.8 4 KIRLOSKAR OIL ENGINES LIMITED I First Edition. knowledge of Genset and its performance under various conditions is necessary. These are usually not predictable. Power factor is unity for purely resistive loads. Beyond that. thyristor.732 x V x A x Power Factor (for 3 phase alternator) 1000 kW = V x A x Power Factor (for a single phase alternator) 1000 *Load variation between phases should not be more than 10%.g Induction motors. A = Line current Power Factor The power factor of electrical system depends upon the nature of characteristics of load e.April 2012I Issued by Customer Support . or which may be added after the installation of the Genset. It is better to select a slightly larger generator capacity than the available load. Where V = Line voltage. Ratings The rating of an alternator is expressed either in kilowatt (kW) or kVA. By having a margin available it is possible to power some loads which may have been overlooked during Genset selection. the effect of the voltage regulation systems plays an important role. the reason is that additional uses are invariably observed after it has been installed. power electronics etc. furnaces. 90 Transformers 0.60 Welding Set (AC Motor-DC Generator) 0.80 .70 Arc furnaces 0. HP delivered at site will vary depending on site conditions (deration due to altitude.90 Induction furnaces 0. ovens 1.60 .95 Block Loading For Naturally aspirated engines : 100% of rated power For Turbocharged and Turbo after cooled engines: Please consult Seller or Kirloskar’s Area Office for load pattern and sequencing.0.0.0.80 . For details of site derations please consult Seller or Kirloskar’s Area Office. KIRLOSKAR OIL ENGINES LIMITED I First Edition.00 Fluorescent lights 0.Sizing of KGPI Genset (General Guidelines) The table below gives power factors of non-motor loads. Deration Factor The engine’s horse power as mentioned on its name plate is the HP which an engine can deliver at MSL at NTP conditions.0. temperature and humidity).80 . Type of load Power Factor Incandescent lights 1.April 2012I Issued by Customer Support 5 .90 Welding Set (Transformer) 0.00 Heating elements. heaters load etc with quantity and name plate details. Step 2 (Applicable For Three Phase Genset) Convert all single phase loads to three phase loads by distributing equally on three phases. ð Starting by DOL will pull up to 6 to 7 times the rated full load kW of a motor.5 times the full load kW of the motor. Loading sequence) will decide Genset size.2 to 1. This voltage dip percentage is usually known to the customer based on equipment type to be powered. Tabulate the details such as lighting load. please consult seller or Kirloskar’s area office) 6 KIRLOSKAR OIL ENGINES LIMITED I First Edition. These two figures will be used to size up the Genset and sequence of loading. A/C load. Rectifier loads may also pull up to 50% above their rated kVA. Step 1 Collect all necessary basic data of load. Step 5 Determine the maximum allowable voltage dip which the Genset should experience when the total starting KVA is applied on this Genset. For motor loads.April 2012I Issued by Customer Support . (For correct sizing of DG Set. motor load. Voltage Dip. mention starting method also. In case of motors. For e. Starting KVA. ð Star/Delta will pull up to 2 to 3 times the full load kW of the motor.g. ð Soft Start will pull up to 1. Step 4 Sum up all the steady state running loads in kVA and sum up all the starting kVA’s. Voltage. Step 6 The previously obtained figures (Running KVA.Sizing of KGPI Genset (General Guidelines) Steps to be followed while sizing the Genset. Step 3 Starting power (kVA) of each equipment is based on type of starting method. KIRLOSKAR OIL ENGINES LIMITED I First Edition. 2. If KGPI Genset is to be installed in the basement. If KGPI Genset is to be installed in Free field condition. clear space of minimum 3 meters from all sides. 4. please ensure dust free location and clear space of 2 times the height of Genset. please ensure proper cross ventilation. 3. proper cross ventilation with respect to wind direction. please ensure structural clearance. clear space of minimum 3 meters from all sides. please ensure ventilation with respect to Air requirement and clear space for easy maintenance. 1. If KGPI Genset is to be installed on a roof top.Installing KGPI Genset Location ! Dust and Fumes are the greatest danger to generating set as they could lead to clogging of cooling and air system which may affect Genset performance. If KGPI Genset is to be installed in the room.April 2012I Issued by Customer Support 7 . Ø Noise n There should be sufficient space around the Genset to avoid resonance and echo effect which contributes to abnormal sound from Genset. Ø For fuel supply and fuel storage arrangement for Genset. n The environment protections n The fire protection Ø In case of high humid atmospheric conditions. Genset is to be installed in heavy dusty conditions. Ø Proper consideration should be given to take exhaust gases away from Genset location and shielded for hot surface.April 2012I Issued by Customer Support .Installing KGPI Genset Layout Ø Allow easy accessibility to Genset for easy operation and maintenance. Ø Locate the Genset considering the prevailing wind direction. n The space should be open without any obstacles. 8 KIRLOSKAR OIL ENGINES LIMITED I First Edition. like stone crusher plant. it is recommended to use heavy duty air cleaners (Please contact Seller or KOEL Area office for further guidelines). garment plant. Ø Genset installation should be as close as possible to the load. follow the local rules and regulations. chemical factory. the Genset should be isolated from the dust. an anti condensation heater should be used for the alternator. paint factory. hazardous and chemical fumes contained in the surrounding air. However in some cases. cement factory. etc. Ø In case. Ø A rooftop installation requires proper planning and the structural design considerations for dynamic loading. Ø Maximum allowed temperature rise above ambient in Genset Enclosure at air intake of engine is 7–9 deg centigrade. supply of fresh air and removal of hot air should be done through forced ventilation with suitable air ducts. Ø The space should be open without any obstacles. clean and fresh air. Ø For room and basement installations. HOT AIR OVER BARRELS/ CYL HEAD ATMOSHPERIC AIR ATMOSPHERIC AIR C ERI SPH O M AT AIR IR TA HO M R O FR IATO D RA KIRLOSKAR OIL ENGINES LIMITED OR DO R DOO I First Edition.Installing KGPI Genset Ventilation Ø Cross ventilation and free flow of cool.April 2012I Issued by Customer Support 9 . Ø Support the dynamic load of Genset while running.April 2012I Issued by Customer Support . Ø Isolate the surrounding structures by absorbing the vibration of generating set while running. Ø To support the weight of the entire generating set. The basic functions of foundation are given below. Ø To provide leveled platform to seat and seal the Genset. Improper foundation may result in alignment and vibration problems which may subsequently lead to pre-mature failure of Genset Components and Safety. Ø Absorb the vibration produced by the rotating and reciprocating masses.Foundation Foundation is one of the important factors affecting the successful operation and life of a generating set. 15 10 300 mm 0m m KIRLOSKAR OIL ENGINES LIMITED I First Edition. 800 Loose.46.500 Soft Clay 9. The table below gives approximate safe bearing capacity of various soils for ref.44.400 Medium Rock Shell 97.600 – 1.000 Loose Fine Sand 9. meter Hard Rock Granite 2.100 – 97.800 – 58.100 – 9.April 2012I Issued by Customer Support 11 . Medium Coarse and Compact Fine Sand 29.600 Hard Clay 39.Foundation While casting the concrete foundation.000 – 48.600 Soft Rock 48.000 – 48.750 – 39.76. Nature of the load bearing material Safe bearing capacity kg/sq.400 Hard Pan 78. the bearing strength of the soil at site of installation should be determined.300 – 39.800 Gravel and Coarse Sand 39.000 Medium Clay 19.500 – 39.750 KIRLOSKAR OIL ENGINES LIMITED I First Edition. 5 times of the total wet weight of the Ø single generating set installation and 2 times of the total wet weight for the multiple generating set installation. which may damage fuel tank at the bottom.Foundation The length and width of foundation should be at least 300 mm more on each side Ø than acoustic enclosure length and width respectively. Ø Ensure that the foundation to support 1. there by leading to leakage of sound and vibration on Genset. it is necessary to have planning and structural design Ø approval. use appropriate thickness of rubber matting above foundation for positive sealing of Genset with base. For rooftop installations. Ensure that the concrete is completely cured before positioning the enclosure.April 2012I Issued by Customer Support . It is recommended to have foundation height of 150 to 200 mm above ground Ø level to maintain cleanliness and avoid flooding. Check the foundation level diagonally as well as across the length and width for Ø even flatness and same should be within + 50 mm in horizontal plane in any one direction only. If Genset is to be mounted on foundation having uneven surface under unavoidable circumstances. 12 KIRLOSKAR OIL ENGINES LIMITED I First Edition. ! Do not install acoustic enclosure on loose sand or clay. Avoid hard / sharp projections such as stone or steel parts on foundation surface. Avoid uneven foundation which may lead to improper resting of Genset on foundation. KIRLOSKAR OIL ENGINES LIMITED I First Edition. Ø Unload the Genset. by lifting with proper lifting tackle/nylon sling/soft sling with spreader bar / spacer plate of suitable capacity to avoid any damage. Ø Use lift points on the acoustic enclosure (canopy) which provides support to the Ø equipment when it is moved.Unloading and Positioning All the Gensets are provided with suitable lifting arrangements. Do not drag the Genset on floor/ground. This makes it easier to set them up on the foundation.April 2012I Issued by Customer Support 13 . Engine Model (Air Cooled) Minimum pipe inside diameter in mm. h = height of building. As per Statutory regulations. exhaust pipe has to be extended above the surrounding stack as below. At the time of Genset installation.April 2012I Issued by Customer Support . increase pipe diameter by 13 mm for every 3 meters. Exhaust bend Bends used in exhaust piping should have a long smooth bend as shown in figure to ensure smooth flow of exhaust gases. please refer to the table below for selecting the size of exhaust pipe. exhaust silencer and expansion bellow are the integral parts of the exhaust system. While taking exhaust gases away from Genset above stack height.2 x v kVA Where H = Minimum height of exhaust stack. d R-2/5d 14 KIRLOSKAR OIL ENGINES LIMITED I First Edition.Exhaust System Genset Exhaust system directs the hot flue gases into the atmosphere harmlessly. EW – Series 63 EA10 / EA16 50 2R / 3R / 4R 63 EA20 63 4RTA / 6RT 75 HA2/ HA3/ HA4 63 4KTA / 6RTA / 6KTA 100 HA4 T/ HA6/ HA6T 75 6SL – Series 125 DV – Series 125 Note : Ø If the extension of exhaust pipe is more than 5 meters above Genset. please ensure proper alignment of exhaust silencer with respect to expansion bellow. H = h + 0. On KGPI Genset. Engine Model (Liquid Cooled) Minimum pipe inside diameter in mm. Exhaust System KIRLOSKAR OIL ENGINES LIMITED I First Edition.April 2012I Issued by Customer Support 15 . Exhaust pipe through out should be cladded by mineral wool with aluminium sheet (0. Type of Exhaust Pipe Use black MS ERW (Electric Resistance Welded) .April 2012I Issued by Customer Support . x GI Socket Bolted flange ERW 16 KIRLOSKAR OIL ENGINES LIMITED GI I First Edition. Exhaust pipes should be joined through flanges.8mm). Minimum thickness of cladding should be 50 mm.Class B Type pipes. Galvanised Iron pipes should not be used.Exhaust System Exhaust Support Proper support is required for the extended exhaust pipe above Genset to ensure no self weight is transferred on to the Genset. Ø Ensure cleanliness of cooling air passages. Ø Ensure ‘Top Up’ only with “K-Cool Super Plus” coolant. Air Cooled Engine Kirloskar Air Cooled Engines use Air as a cooling media for removal of heat generated in the engine through cooling passages and to maintain optimum operating temperature for efficient engine operation. KIRLOSKAR OIL ENGINES LIMITED I First Edition. Ø Ensure NO addition of water in coolant. KGPI Genset – Liquid Cooled are delivered with initial fill of Pre-mixed Coolant “K-Cool Super Plus”.April 2012I Issued by Customer Support 17 . Ø Ensure coolant level in Compensation Tank between “Min and Max” Level.Cooling System Liquid Cooled Engine Kirloskar Liquid Cooled Engines use premixed coolant for removal of heat generated in the engine due to internal combustion and to maintain optimum operating temperature for efficient engine operation. û Sluggish performance. ? Ensure fuel dilution does not occur. ? Care should be taken while filling of tank to prevent ingress of dust & moisture inside diesel tank. ü Reduced carbon deposits. Ø Check the Lub Oil level with the help of Dipstick to “H” Mark and top up if required with “K-Oil Super” only. ü Protection against rust and corrosion. Cooling and Cleaning of internal components.April 2012I Issued by Customer Support . KIRLOSKAR OIL ENGINES LIMITED I First Edition.Lub Oil System Lub Oil System Kirloskar engines utilize the pressure lubrication system with the lub oil filter adequately designed to handle the flow of lubricating oil at the designed pressure and temperature for Lubrication. û Excessive fuel consumption û Increased wear of bearings and other moving components. ! 18 It is recommended not to fill fuel during running of Genset. KGPI Gensets are delivered with initial fill of Lub Oil “K-Oil Super”. ü Reduced frictional wear. Fuel System The fuel (High Speed Diesel) should comply with the following International Standards. ü Better oxidation stability and hence less top-ups. ü Increased internal cooling. DIN 51601 IS : 1460 1995 ASTM D 975–81 : 1D & 2D ? Ensure fuel filling point is accessible and clean all the time. ? It is recommended to fill fuel after stopping of the Genset to avoid condensation. ? Ensure all fuel piping is leak free. ! Use of the wrong grade of oil could lead to: û Overheating of the engine. K-Oil Super SAE 15W 40 is a specially blended engine oil which ensures: ü Increased change intervals. ? Avoid fuel spillage. Ø 2 earthing pits for Genset / control panel body Ø 2 earthing pits for neutral. Genset Rating Recommended Earth Strip / Cable 5 – 82. 4 numbers of earth pits are required as per Indian Electricity rules / local electricity regulations. The generating set and all associated equipment must be earthed before the set is put into operation. KGPI Genset should be connected to earth in accordance with local regulations. Typical Earth Pit diagram is as shown in figure. Resistance between 2 earth pits should not be more than 5 ? .Electrical System Earthing Any leakages in current will be earthed through the shortest route in the link. The size of the link used for the main earth connection should be of adequate size as shown in table below.April 2012I Issued by Customer Support 19 .5 kVA 8 SWG – Copper 100 – 250 kVA 25x3mm CU / 25x6mm GI 320 – 500 kVA 50x6mm CU / 50x6mm GI 2 runs 625 – 750 kVA 50x6mm CU / 50x6mm GI 2 runs TYPICAL EARTH PIT / STATION ARRANGEMENT Chamber Cover Brick Work External Earth Connection Ground Level Mud/Soil Layers of Salt & Charcoal GI Pipe 1 Inch Dia Earth Pit GI Or Copper Plate KIRLOSKAR OIL ENGINES LIMITED I First Edition. April 2012I Issued by Customer Support .Electrical System 20 KIRLOSKAR OIL ENGINES LIMITED I First Edition. April 2012I Issued by Customer Support 21 .Electrical System Typical Cable Sizes for KGPI Genset Cable selection chart A) Three Phase Generators: KIRLOSKAR OIL ENGINES LIMITED I First Edition. Type of cable gland: Single Compression Heavy Duty Cable Gland. 5. For grouping of cables (multiple runs) the derating factors are considered as per duct laying method of cable. Considered amb temp: 400 C. Please use Comet make cable glands.April 2012I Issued by Customer Support . 4. rating of cable is considered as per duct laying method and 700 C operating Temperature mentioned in manufacturers catalogue. The amp. 2. 6. The distance between two parallel cables is considered 30 mm for deration. 3. Material of cable gland: Brass. 7. 22 KIRLOSKAR OIL ENGINES LIMITED I First Edition.Electrical System Typical Cable Sizes for KGPI Genset Cable selection chart A) Single Phase Generators: Important Notes: 1. 24 gm/cc (Yellow) 70% Charged – 1. mm Ensure that the polarity of the battery connections are correct before switching on the DC controls. Specific Gravity of Lead Acid in the Battery at various stages: 100% Charge – 1.April 2012I Issued by Customer Support 23 . 494T HA 694. Get the battery charged or replaced and then try to start.Battery Engine model E Series HA 294. 6R 1080T. 694T 2R 1040. For prolonged storage. Mm Multistrand PVC flexible Red and Black colour 1. 35 sq. 4K1080 Ambient Temp Battery Specification 12V Starting 24V Starting System System >+10 88 - -20 to +10 135 - >+10 88 - -20 to +10 135 - >+10 100 - -20 to +10 150 - >+10 150 - -20 to +10 180 - >+10 88 - -20 to +10 135 - >+10 135 - -20 to +10 160 - >+10 150 - 6K 1080. 3R 1040 4R 1040.20 gm/cc (Blue) Needs Recharge – Below 1. used static battery charger to keep battery fully charged. Never attempt to start the Genset if battery charge is insufficient to start the engine. mm 50 sq. 394 HA 494. disconnect the battery. During installation and maintenance. -20 to +10 160 - 6R 1080TA >+10 SL Series DV Series 150 - -20 to +10 - 2 x 12V 200 AH >+10 - 2 x 12V 180 AH -20 to +10 - 2 x 12V 200 AH >+10 - 2 x 12V 180 AH Battery cable size. 4R 1040T 4R 1040TA.24 to 1.20 gm/cc (Red) KIRLOSKAR OIL ENGINES LIMITED I First Edition.25 mts Copper cable with suitable lugs (one side battery lugs and one side round lugs) 70 sq.27 to 1. Ø Check all other electrical connections and tightness. Lubrication: Ø Check Lub oil level with help of Dipstick and if required.April 2012I Issued by Customer Support . 24 KIRLOSKAR OIL ENGINES LIMITED I First Edition. hose clamps. Ø Check Battery cables are correctly connected and secured. Ø Bleed the fuel system as shown in maintenance manual. Cooling: Liquid Cooled Engines. top up to H-Mark with “K-Oil Super”. Air Cooled Engines: Ø Check Blower Fan belt tension. Electrical: Ø Check Battery Polarity. Ø Check Coolant level inside Radiator and Compensatory tank. V-belt tension as per specifications.Starting and Stopping A New KGPI Genset Ensure tightness of all external fasteners. Ø Fill fuel tank with clean High Speed Diesel. If required Top up with “K-Cool Super Plus”. Fuel: Ø Ensure fuel tank is clean from inside. Ø Ensure Emergency Push Button is in released condition. Ensure Cleanliness of the Genset. Ø Ensure Load Change Over Switch / Breaker is in Off condition. Ø If engine fails to start. push Stop button gently once and release. Ø Check the lub oil. Ø For Push Button Start. Ø Ensure proper closing of Genset Enclosure. PF on all phases. put Ignition key in “Off” condition. Ø Check for V-belt. Ø Check for A C Alternator parameters like Voltage. coolant and fuel levels – top up if required as per recommendation given. KW. Ø Top up the Fuel Tank. Hoses and external leakage if any. After Stopping Ø Check for leakages if any. KIRLOSKAR OIL ENGINES LIMITED I First Edition. Ø Check for leakages if any. Ampere. Ø Check for abnormal noise if any. Leave ignition switch in “ON” position. Coolant Temp and Battery charging rate at regular intervals while the Genset is in operation and maintain log book. Ø Ensure load is balanced in all phases as per recommendation and within rated output of Genset. Ø Check for Engine parameters like Oil Pressure. For Push Button Starting Ø Gently press Start button once and release. release the start key. On Starting For Key Starting Ø Do not crank engine for more than 5 seconds.April 2012I Issued by Customer Support 25 . Ø Check for exhaust smoke. Ø Check all gauges and meters provided in Control Panel are working. Ø For Key Start. Ø As soon as engine fires. wait for a minute and try again. Ø Allow the engine to idle for 3 minutes and then start loading the Genset gradually in steps. Ø Ensure Load Change Over Switch / Breaker is in Off condition. Procedure: Stopping KGPI Genset Before stopping Ø Remove the load from Genset and let it run for about 3 minutes.Starting and Stopping A New KGPI Genset Procedure: Starting KGPI Genset Before Starting Ø Clean the Genset with dry cloth. LOG Sheet LOG SHEEET (Sample for use) The user is requested to maintain a separate log book registering the following mentioned parameters in the table. (ml) 26 KIRLOSKAR OIL ENGINES LIMITED I First Edition.April 2012I Issued by Customer Support . Following tables are meant for providing a reference to you. Series Oil Change hours Oil Filter Fuel Filter Change hours Change hours* Air Cleaner element change hours** V Belt Change hours EW/EA 500 500 500 1000 1000 500-for HA4/HA6 (1.April 2012I Issued by Customer Support 27 . for 1.for dry type air 1000 cleaner element.5 Ltr.Maintenance Tips First oil change @ 50 hrs or 7 days of commissioning. ** Air filter change is based on Ideal site condition. 250 – Oil change for HA 500 500 Oil bath Air Cleaner RB/RV * 250 250 250 1000 1000 R1040/R1080 500 500 500 1000 1000 SL90 500 500 500 1000 1000 Dv Series 500 500 500 500 2000 Fuel Filter Pre and Micro to be replaced alternatively after 250 hrs. It is recommended to get the routine maintenance done through Kirloskar Authorized dealer.1 Ltr. and 125 hrs. for 0.1 Ltr) 1000. KIRLOSKAR OIL ENGINES LIMITED I First Edition. however extreme dusty condition change frequency is based on occurrence of red band in restriction indicator. gauges. Open the air duct while cleaning of Air Cooled Engine. Ø When deposits are hard. Recommended Preservatives: Manufacturer Engine lub oil and Fuel system Engine cooling system for liquid cooled Unpainted ferrous metal parts Bharat petroleum Bharat Preserve oil 30 Bharat Sherol B Emulsion with water ratio 1:20 Bharat Rustrol 152 Hindustan petroleum Autoprun T120 Koolkit 40. – Veedol 30/40 – Veedol Amulkut 4 Emulsion with water in ratio 1:15 Russtilo DW 904 OR DW901 Veedol Rustop IT Alternatively 'Surprabha VCL 302' of Suprabha products can be used in engine cooling System. starter. etc. For preservation and recommissioning. When the Genset is kept idle for more than 6 months. internal corrosions and rodents.Cleaning and Preservation of KGPI Genset Remove dust deposit from the cylinder heads. condensates. Cleaning with diesel fuel or kerosene may cause dust to deposit again on the cleaned parts.April 2012I Issued by Customer Support . lub oil cooler fins.5%Emulsion with water Rustop 274 Indian oil corporation Servo Preserve 30 OR Servo 'Run-N' Oil 30 Servo Cut S 20% Emulsion with water Servo RP 125 Castrol India Veedol tide water oil co. control panel. it is advisable to protect it Ø from atmospheric moisture. scrape and clean with a water jet. Ø Cleaning should be done from the opposite side of the system air flow. Ø radiator and A C Alternator with compressed air. Do not clean electrical components like main alternator. please consult KOEL Area Office. wiring connections. liners fins. with water. charging Ø alternator. 28 KIRLOSKAR OIL ENGINES LIMITED I First Edition. Run the engine after Ø such cleaning till all the water evaporates. Ø Our service team is always round the corner to provide onsite assistance and comprehensive Service support ensuring your power needs are fulfilled Ø Before commissioning the KGPI Genset. Ø For any of your service requirements please contact nearest service dealer or KOEL Help Desk. Where your business operations are far reaching across the country & moreover when they are located in absolute remote places. Ø We understand how important after-sales support is to your business. Ø We are committed to provide adequate after sales service support & believe in creating an enduring relationship with every individual customer we serve. Service dealers are equipped with all necessary tools and tackles to take care of every need of service. please go through the contents of the warranty document.KGPI .April 2012I Issued by Customer Support 29 .Customer Support Network Ø The after sales service to KGPI Genset is provided through KOEL’s country-wide network of authorized spare and service dealers. your business counts on reliability & availability of prompt service to ensure minimum downtime. KIRLOSKAR OIL ENGINES LIMITED I First Edition. April 2012I Issued by Customer Support .Notes 30 KIRLOSKAR OIL ENGINES LIMITED I First Edition. rtwfasdfafasfasf . 105 332 .