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Geko 640000ED-S/MEDA Operating And Maintenance Manual

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OPERATING AND MAINTENANCE MANUAL
MODEL:
YEAR OF MANUFACTURE:
Metallwarenfabrik Gemmingen
Stromerzeuger
Industriestr. 1
D – 75050 Gemmingen
GENERATING SET
STROMAGGREGATE
BETRIEBSANLEITUNG
&
640000ED-S/MEDA
2004
Telefon: 07267 / 806 193
Telefax: 07267 / 806 198
www.metalwarenfabrik.com
Lukanowski@metallwarenfabrik.com

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  • Page 1 GENERATING SET STROMAGGREGATE OPERATING AND MAINTENANCE MANUAL BETRIEBSANLEITUNG MODEL: 640000ED-S/MEDA YEAR OF MANUFACTURE: 2004 Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger & Telefax: 07267 / 806 198 Industriestr. 1 www.metalwarenfabrik.com D – 75050 Gemmingen Lukanowski@metallwarenfabrik.com...

  • Page 2: Table Of Contents

    INDEX: 3.0 SAFETY SIGNS 4.0 SAFETY RULES AND DEVICES 5.0 MACHINE COMPONENTS • description and identification of the generating set • diesel motor - starting system - cooling system - alternator - base and tank - vibration dampers - silencer and exhaust system - electric panel aboard machine - electric control board - housing - container 6.0 TECHNICAL SPECIFICATIONS •...

  • Page 3: Safety Signs

    ANY MECHANICAL, HYDRAULIC, PNEUMATIC, ELECTRICAL AND ELECTRONIC TAMPERING OR FAILURE TO OBSERVE THE ABOVE INSTRUCTIONS SHALL IMMEDIATELY NULLIFY THE WARRANTY AND RELIEVE Geko OF ALL AND ANY CIVIL OR CRIMINAL RESPONSIBILITY FOR ANY DAMAGE OR INJURY CAUSED BY THE MACHINE.
  • Page 4 FAILURE TO OBSERVE THE ABOVE CONDITIONS AND THE SAFETY AND ACCIDENT-PREVENTION RULES DESCRIBED BELOW, RELIEVES Geko OF ALL AND ANY LIABILITY. NEITHER CAN GEKO BE HELD RESPONSIBLE FOR ANY DAMAGE OR INJURY CAUSED BY IMPROPER USE OF THE MACHINE OR BY UNAUTHORISED ALTERATIONS MADE TO THE SAME.
  • Page 5 DO NOT REMOVE AND/OR TAMPER WITH PROTECTIVE AND SAFETY DEVICES. IF THE CUSTOMER INSTALLS THE MACHINE, GEKO IS NOT LIABLE FOR ANY SITUATIONS OF HAZARD CAUSED BY FAILURE TO COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS MANUAL. IF THE GENERATING SET IS OUT OF ORDER, PLACE A DANGER SIGN ON IT AND DISCONNECT THE NEGATIVE OF THE BATTERY.

  • Page 6: Noise Level

    DO NOT SWALLOW OR TOUCH DIESEL FUEL, OIL, ENGINE WATER, LUBRICANTS AND BATTERY ACID. IF SWALLOWED, SEEK FIRST AID IMMEDIATELY. IF THESE SUBSTANCES COME INTO CONTACT WITH THE SKIN, WASH IMMEDIATELY WITH SOAP AND WATER. DO NOT WEAR CLOTHES SOILED WITH DIESEL FUEL OR LUBRICATING OIL. WEAR ACID-PROOF APRONS AND PROTECTIVE SHIELDS OR GOGGLES FOR THE FACE WHEN CARRYING OUT MAINTENANCE ON THE BATTERY.
  • Page 7 SING THIS SIGN FOR THE SAFETY PROCEDURES ORMALLY T IS INSTALLED ON THE CANOPY IF THE GEN SET IS OPEN THIS SIGN IS WITH THE MANUALS FOR TO INSTALL OUTSIDE OF THE GEN SET LOCAL Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger &...
  • Page 8 ELECTRICAL SAFETY DEVICES If the electrical equipment of the generating set is correctly installed, used and maintained, operations are safe and efficient. THE GENERATING SET SHOULD ONLY BE STARTED UP BY QUALIFIED, TRAINED PERSONNEL WHO ARE AUTHORISED TO WORK AND IN COMPLIANCE WITH THE LAWS IN FORCE IN THE COUNTRY OF INSTALLATION.
  • Page 9 FIRST AID IN THE EVENT OF ELECTROCUTION In an emergency, while waiting for the first-aid personnel to arrive, follow the general instructions given below to give immediate aid. DO NOT TOUCH THE VICTIM WITH BARE HANDS UNTIL THE VOLTAGE HAS BEEN ANNULLED. •...

  • Page 10: General Description

    GENERAL DESCRIPTION fig. 5.02 Generating set with separate control board for emergenc Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger & Telefax: 07267 / 806 198 Industriestr. 1 www.metalwarenfabrik.com D – 75050 Gemmingen Lukanowski@metallwarenfabrik.com...
  • Page 11 There is a fan inside the alternator for cooling its components. ALTERNATOR (POINT 1) As for the prime mover, also the alternators used in making Geko generating sets are of different makes and types, chosen from among the most qualified manufacturers. The alternator is a synchronous electric machine, the synchronous speed of which is determined by the number of pole pairs that are present in the machine excitation circuit.
  • Page 12 VIBRATION DAMPERS VIBRATION DAMPERS are inserted between the alternator/engine supports and the base to reduce and attenuate engine vibrations transmitted to the base. Alternatively in other models, the engine/alternator unit is rigidly mounted onto the base and the vibration dampers are installed between the base and the floor.
  • Page 13 RAILER-MOUNTED GENERATING SETS Geko generating sets may be trailer-mounted or encased. The trailer used is the type for multi-purpose slow towing and is intended to allow handling of the generating set within a buildiing site or private space. Under no circumstances may...

  • Page 14: Technical Specifications

    TECHNICAL SPECIFICATIONS 6.1 GENERAL TECHNICAL SPECIFICATIONS • 3720x1610x2300 mm Dimensions (L x W x H) • 5400 kg Weight • 24 Vdc Electric power supply • 25 °C Working temperature • 60÷80 % Relative humidity • 640 kVA Continuous power •...

  • Page 15: Packing, Loading And Transportation

    • PACKING Packing of the generating sets is carried out suitably and correctly by Geko personnel. Whenever transportation is necessary, due to changes in the place of installation, the following instructions must be observed: • protect the generating set from the elements by sealing it in nylon wrapping;...
  • Page 16 PREPARE AND USE SUITABLE LIFTING EQUIPMENT. KEEP UNAUTHORISED PERSONS AT A SAFE DISTANCE FROM HANDLING AREAS. CIRCULATE WITH LOWERED LOADS. Max 60° -The lift of generaring set can be made without fig.7.01 pallet or glut blocks Examples of ways of lifting - The capacity of lifthing must be >= the weight of generating set.
  • Page 17 fig.7.02 Examples of ways of lifting The support cables have to be long for exclude any deterioration on control panel or on other protruding components. Sling lifting Sling lifting Get by the support cables below the corner lugs of the baseframe. fig.7.03 Examples of ways of lifting Metallwarenfabrik Gemmingen...

  • Page 18: Installation

    If any damage is found, the user shall: make a note on stamped paper that the machine is accepted under reservation inform Geko that the damage will be reported to the insurance company, which shall immediately send an inspector; keep the machine available for the insurance company inspector in the state in which it was when the damage was discovered, suspending any further operation of unpacking, handling, installation etc..
  • Page 19 INSTALLATION This chapter contains the procedures to be observed in order to choose the site, the base, the position and the connection of the various parts of the generating set correctly. THE MACHINE MUST BE INSTALLED IN COMPLIANCE WITH THE ENCLOSED INSTRUCTIONS AND RULES OF GOOD WORKMANSHIP 8.1 AREA OF INSTALLATION The appropriate place for installing a generating set should be regular in shape and if possible should rest on solid ground...
  • Page 20 VIBRATION DAMPERS To minimise engine vibrations transmitted to the building, the generating set is fitted with vibration dampers. The position of the vibration dampers depends on the type of alternator support.If the alternator has a monobloc support, the vibration dampers are inserted between the alternator/engine unit and the base. During installation it is advisable to insert a 1cm thick rubber shim between the base and the foundation.
  • Page 21 COOLING AND FORCED AND ENVIRONMENTAL VENTILATION The alternator, engine and exhaust pipes irradiate heat, which may be at a sufficiently high temperature to have a negative effect on the running of the actual generating set. It is therefore very important to make sure that the room is adequately ventilated to create the conditions for perfect cooling of the diesel engine and also to ensure an appropriate temperature for service personnel.

  • Page 22: Exhaust System

    EXHAUST SYSTEM The purpose of an exhaust system is to convey smoke and odours to the outlet, which is in such a place and height that they cannot become bothersome or risky, offering the minimum possible resistance to gas flow. A silencer may be incorporated to reduce the machine noise level, which consists of baffles, pipes or expansion openings and is connected to the pipes of the exhaust outlet.

  • Page 23: Connection

    PROTECT THE EXHAUST PIPES AGAINST ACCIDENTAL CONTACT UP TO A HEIGHT OF 2.5m. 5. Carry out any water connections if required (automatic filling, topping up of oil, radiator connection, etc..). ELECTRICAL CONNECTIONS EVERY OPERATION OF AN ELECTRICAL NATURE MUST BE CARRIED OUT BY PERSONNEL WITH THE NECESSARY PREREQUISITES AND TECHNICAL KNOW-HOW.

  • Page 24: Commissioning

    2. Check the level of the lubricating oil, the fuel and the cooling water. Geko generating sets come with the engine already filled with lubricating oil of the SAE 15W-40 type. It is sufficient to check before starting and after a brief period of operation that the oil level is up to the top notch on the dipstick. Use the same type of oil both for the air cleaner bowl, if it is the oil bath type and needs topping up to the mark, and for the injection pump casing.
  • Page 25 ACCUMULATORS IN ORDER TO AVOID EXPLOSIONS. Geko generating sets come complete with lead batteries for starting; these batteries are normally the “dry charging” type and when commissioning, all the elements should therefore be filled (up to a level exceeding that of the plates by 5-10 mm) with a solution of sulphuric acid for lead batteries.
  • Page 26 IT System : the neutral is insulated or connected to earth through an impedance. The earths are connected to a local earthing system, which may be separate or connected to that of the neutral. It should be emphasised that if the generating set provides energy for safety services, the interruption of which could jeopardise the safety of persons, an IT system should preferably be adopted, since it avoids cut-off for first earth fault.
  • Page 27 The neutral, insulated from the earth, also makes any possible direct contact less dangerous, considering the limited extension of the circuit. To allow practical execution of the above, Geko generating sets come supplied with the neutral insulated and accessible; furthermore, all the metal earths are electrically connected...

  • Page 28: Daily Tank Automatic Filling System

    11.0 DAILY TANK AUTOMATIC FILLING SYSTEM 11.1 COMPONENTS The system basically consists of: - electric gear pump with by-pass, capacity 10 l/min, delivery head 50 m and suction head 5 m, single phase asynchronous motor 0.25 kW - 230 V - 50 Hz - alternative manual pump - 1 manually-operated 1/2”...
  • Page 29 position “O CUT-OUT”, all pump operation is cut out while the luminous indicators “LOW FUEL WARNING”, “NO FUEL” and “MAXIMUM FUEL LEVEL” remain active. Putting the switch to position “2-MANUAL”, the pump starts immediately; in this position not only the warning indicators are activated, but also the pump protective devices, including those for the daily tank maximum level and the storage tank minimum level.
  • Page 30 Automatic filling device with underground storage tank (fig. 11.2) Automatic filling device with external storage tank (fig. 11.2) Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger & Telefax: 07267 / 806 198 Industriestr. 1 www.metalwarenfabrik.com D – 75050 Gemmingen Lukanowski@metallwarenfabrik.com...
  • Page 31 If the pump does not work, the pump operation switch must be put to “O-CUT OUT” and the manually-operated three-way valve must be activated to cut out the electric pump. Fill the tank using the hand cranked pump. Having completed the operation, use the three-way valve to cut out the manual pump.
  • Page 32 fig 11.3 Manipulation function diagram for three way valve Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger & Telefax: 07267 / 806 198 Industriestr. 1 www.metalwarenfabrik.com D – 75050 Gemmingen Lukanowski@metallwarenfabrik.com...

  • Page 33: Maintenance

    The generating set must be kept clean. If necessary clean with aqueous industrial products; do not use inflammable solvents for this purpose. Any parts, components, spare parts that need replacing must absolutely comply with the bill of materials that Geko has enclosed with this manual.

  • Page 34: Alternator Maintenance

    For stand-by generating sets which operate for relatively few hours a year, it is advisable to change the engine oil twice a year and not at the time intervals given by the manufacturer. This is because the quality of the oil deteriorates if it remains almost inactive for months;...

  • Page 35: Troubleshooting

    12.7 MONTHLY MAINTENANCE for low-load generators 1. carry out the operations described under routine maintenance 2. check the generating set operations and load 3. start the generating set and let it tick over at 50% load for 1 or 2 hours 12.8 MAINTENANCE EVERY 6 MONTHS or 250 HOURS Repeat the daily procedures already described and carry out the following:...
  • Page 36 ANOMALY REMEDY The engine does not The engine does not start 1. Check the key switch start (for manually- when the key switch is 2. Check for faults shown by the indicator lights. If necessary, reset operated control turned to the START the generator after having remedied the indicated fault.
  • Page 37 The generating set The high temperature 1. Check that the generator is not overloaded. stops due to high indicator light comes on 2. Check if the air or water passages of the radiator are clogged. temperature 3. Check for obstructions in the filter or the intake system. 4.
  • Page 38 3. Check if there is a fault in the voltmetric relay. For any faults with Refer to the alternator handbook. the alternator IN THE EVENT OF MALFUNCTIONING OR FOR FURTHER INFORMATION, CONTACT THE Geko SERVICE CENTRE Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger &...
  • Page 39 Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger & Telefax: 07267 / 806 198 Industriestr. 1 www.metalwarenfabrik.com D – 75050 Gemmingen Lukanowski@metallwarenfabrik.com...
  • Page 40 Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193 Stromerzeuger & Telefax: 07267 / 806 198 Industriestr. 1 www.metalwarenfabrik.com D – 75050 Gemmingen Lukanowski@metallwarenfabrik.com...

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