Doosan G20 Operation & Maintenance Manual
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Doosan G20 Operation & Maintenance Manual

50/60hz xf/xw
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G20, G30, G45, G60 50Hz (XF/XW)
G24, G36, G48, G71 60Hz (XF/XW)
OPERAT
ION & MAINTENANCE MANUAL
Original Instruction
SP001/01/09/17 -ENG-
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.

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Summary of Contents for Doosan G20

  • Page 1 G20, G30, G45, G60 50Hz (XF/XW) G24, G36, G48, G71 60Hz (XF/XW) OPERAT ION & MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine. SP001/01/09/17 -ENG-...
  • Page 3 Write the correct information for YOUR DIPP generator in the spaces below. Always use these numbers when referring to your DIPP generator. Generator Serial Number Engine Serial Number NOTES: YOUR DIPP DEALER: ADDRESS: PHONE: Doosan Bobcat EMEA s.r.o. U Kodetky 1810, Dobris, 263 12 Czech Republic...
  • Page 5 FOREWORD CONTENTS FOREWORD ............................6...
  • Page 6 The intended uses of this machine are outlined below © COPYRIGHT 2017 and examples of unapproved usage are also given, DOOSAN COMPANY however the company cannot anticipate every application or work situation that may arise. IF IN DOUBT CONSULT SUPERVISION.
  • Page 7 GENERAL DATA CONTENTS GENERAL DATA............................ 8 ELECTRICAL DATA ..........................9...
  • Page 8 GENERAL DATA UNIT MODEL (50Hz) 1500 1500 1500 1500 Diesel Diesel Diesel Diesel Cummins Cummins Cummins Cummins X2.5-G2 X3.3-G1 S3.8-G6 S3.8-G7 FLUID CAPACITIES t i l 11.0 11.0 t i l & t i l 12VDC 12VDC 12VDC 12VDC UNIT MEASUREMENTS / WEIGHTS l l a 2200 2200...
  • Page 9 ELECTRICAL DATA 50Hz GENSET GENSET ENGINE ALTERNATOR 400/230V CB Size MODEL DUTY MODEL MODEL Standby X2.5G2 S0L2-G1 Prime X2.5G2 S0L2-G1 X3.3G1 S0L2-P1 Standby Prime X3.3G1 S0L2-P1 Standby S3.8G6 S1L2-N1 Prime S3.8G6 S1L2-N1 Standby S3.8G7 S1L2-Y1 Prime S3.8G7 S1L2-Y1 50Hz 415/240V GENSET GENSET CB Size...

  • Page 10: Table Of Contents

    SAFETY CONTENTS SAFETY DECALS ..........................11 GRAPHIC FORM AND MEANING OF ISO SYMBOLS ..............11 SAFETY INSTRUCTIONS ........................13 EARTHING ............................14 IF USED AS ALTERNATE POWER SUPPLY .................. 14 HAZARDOUS SUBSTANCE PRECAUTION ................... 15 GENERAL INFORMATION ......................15 Electricity Materials Battery Radiator...

  • Page 11: Safety Decals

    SAFETY DECALS GRAPHIC FORM AND MEANING OF ISO SYMBOLS PROHIBITION / MANDATORY INFORMATION / INSTRUCTIONS WARNING WARNING: Electrical shock risk. WARNING - Hot surface. Tie down point. Lifting point. On (power). Off (power). Read the Operation & Maintenance Diesel fuel Crush Warning manual before operation or No open flame.
  • Page 12 WARNING - Flammable liquid.

  • Page 13: Safety Instructions

    SAFETY INSTRUCTIONS DANGER CAUTION This machine is not designed for operating life- Exercise extreme caution when using booster sustaining equipment. It is equipped with a safety battery. To jump battery, connect ends of one booster shutdown system that will cause the machine to stop cable to the positive (+) terminal of each battery.

  • Page 14: Earthing

    WARNING WARNING Failure to properly earth the Generator Set can result Electrical Shock - in severe injury or death. Do not operate electrical equipment while standing in IF USED AS ALTERNATE POWER SUPPLY water, on wet earth or with wet hands or shoes. Connect only after the main service entrance switch Use extreme caution when working on electrical has been DISCONNECTED and LOCKED OPEN.

  • Page 15: Hazardous Substance Precaution

    HAZARDOUS SUBSTANCE PRECAUTION Make sure that all protective covers are in place and that the canopy / doors are closed during operation. The specification of this machine is such that the CAUTION machine is not suitable for use in flammable gas risk areas.

  • Page 16: Battery

    The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: • anti-freeze • engine lubricant • preservative grease • rust preventative • diesel fuel • battery electrolyte AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.
  • Page 17 OPERATING INSTRUCTIONS CONTENTS OPERATING INSTRUCTIONS ....................18 COMMISSIONING ..........................CONNECTING THE LOAD ........................PRIOR TO STARTING .......................... STARTING ............................STOPPING ..............................................20 DESCRIPTION OF CONTROLS ..... CONTROL PUSH BUTTONS ..........................................24 MODULE DISPLAY ..... VIEWING THE INSTRUMENT PAGES ..

  • Page 18: Operating Instructions

    OPERATING INSTRUCTIONS Never operate unit without first observing all safety Always use the 5 connections, 3 phases, neutral and warnings carefully reading the operation & earth. maintenance manual shipped from the factory with this Make sure your installation is in compliance with local machine.

  • Page 19: Starting

    WARNING DANGER Do not remove the cap from a HOT engine radiator. POWER is present upon cranking the engine. The sudden release of pressure from a heated cooling system can cause severe injury or death. CAUTION CAUTION Allow starter to cool for one minute between start attempts.

  • Page 20: Description Of Controls

    DESCRIPTION OF CONTROLS CAUTION The module may instruct an engine start event due to external influences. Therefore, it is possible for the engine to start at any time without warning. Prior to performing any maintenance on the system, it is recommended that steps are taken to remove the battery and isolate supplies.
  • Page 21 DSE6010 MKII Menu Module Fault LED. Will be Navigation Display constant on warning and flash upon Electrical Trip and Shutdown Fault Close Open Generator Generator (Manual Mode (Manual Mode Only) Only) Start Stop / Reset Manual Auto Alarm Mute Mode Mode Mode &...

  • Page 22: Control Push Buttons

    CONTROL PUSH-BUTTONS Description Icon Stop / Reset Mode This button places the module into its Stop/Reset Mode . This clears any alarm conditions for which the triggering criteria have been removed. If the engine is running and the module is put into Stop mode, the module automatically instructs the generator to unload (Close Generator and Delayed Load Output 1, 2, 3 &...
  • Page 23 Icon Description Auto Mode This button places the module into its Auto Mode . This mode allows the module to control the function of the generator automatically. The module monitors the remote start input and once a start request is made, the set is automatically started and placed on load (Close Generator and Delayed Load Output 1, 2, 3 &...

  • Page 24: Module Display

    Instrumentation Icons MODULE DISPLAY When viewing instrumentation pages, an icon is The module’s display contains the following sections: displayed in the Inst. Icon section to indicate what section is currently being displayed. Note: Depending upon the module’s configuration, some display screens may be disabled. For Icon Details further details of module configuration, refer...
  • Page 25 Front Panel Editor (FPE) / Auto Run Icon If multiple alarms are active at the same time, the Alarm Icon automatically cycles through all the appropriate icons to indicate each alarm which is active. Note: For further details about the Front Panel Editor, see the section entitled ‘Front Panel Example Editor’...
  • Page 26 Alarm Icons (Cont’d) 1. Warning Alarm Icons Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition. By default, warning alarms are self-resetting when the fault condition is removed. However enabling all warnings are latched causes warning alarms to latch until reset manually.
  • Page 27 Alarm Icons (Cont’d) 2. Electrical Trip Alarm Icons Note: The alarm condition must be rectified before a reset takes place. If the alarm condition remains, it is not possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar active from safety on alarms, as the oil pressure is low with the engine at rest).
  • Page 28 Alarm Icons (Cont’d) 3. Shutdown Alarm Icons Note: The alarm condition must be rectified before a reset takes place. If the alarm condition remains, it is not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar active from safety on alarms, as the oil pressure is low with the engine at rest).
  • Page 29 Alarm Icons (Cont’d) Icon Fault Description Generator Under The generator output frequency has fallen below the pre-set alarm Frequency setting after the Safety On timer has expired. Generator Over The generator output frequency has risen above the pre-set alarm Frequency setting.

  • Page 30: Viewing The Instrument Pages

    General Navigation VIEWING THE INSTRUMENT PAGES Navigation Menu Note: For further details of module configuration, refer to DSE Publication: 057-223 DSE60xx MKII Configuration Software Manual. To enter the navigation menu, press both the (up) and (down) buttons simultaneously. It is possible to scroll through the display to view different pages of information by repeatedly operating the (up) (down) naviagation buttons.
  • Page 31 Total Load (kVA) Generator Voltage (ph-N / ph-ph) Load ph-N (kVAr) Mains Voltage (ph-N / ph-ph) (DSE6020 MKII only) Total Load (kVAr) Power Factor ph-N Generator Power Factor Average Accumulated Load (kWh, kVAh, kVArh) These pages contain electrical values of the generator, measured or derived from the module’s voltage inputs.
  • Page 32 Event Log Icon to indicate that Icon to indicate the electrical the event log is trip or shutdown alarm Note: For further details of module configuration, currently display that has been recorded refer to DSE Publication: 057-223 DSE60xx MKII Configuration Software Manual. 23 h This module’s event log contains a list of the last 50 recorded events and the engine hours at which they...

  • Page 33: Operation

    OPERATION STOP/RESET MODE Note: The following descriptions detail the sequenc- Note: If a digital input configured to Panel Lock is es followed by a module containing the stand- active, changing module modes is not possi- ard ‘factory configuration’. Always refer to ble.

  • Page 34: Manual Mode

    Once the generator has been placed on load, it is not MANUAL MODE automatically removed. To manually remove the load either: Manual Mode is activated by pressing the Manual Mode button. The Manual Mode icon is displayed to indicate Manual Mode operations.

  • Page 35: Test Mode

    TEST MODE Once the generator has been placed on load, it is not automatically removed. To manually remove load either: Note: If a digital input configured to Panel Lock is active, changing module modes is not be Press the Manual Mode button followed by the possible.

  • Page 36: Automatic Mode

    AUTOMATIC MODE After the starter motor has disengaged, the Safety On Delay timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Note: If a digital input configured to Panel Lock is Auxiliary fault inputs to stabilise without triggering the active, changing module modes is not be fault.

  • Page 37: Maintenance Alarm

    Example 3: Screen capture from DSE Configuration Suite MAINTENANCE ALARM Software showing the Maintenance Alarm Reset ‘button’ in the DSE Configuration Suite SCADA | MAINTENANCE Depending upon module configuration one or more levels section. of engine maintenance alarm may occur based upon a configurable schedule.
  • Page 38 Test Mode Scheduled runs do not occur when the module is in Test Mode waiting for a start request. Auto Mode Scheduled runs operate ONLY if the module is in Auto Mode with no Shutdown or Electrical Trip alarm present. If the module is in Stop/Reset Mode or Manual Mode...

  • Page 39: Front Panel Configuration

    FRONT PANEL CONFIGURATION This configuration mode allows the operator to fully configure the module through its display without the use of the DSE Configuration Suite PC Software. Use the module’s facia buttons to traverse the menu and make value changes to the parameters: Next Section (101→201→301) Previous Section...
  • Page 40 When viewing the parameter to be edited, press the Auto Mode ) button and the value begins to flash. Press the ( + ) or ( - ) navigation buttons to adjust the value to the required setting. Press the Auto Mode button the save the current value, the value ceases flashing.

  • Page 41: Fault Finding

    FAULT FINDING STARTING Symptom Possible Remedy Symptom Possible Remedy Unit is inoperative Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse. Read/Write configuration does not operate Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70°C.

  • Page 42: Alarms

    ALARMS Symptom Possible Remedy Symptom Possible Remedy Low oil Pressure fault Check engine oil pressure. Check oil pressure switch/sensor and operates after engine has wiring. Check configured polarity (if applicable) is correct (i.e. fired Normally Open or Normally Closed) or that sensor is compatible with the module and is correctly configured.

  • Page 43: Miscellaneous

    MISCELLANEOUS Note: The above fault finding is provided as a guide check-list only. As the module can be configured to provide a wide range of different features, always refer to the source of your module configuration if in doubt. Symptom Possible Remedy Symptom Possible Remedy...

This manual is also suitable for:

G30G45G60G24G36G48 ... Show all

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