AIE G Series Install & Maintenance Manual

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G-SERIES INSTALL &

MAINTENANCE MANUAL

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Page 1 G-SERIES INSTALL & MAINTENANCE MANUAL...
Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY INTRODUCTION MODEL IDENTIFICATION LOCATION OF IMPORTANT COMPONENTS AND CONNECTIONS FUEL RECOMMENDATIONS ENGINE OIL RECOMMENDATIONS OPERATOR INTERFACE INSTALLATION SHELTER CONSTRUCTION MOUNTING / FLOOR LOADING VIBRATION VENTILATION AIR INLET AIR OUTLET EXHAUST PIPING FUEL SYSTEM DIESEL AND GASOLINE FUEL GASEOUS FUELS ELECTRICAL CONNECTIONS / EMERGENCY STOP WIRING / BATTERY TESTING...
Page 3: Safety
TROUBLESHOOTING/ FAULT ICONS SUPPORTING DOCUMENTS APPENDIX B: AC WIRING SCHEMATIC AIE EMISSIONS HOLD HARMLESS STATEMENT SAFETY Thoroughly read this manual before operating the genset. The following symbols are used throughout this manual and on the genset to warn of the potential hazards to the operator, service personnel, or equipment.
Page 4 EXHAUST GAS IS DEADLY • Engine exhaust fumes can be very harmful if allowed to accumulate. Only operate the engine in a well-ventilated area. Inspect for exhaust leaks at every startup and after every eight hours of operation. • • Exposure to exhaust gases can cause carbon monoxide poisoning.
Page 5 MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Disable any automatic starting systems before performing inspections or service on the genset to avoid unexpected start. • Do not wear loose clothing or jewelry near moving parts such as fans, belts and pulleys. •...
Page 6: Introduction
INTRODUCTION This manual covers the installation, operation, and maintenance of the G-Series family of gensets. Be sure to read the entire manual thoroughly before first use and obey all safety warning information contained within. Proper installation and use as described in this manual will ensure your genset operates at peak performance. The owner is responsible for proper installation observing all local electrical and building codes.
Page 7 MODEL AND SERIAL NUMBER LOCATION (JCB): JCB Engine Model and Serial Number location on side of block under exhaust and on back engine above the flywheel housing. / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 8 / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 9: Location Of Important Components And Connections
LOCATION OF IMPORTANT COMPONENTS AND CONNECTIONS The location of major components needed for operation and maintenance are shown below. For more details see the MAINTENANCE section in the manufacture’s engine manual provided with the genset. G-9 TO G-13 MECHANICAL DIESEL OPEN UNIT / 44 ai-engines.com info@ai-engines.com...
Page 10 G-20 TO G-30 COMMON RAIL DIESEL OPEN UNIT / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 11 G-20 TO G-50 SPARK IGNITED OPEN UNIT (KUBOTA ENGINE) G-20 / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 12 G-30 / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 13 G-50 / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 14 G-50 DIESEL (JCB ENGINE) / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 15 G-9 TO G-50 OPEN AND ENCLOSED UNIT DETAIL NUMBER ITEM / FUNCTION 3, 4, 9 EMERGENCY STOP EXHAUST OUTLET GENERATOR CONTROLLER MAIN CIRCUIT BREAKER RADIATOR FILL FUEL FILTER AIR FILTER OIL DRAIN FUSE/RELAY PANEL OIL FILL GENERATOR AVR 3, 4, 9 / 44 ai-engines.com info@ai-engines.com...
Page 16: Fuel Recommendations
FUEL RECOMMENDATIONS ***Fuel is combustible and can cause severe personal injury or death. Do not smoke near fuel tanks or equipment. Keep all flames, sparks, or all other sources of ignition well away.*** For diesel engines, the use of ultra-low sulfur fuel (15ppm or 0.0015 wt.%) is mandatory when operated in US EPA regulated areas.
Page 17 FIGURE 4: OIL VISCOSITY VS. AMBIENT TEMPERATURE KUBOTA SPARK IGNITED ENGINES Engine oil should have properties of API classification SL or higher Change the type of oil according to the ambient temperature SAE 30 or SAE 10W-30 / Above 25 degrees C (77 degrees F) SAE 15W-40 0 degrees C to 25 degrees C (32 to 77 degrees F) SAE 20 or SAE10W-30...
Page 18: Operator Interface
OPERATOR INTERFACE The main operator interface is installed in the control box on the outside of the genset enclosure or mounted in the same control box on an open unit. The control box contains a Deep Sea control panel (see below various Deep Sea control panels), main generator breaker, voltage sensing fuses and current transformers.
Page 19 DEEP SEA 6110 MKIII STARTING THE GENSET NOTE: For further details, see Section 5 in the Deep Sea Operators Manual entitled Operation STOPPING THE GENSET / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 20 DEEP SEA 7310 STARTING THE GENSET NOTE: For further details, see Section 5 in the Deep Sea Operators Manual entitled Operation STOPPING THE GENSET / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 21: Installation
INSTALLATION This section will guide you through proper installation of a G-Series genset. Proper installation is key to correct genset operation and ensuring the long life of the unit. ***Read this entire section thoroughly BEFORE installing the genset.*** The G-Series genset requires an external fuel source and 12V DC battery. Except for the gasoline fuel genset which come pre- plumbed, it is up to the installer to provide an acceptable fuel tank/regulator, install fuel lines, provide, and install a recommended battery (See table 1 below for battery...
Page 22: Shelter Construction
Exhaust gas is deadly. Never operate the genset without proper ventilation. Check for leaks in the exhaust system regularly. Exposure to exhaust gases can cause carbon monoxide poisoning. Symptoms of carbon monoxide poisoning include dizziness, throbbing in temples, nausea, muscular twitching, headache, vomiting, weakness and sleepiness, and inability to think clearly. If you or anyone experiences these symptoms, get to fresh air immediately.
Page 23: Mounting / Floor Loading
The structure should be designed to restrict access to the generator set and other utilities from unauthorized people. Access to the shelter or any maintenance work should only be performed by people that are qualified and professionally trained on the safe operation and service of the generator, fuel system and all other electrical components. Generator sets can start automatically and must be properly disabled before any service work begins.
Page 24: Vibration
VIBRATION The generator sets produce electricity with rotating equipment that causes vibration to be transmitted to any surface it comes into contact with. G-Series generators are equipped with vibration isolation mounts between the engine and generator ends and the base frame. This allows the base frame to safely be mounted to the concrete pad directly without any additional vibration dampening.
Page 25: Air Inlet
AIR INLET The cooling air inlet should be at least 150% of the radiator outlet opening. The extra inlet area is essential to minimize restriction and to provide combustion air for the engine. When calculating the inlet area remember that some of the space will be obstructed by screens, louvers or baffles.
Page 26: Air Outlet
AIR OUTLET The radiator output must be over 100% of the total radiator area. Remember to take into account obstructions from louvers and turns when calculating the required outlet area. The ducting to the outside must be tight to the radiator to prevent air escaping and recirculating in the room. On models where the duct flange is connected directly to the radiator to include a section of flexible ducting to prevent damage to the equipment.
Page 27: Exhaust Piping
The exhaust system should be designed to be as short as possible. On runs over 25 feet consult AIE application engineering. Do not use more than three 90-degree elbows or six 45-degree elbows. The pipe must be at least the same internal diameter of the exhaust manifold on the engine or larger.
Page 28 * Back Pressure Limits measured at exhaust manifold. Total pressure must be taken into account all aftertreatment, silencers, and piping. / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 29: Fuel System
FUEL SYSTEM A proper fuel supply system is critical to achieving acceptable performance from an engine or generator. Always follow the appropriate standards and codes when installing the fuel system. The closer the fuel supply is to the generator installation, the easier and cheaper the fuel installation will be. LSI-LN ENGINE LSI-G ENGINE KUBOTA COMMON RAIL DIESEL...
Page 30: Diesel And Gasoline Fuel
Diesel tanks that are above the generator set may generate excessive head pressure. Consult with AIE application engineering to see if your model is compatible with above ground systems.
Page 31: Gaseous Fuels
GASEOUS FUELS These systems run on LP or natural gas. In order to achieve the full output of the generator it is essential that both the specified pressure and volume is required. The flow and input pressure are available in the Engine Operator’s Manual, specification sheet and the generator fuel inlet decal.
Page 32: Testing
TESTING Before finishing the commissioning of a system run the system, under load and observe the coolant temperatures from the controller. The temperature should rise steadily and then stabilize if there is sufficient cooling air. A warning alarm is set in the controller when the system is approaching the maximum allowable operating temperature.
Page 33: Before Starting The Genset
BEFORE STARTING THE GENSET Check all belts, guards and panel covers are firmly secured. • Check the installed wiring to ensure all connections are firmly installed in the correct position, and that wires are in • good condition. • Make sure the battery connections are secure and polarity of connections are correct. •...
Page 34: Operating At High Altitudes
OPERATING AT HIGH ALTITUDES The maximum output power available decreases as altitude increases due to a drop in air density. For every 1,000 foot increase in elevation, you can expect power output to drop by approximately 3%. For all specifications published, please assume an elevation of 0 feet (sea level).
Page 35 EXERCISING THE GENSET ***IF THE GENSET IS USED FOR BACKUP POWER OR STANDBY POWER FOR A RESIDENCE OR COMMERCIAL BUILDING WHERE IT IS NOT APPROPRIATE TO PLACE IN LONG TERM STORAGE, THE GENSET SHOULD BE RUN PERIODICALLY. RUN THE GENSET EVERY 30 DAYS AT 50% LOAD FOR 30 MINUTES TO KEEP THE ENGINE AND GENERATOR IN PROPER WORKING ORDER.
Page 36 To return the generator to service, use the following procedure: Verify that oil used to store the unit is appropriate for its new use. If necessary, replace with correct engine oil. See ENGINE OIL RECOMMENDATIONS on page Re-install and reconnect the battery, starting with the positive (+) battery cable. Remove plug from exhaust pipe.
Page 37 If you are experiencing trouble with your genset, use the tables below to try and resolve your issue. If you are still experiencing problems, contact AIE’s Service Department at 1-888-737-8375. The Deep Sea controller is capable of providing valuable diagnostic information in the event of an unexpected genset shutdown.
Page 38 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE SOLUTION Clean and tighten positive and Bad battery connection negative battery cable connections on battery and at genset. Low Battery Voltage Recharge or replace battery. Low cranking speed Replace engine oil with D5W40 or Engine oil viscosity too high D10W40 for cold weather.
Page 39 / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 40 / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 41 MECC ALTE SERIES ECP OPERATORS MANUAL AND SPECIFICATION SHEETS • MECC ALTE DSR AND DER1 DIGITAL REGULATOR SPECIFICATION SHEETS • APPENDIX A: AC WIRING SCHEMATIC • AIE WARRANTY STATEMENT • KUBOTA WARRANTY STATEMENT • JCB WARRANTY STATEMENT https://www.gsupport.ai-engines.com / 44 ai-engines.com...
Page 42 APPENDIX B: AC WIRING SCHEMATIC / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 43 APPENDIX B: AC WIRING SCHEMATIC (CONT.) / 44 ai-engines.com info@ai-engines.com rev 1.5 (02/01/22)
Page 44 G-Series generators will be shipped from AIE in a ‘Certified State’ with all emissions control devices (air cleaners, aftertreatment devices, etc.) installed on the engine. In the rare instance when engines are not shipped in a ‘Certified State’, an ‘End User Delegated Assembly’...