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HGI Generators HRD270T1 Operation And Maintenance Manual

27kva 3 phase diesel generator
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Ravenstor Road
Wirksworth
Derbyshire
DE4 4FY
ENGLAND
Sales Tel:
+44 (0) 1629 824 284
Sales Fax:
+44 (0) 1629 824 613
Email:
info@hgigenerators.com
sales@hgigenerators.com
Website:
www.hgigenerators.com
Operation and Maintenance Manual
27kVA 3 Phase Diesel Generator
Build No: HRD270T1, HRD270T1+
Publication 498-1052
© Harrington Generators International Limited
All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in
any medium by electronic means or other) without the written permission of the copyright holder except in accordance with
the provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holder's written permission to reproduce any part of this publication should be addressed to
Harrington Generators International Limited at the address above.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Harrington Generators International Limited reserves the right to change the contents of this document without prior notice.

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  • Page 1 Operation and Maintenance Manual 27kVA 3 Phase Diesel Generator Build No: HRD270T1, HRD270T1+ Publication 498-1052 © Harrington Generators International Limited All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988.
  • Page 2 Change Control Date Version Author Reason for change Feb 14 Provisional Draft for Review by Ken Croft July 14 Updated and released following review Mar 16 Updated for Coolant Notice, revised battery isolator and addition of fuel priming switch. DofC notice, Installation notes, Wiring Diagrams Jan 17 General Update, Warranty Iss H, Wiring Sept 17...

  • Page 3: Table Of Contents

    INTRODUCTION ..................... 1 CERTIFICATION ..................... 2 EC Declaration of Conformity ..............2 Data Plate ....................... 3 SPECIFICATION ..................... 4 General Arrangement HRD270T1 ..............6 270T1+ .............. 8 SAFETY ......................10 A few words about safety ................10 Operator Responsibility ................10 Precautions ....................
  • Page 4 Functional Spares ..................41 TRANSPORTATION AND STORAGE ............42 WIRING ......................43 HRD270T1..................... 43 HRD270T1+ ....................44 MANUFACTURER’S SERVICE AND USER GUIDES LINKS ...... 45 Kohler Operators and Maintenance Manual ..........45 Deep Sea 4510 User Guide ................ 45 Mecc Alte ECO / ECP User Manual ............45...
  • Page 5 HRD270T1 1500 RPM Diesel Generator * for illustration only...

  • Page 6: Introduction

    Harrington Generators International Introduction Introduction Thank you for purchasing a quality generator, carefully Every effort has been made to ensure that the manufactured to the highest standards by one of information given in this manual is correct at the time of the World’s leading generator manufacturers, HGI publishing.

  • Page 7: Certification

    Certifi cation Harrington Generators International In accordance with ISO/IEC 17050-1:2010 Conformity Assessment - Suppliers’ Declaration of Conformity Certifi cation EU DECLARATION OF CONFORMITY EC Declaration of Conformity HGI Harrington Generators International Ltd. Ravenstor Road Wirksworth, Derbyshire DE4 4FY Declare that Equipment : Diesel Generator Model name /Number : HRD270 range...

  • Page 8: Data Plate

    Ravenstor Road Wirksworth Derbyshire, DE4 4FY Tel: +44(0)1629 824284 Fax +44(0)1629 824613 www.hgigenerators.com info@harringtongen.co.uk Generating Set ISO 8528 COP Class G2 Model: Serial No: 70366893 Build Code: HRD270T1 Year of Manufacture: 2014 Electrical Power: 27.0kVA / 21.6kW 0.8 Frequency: 50 Hz Voltage Volts: 400V...

  • Page 9: Specification

    Specifi cation Harrington Generators International Specifi cation General Specifi cation 20.0 kVA Canopied Diesel Generator Set. Canopied set with integral bunded 150 Litre fuel tank. With local or remote starting using DeepSea 4510 module. Switched Multi-Voltage by 2 position switch from 400V 3 Phase to 230V and 110V Single Phase. 400V 3 Phase 27.0 kVA/21.6 kW 400V 3 Phase 27.0 kVA 21.6 kW...
  • Page 10 Harrington Generators International Specifi cation Engine Engine model: Kohler KDI 2204 M Service Interval: 500 hours Engine Speed: 1500 rpm Engine Cooling: Water cooled Starting Method: Electric Start Specifi c Fuel Consumption 220 g / kW h Electrical System: 12V DC system Emissions Level: European Stage 3 A.

  • Page 11: General Arrangement Hrd270T1

    Specifi cation Harrington Generators International 498-1052 HRD Diesel Generator...
  • Page 12 Harrington Generators International Specifi cation HRD Diesel Generator 498-1052...

  • Page 13: 270T1

    Specifi cation Harrington Generators International 270T1+ 498-1052 HRD Diesel Generator...
  • Page 14 Harrington Generators International Specifi cation HRD Diesel Generator 498-1052...

  • Page 15: Safety

    Safety Harrington Generators International Safety Operator Responsibility • Know how to stop the generator quickly in case of A few words about safety emergency. • Understand the use of all generator controls, Your safety and the safety of others are very important output sockets, and connections.
  • Page 16 Harrington Generators International Safety The generator is fi tted with a number of labels that alert the user to the safe operation and safety requirements. A full explanation of these is contained here. If any of the labels are missing or unreadable a duplicate should be obtained and fi...
  • Page 17 Safety Harrington Generators International Pt No. 499-945-009 FORK LIFT POINT Qty 4 The generator can be lifted from the sides or from the front or rear using a fork lift Above Fork Lift Pockets truck with correctly spaced forks. It is intended that when lifting from the sides, that one fork passes through the part of the frame that forms a loop and foot.
  • Page 18 Harrington Generators International Safety Pt No 499-945-011 KEEP FLAMMABLE MATERIAL AWAY FROM THE GENERATOR On side panel: The exhaust and some surfaces are hot and fl ammable material should not be allowed near the generator. Pt No 499-945-011 OPERATE ONLY IN WELL VENTILATED AREAS.
  • Page 19 Safety Harrington Generators International Pt No 499-945-011 DO NOT OPERATE WITH ANY COVERS OPEN On side panel: If covers are open (or missing) the generator will exceed the European Noise Regulations and the cooling of the engine and alternator will be affected which could cause damage to them.
  • Page 20 Harrington Generators International Safety Pt No. 499-945-014 MCB1 IDENTIFICATION Qty 1 Informational label showing position of MCB1. On Control Panel for DC MCB Pt No. 499-945-019 3 PhaseTERMINALS Qty 1 Informational label showing terminal posi- tions. Below Terminals in Terminal Pod of 3 Phase Generators Pt No.
  • Page 21 Safety Harrington Generators International Pt No. 499-945-024 USB PORT Qty 1 Information label advising position of USB Port. On Control Panel below the USB Port Pt No. 499-945-025 RADIATOR DRAIN Qty 1 Advisory label showing the position of the Radiator Drain Point On Bottom of Radiator next to Drain Point Pt No.
  • Page 22 Harrington Generators International Safety Pt No. 499-945-039 110V Qty 1 Advisory of voltage on socket output On Top of the Top 110V Socket if used Pt No. 499-945-040 400V Qty 1 Advisory of voltage on socket output On Top of the Top 400V Socket if used Pt No.
  • Page 23 Safety Harrington Generators International Battery Compartment On front panel over battery DANGER ELECTRICITY compartment The battery is 12 V DC and care should Part of label be taken not to come into contact with the No: 499-945-006 terminals. On front panel over battery DANGER ACID compartment The battery contains acid and if any liquid is...

  • Page 24: Electrical Safety

    Harrington Generators International Safety • Positioned or installed to prevent the risk of injury, Electrical Safety e.g. from the equipment or the load falling or striking people. In addition to the information given previously the- generator should be installed, earthed and used with •...

  • Page 25: Hazards To Health

    Safety Harrington Generators International Hazards to Health A list of the hazards that may affect health are included with safety precautions and fi rst aid instructions. Material / Hazard First Aid Measures Location Engine Oil When hot may burn the skin but not Burns: Rinse with clean water, cover with a ster- expected to give rise to an acute hazard ile pad and obtain medical assistance.
  • Page 26 Harrington Generators International Safety Asbestos This generator is asbestos free. Battery The User and Service Technicians will not Skin Contact: Remove contaminated clothing Acid normally come into contact with acid. and wash thoroughly with soap and water. If persistent irritation occurs obtain medical Battery is Battery contains acid electrolyte which is attention.

  • Page 27: Operation

    Large access doors on both sides enable ease of servicing and maintenance in a tight space. Service Access The HRD270T1 utilises a standard control panel using Door a Deep Sea Electronics 4510 (DSE4510) controller. Emergency Stop The Deep Sea controller can be confi...

  • Page 28: Output Panel

    Harrington Generators International Operation Output Panel Item Description Fuses: F1 - 5A Control Module Fuse F2 - 10A DC Fuse F3 - Generator Sense L1 F4 - Generator Sense L2 F5 - Generator Sense L3 Control Module Protection MCB Output Protection Panel DSE4510 Control Module Phase Selection Switch DC Isolation Switch...
  • Page 29 Operation Harrington Generators International Wiring diagrams for the Deep Sea 4510 and other NOTICE panel wiring are included in this document. When generator not required switch off to minimise The DSE module will go into standby when no com- battery drain. mon alarms have been triggered after 1 minute of inactivity.
  • Page 30 Harrington Generators International Operation alarm indicator is illuminated one of the following icons GENERATOR OVER will be displayed on the modules LCD. FREQUENCY The generator output frequency Icon Description has risen above the pre-set pre- alarm setting. BATTERY UNDER VOLTAGE / BATTERY OVER VOLTAGE GENERATOR UNDER The DC supply has fallen below...

  • Page 31: Emergency Stop

    Operation Harrington Generators International Emergency Stop Item Description Three Phase and Neutral Terminal Pressing the emergency stop Connections pushbutton will immediately stop Remote Connection Terminals the engine and prevent it from restarting. Auto Shutdown Switch Cable Gland The emergency stop button must Earth Stud only be used to stop the machine in an emergency and not to stop the set during normal...

  • Page 32: Battery Isolator

    Harrington Generators International Operation Battery Isolator Pre-Operation Checks Before carrying out the following checks, ensure that the control module is switched off and/or the battery is isolator is switched off. Engine Oil Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped.
  • Page 33 Operation Harrington Generators International Replace the engine oil after the fi rst 50 hours, then NOTICE every 200. When changing the oil or topping-up, use oil of a grade suitable for the prevailing ambient tem- DO NOT use the expansion bottle as indicator of peratures (see table in engine handbook).
  • Page 34 Harrington Generators International Operation 2. Locate the fuel lever mounted on a bracket from If the engine is running the fuel level can be the base of the generator. checked at the DSE4510 control module. If the fuel is low the Low Fuel Alarm indicator will be lit and the generator will shutdown to prevent air locking in the fuel system.

  • Page 35: Starting

    Operation Harrington Generators International If the engine fails to start after 3 attempts then inititate Starting fault fi nding to rectify the problem. Local Operation NOTICE 1. Perform the Pre-Operation Checks. If the generator is not required switch it off and avoid 2.

  • Page 36: Fault Finding

    Harrington Generators International Fault Finding Fault Finding IMPORTANT: If the following checks and investigations can be completed without the use of tools then the operator can safely undertake them. If tools are needed then ONLY trained technicians can undertake the work safely. Wiring diagrams can be obtained from HGI to help with electrical fault fi...

  • Page 37: Engine Starts But Then Stops

    Fault Finding Harrington Generators International Engine Starts but then Stops Symptom Cause and Remedy • Check control circuit fuse and MCB. Engine starts but then closes • Check battery charger circuit fuse. down. • Check the 12V DC supply from the battery and battery charger has not been lost.

  • Page 38: No Electrical Output

    Harrington Generators International Fault Finding No Electrical Output Symptom Cause and Remedy • For three phase generators ensure that the correct selection has Check the electrical output been made on the phase selection switch. selector switch is set to the correct position.

  • Page 39: Maintenance

    Maintenance Harrington Generators International Maintenance Good maintenance is essential for safe, economical, and trouble free operation. This not only ensures that your engine is at its optimum in fuel effi ciency, but maintains the engine in order to minimize the risk of breakdowns. Maintenance Schedule Service intervals will have to be reduced if the welder-generator is operated in dusty or severe conditions.

  • Page 40: Safety Precautions

    Harrington Generators International Maintenance Replace the engine oil every 500 hours operation. Safety Precautions When changing the oil or topping up, it is recommended to use oil of grade SAE10W40. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable Drain the oil in the engine while the engine is warm.
  • Page 41 Maintenance Harrington Generators International The radiator should be fi lled to typically 1 cm above Battery the core of the radiators matrix. The battery is a maintenance free unit and should not require the electrolyte being topped up. Replace coolant every 12 months or as specifi ed by the engine manufacturer’s guidelines.
  • Page 42 Harrington Generators International Maintenance Check Operation of MCBs Exhaust System No maintenance can be carried out on MCBs other Inspect the exhaust system and silencer at the fl exible than a physical check to ensure the MCB latches in sections and joints in particular. the On position and no sign of external damage can be seen.
  • Page 43 Maintenance Harrington Generators International Correct sealing / fi tting of exhaust pipe: Remove the front panel and check the silencer and exhaust pipe is correctly fi tted and sealed at its mounting fl ange with no signs of blowing. Lifting Points: Inspect the lifting points for obvious signs of wear, damage or distortion.
  • Page 44 Harrington Generators International Maintenance (for use by owner / service agent) Maintenance Record Sheet Name of Owner: Name of Service Organisation: Address: Address: Order No: Job No: Generator Details (from Data Plate) Date of Service: Model: Hours Run meter reading: (hrs) Serial No: Build Code:...

  • Page 45: Parts And Service

    Parts & Service Harrington Generators International Parts and Service Contact Details Technical Help Line Parts Department Staffed by friendly Technical Engineers who will Tel: +44 (0) 1629 821 645 advise on the correct generator for your power Fax: +44 (0) 1629 821 606 requirements, its application and safe use.

  • Page 46: Functional Spares

    Relay Module 140-560 Automobile Fuse 15A 100-212 Automobile Fuse 20A 100-213 Automobile Fuse 35A 100-304 *Alternator HRD270T1 020-658-DER *Alternator HRD270T1+ 020-661-DER * The AVR on the Alternators need to be programmed specifi cally for NOTICE these generators. HRD Diesel Generator...

  • Page 47: Transportation And Storage

    Transportation / Storage Harrington Generators International Transportation and Storage Do not lay the generator on its side when moving, storing, or operat- NOTICE ing it. Oil may leak and damage the engine or your property If the generator has been used, allow it cool for at least 15 minutes before loading the generator on the transport vehicle.

  • Page 48: Wiring

    Harrington Generators International Wiring HRD Diesel Generator 498-1052...

  • Page 49: Hrd270T1

    Wiring Harrington Generators International 498-1052 HRD Diesel Generator...

  • Page 50: Manufacturer's Service And User Guides Links

    Harrington Generators International Manufacturer’s Service and User Guides Manufacturer’s Service and User Guides Links Every effort is made to ensure that the manufacturer’s user and service guides contained in this manual are the latest available at the time of publication. If in doubt about the recency of the documents then please contact the manufacturer or visit their website for the latest information.

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Hrd270t1plus

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