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Summary of Contents for Hyundai DHY22KSE-3
- Page 1 DIESEL G E NERATOR DHY22KSE-3, DHY28KSE-3, DHY45KSE-3, DHY65KSE-3, DHY85KSE-3, DHY110KSE-3 User Manual...
- Page 2 CONTENTS 1. Contents 2. Preamble 2.1. Introduction 2.1.1 General recommendations 2.1.2. Structur e of the reference materia 2.1.2.1 Level A 2.1.2.2 Level B 2.2. Pictograms and their meanings 2.3. Safety instructions and regulations 2.3.1 General advice 2.3.2 Risks related to feed gas (concerns gas sets) 2.3.3 Risks related to exhaust gases and fuels 2.3.4 Risks related to toxic products 2.3.5 Risk of fire, burns and explosion...
- Page 3 3.3.2.2 Dynamic requirements 3.3.2.3 Construction 3.3.2.4 Base of the set 3.3.2.5 Openings 3.3.2.6 Lifting 3.3.2.7 Soundproofing 3.3.2.8 Ventilation 3.3.2.9 Fuel 3.3.2.10 Burnt gas exhaust 3.3.2.11 Electricity 3.3.2.12 Cooling 3.3.2.13 Special arrangements 4. Installation of mobile site sets 4.1 General information 4.2 Specific arrangements 5.
- Page 4 Attached documents User manual for the control unit, if fitted (level A) User and maintenance manual for the engine (level A) User and maintenance manual and spare parts catalogue for the alternator (level A) Wiring diagrams (supplied with the reference material or with the electrical generating set) (Level A) Engine spare parts catalogue (level B) 3/42...
- Page 5 2. P REAMBLE 2.1. Introduction 2.1.1 General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to help you operate and maintain your electrical generating set correctly. Read the safety instructions carefully in order to prevent any accident incident or damage.
- Page 6 2.1.2. Structure of the reference material The reference material delivered with the generating sets is divided into 3 levels: 2.1.2.1 Level A This basic level gives all the user and maintenance procedures for the generating set or power station. This reference material enables you to get to know the equipment operate it and maintain it both on a daily basis and periodically.
- Page 7 2.2. Pictograms and their meanings Publications delivered with the generating set Warning danger must be referred to Warning, risk of electric Protective clothing shock must be worn Your eyes and ears Warning, toxic materials must be protected Periodic maintenance Warning, pressurised must be carried out liquids Warning, high...
- Page 8 Naked flames and un protected lights prohib Warning, risk of explosion ited. No smoking Exctinction by water prohibited Entry prohibited to non- authorised persons When on a trailer eatth the set before Power starting it Earth Emergency cut-out Application of EU Machine Directive 98/37 of 22 June 1998 in relation to generating sets. - access restricted to authorised personnel only according to the legislation in force - live installation: possible automatic start-up.
- Page 9 2.3. Safety instructions and regulations If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows.
- Page 10 Disconnect the battery and pneumatic starter (if there is one) before carrying out any repair to prevent the engine from starting accidentally. Fit a panel over the controls to prevent any attempt at starting. - Do not modify the engine. - Only use the correct techniques for turning the crankshaft to rotate the crankshaft manually.
- Page 11 2.3.2 Risks related to feed gas (concerns gas sets) WARNING DANGER The gas is explosive. It is forbidden to smoke go near or create sparks when the tank is being filled and near to the generating set. Request the user technical notes and LPG or NG safety data sheets from your gas supplier.
- Page 12 2.3.4 Risks related to toxic products WARNING DANGER The corrosion inhibitor contains alkali. This substance should not come into contact with the eyes. Avoid any prolonged or repeated contact with skin. It should not be swallowed. In the event of skin contact wash thoroughly with water and soap. In the event of contact with eyes rinse immediately with plenty of water for at least 15 minutes.
- Page 13 Good ventilation is required for your generating set to work properly. Without ventilation the engine will quickly reach an excessive temperature that could lead to accidents or damage to the equipment and surrounding items. Do not take off the radiator cap when the engine is hot and the coolant is pressurised due to risk of burns.
- Page 14 - The generating set should not be connected to any other power sources such as the public distribution network. In specific cases where there is a reserve connection to existing electrical networks it must only be carried out by a qualified electrician who should take the operating differences of the equipment into account according to whether the public distribution network or generating set is being used.
- Page 15 2.3.9 Recommendation for the operator and environment - Operating personnel should be aware of the safety and operating instructions. These will be regularly updated. Operating should be monitored directly or indirectly by someone designated by the operator who is familiar with the installation and dangers and problems regarding products stored and used in the installation.
- Page 16 - The presence of dangerous or combustible materials on premises where combustion apparatus is sheltered is limited to what is required for the operation. The installations must be operated underthe constant supervision of a qualified person. This person should periodically check that the safety devices are working properly and ensure the correct fuel supply to the combustion apparatus.
- Page 17 3. I NSTALLATION WARNING Sections 3 4 and 5 contain only general recommendations. It is recommended that you use a professional to ensure correct installation and start-up. The company cannot be held responsible for breakdowns related to the conditions of installation.
- Page 18 3.1.3.2 Fork lift truck - position the arms of the fork lift under the frame making sure that only the cross beams are resting on the arms. - lift and handle the equipment carefully. - set down the generating set in its unloading position. 3.2 Handling instructions - carefully lift the edge on the engine side with 2 jacks then slide 3 pipes under the frame.
- Page 19 It is recommended to use a fork lift truck with arms that are longer than the width of the frame If you are using a rail or crab once it is in position continue in the same way as described in the !slings"...
- Page 20 3.3 Installation of fixed sets NOTE If you do not follow the basic principles the installation assembly will suffer damage and abnormal wear. The procedure described gives the main requirements for installing a !conventional" generating set made up of a heat engine a generator and electric panel. These requirements are general principles to be observed.
- Page 21 3.3.1 Position It should be determined on the basis of use. There are no specific rules governing the choice of location other than proximity to the electric distribution panel and disturbances caused by the noise. However fuel supply burnt gas evacuation and the direction of these gases and the noises emitted should be taken into account.
- Page 22 3.3.2.2 Dynamic requirements These are the measurements to be adhered to between each piece of equipment to allow for refitting and possible removal. About a 1 metre space around the set is considered the minimum required for carrying out problem -free maintenance. This will give enough space to check that the doors of covered sets open fully that equipment can be accessed for maintenance and that integral removal of the...
- Page 23 3.3.2.5 Openings The room should include a certain number of openings which are required for it to operate: - a door giving access to the generating set and its accessories preferably in line with the set#s floor plate - ventilation openings (fresh air inlet and hot air outlet) located so that scavenging takes place in the direction from the alternator towards the engine.
- Page 24 General arrangements - building structure made from framing concrete or solid concrete blocks 20 cm thick minimum - anti-vibrating floor plate under the generating set when adjoining sensitive areas. - ceiling and walls covered if necessary with absorbent materials - choice of adapted exhaust silencer (s) . - soundproofed door for access to the room and if required to the pressure lock for a very low sound level.
- Page 25 3.3.2.9 Fuel Since the fuel is classed as a "dangerous product" certain regulations for storage and distri bution must be followed. It is also necessary to consult current laws when carrying out the installation. It is usual to fit fixed installations with a daily service tank and storage tank. These two tanks can be joined into one if the generating set consumption is low.
- Page 26 3.3.2.10 Burnt gas exhaust Studying the evacuation of burnt gases by a generating set should not be seen as a minor detail due to the fact that a pipe can always be installed even in the most inaccessible areas. In fact there are a certain number of constraints to be considered such as drops in pressure caused by the exhaust insulation suspension noise level and air pollution.
- Page 27 Figure 1 : Pipes It is recommended that you use seamless pipes. However for weight reasons rolled steel pipes can be used. In any event welded !bars" inside the duct are to be avoided. Figure 2: elbows The elbow should have a minimum curve radius of 2D if possible in a single compo nent.
- Page 28 Figure 7: suspension line Generally made up of a flat iron ring attached to the ceiling. The suspension line enables the pipes to expand freely. Figure 8: needle frame Used for vertical sections the needle frame allows the pipes to expand while holding them laterally.
- Page 29 Figure 12: silencers These reduce noise by absorbing or causing phase differences in the sound wave. An exhaust should be effectively suspended the supports should never rest on the set (except for original fittings). An exhaust compensator will be fitted to the engine outlet. The pipes will never have a diameter less than the set (refer to us about vermin ) and be directed so that gas cannot return to the room.
- Page 30 b) Power cables These can be unipolar or multipolar according to the power of the generating set. Power cables should preferably be installed in ducts or on a cable tray for this purpose. c) Battery cables Install the battery or batteries immediately beside the electric starter motor. The wires will be connected directly from the battery terminals to the starter motor terminals.
- Page 31 c) Lost water exchanger This type of cooling consumes a non negligible degree of water and hence there is an operating cost to be taken into account. This the solution when local provisions ensure the flow of water and do not allow the ventilation provisions to be made for cooling by a ventilated radiator or air recooler.
- Page 32 4. I NSTALLATION OF MOBILE SITE SETS 4.1 General information Besides the advice and rules given for fixed sets certain arrangements must be made for "site" sets. 4.2 Specific arrangements An area will be reserved to install the generating set. Its should be flat and strong enough so that the generator does not sink into it.
- Page 33 5. R OAD TRAILER 5.1 Trailer linkage Before attaching the trailer check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly. WARNING DANGER Trying to tow a trailer with a non-matching device (bar wires cords etc.) could lead to serious accidents.
- Page 34 5.2 Check before towing Before towing carry out the following checks: - wheel torquing - lock trailer hook - tyre pressure - light signals working - cover doors closed - parking brake off - front wheels and rear supports lifted. - tightening and fixing the draw bar arms locking levers - brake test for "road"...
- Page 35 5.5 Implementation for installation Procedures to be carried out: - check that the ground is strong enough for the assembly not to sink into it - using the front wheel position the set as horizontally as possible - engage the handbrake. - lower the rear trailer supports and lock them 34/42...
- Page 36 6. I NSTALLATION OF ELECTRICAL GENERATING SETS IN CONTAINERS WARNING When the generating set is working in automatic start mode the air evacuation doors must be open. WARNING When the generating set is working in manual start mode the air evacuation doors must be open before it starts.
- Page 37 Examples of equipment and handling Example of container lifting using a lifting Example of grip by Example of grip by a beam fitted with hooks shackles or manually an ordinary hooksafety hook safety hook coupled lock Example of grip by a Example of shackle manually coupled lock grip...
- Page 38 Example of a lifting method not to be used Example of a handling method not to be used 6.1.2 Transport The transport of containers should be in accordance with the highway code (for the relevant coun tries). The transport equipment (trailer semi -trailer container holder etc.) should be suitable for this use and provide all safety guarantees in terms of its capacity to support the load and the attach ment devices.
- Page 39 6.1.3 Installation - positioning The position should first be considered in relation to the electricity distribution centre fuel stor age the general environment and type of ground before the equipment can be accommodated. The installation area should be flat enough for the frame to rest level on it and strong enough so that the container does not sink down.
- Page 40 The environmental impact should also be analysed so that the disturbances to be caused by the equipment will not affect those living close by. Therefore it is essential to be aware of the regulations in force in order not to be vulnerable to future legal action.
- Page 41 6.2 M aintenance - lubricate the hinges and locks regularly - lubricate the joints with silicone grease - wash and clean the bodywork using products designed for car bodywork - check the condition of the bodywork and retouch any scratches straight away (to prevent the start of corrosion).
- Page 42 7. P REPARATION BEFORE OPERATING THE SET WARNING DANGER The inspections referred to in this section enable the electrical generating set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could lead to incidents or very serious ac cidents.
- Page 43 8. B ATTERY MAINTENANCE WARNING DANGER - install the battery so that it has the correct ventilation - never place the battery close to a flame or fire - use only insulated tools - never use sulphuric acid or acid water to top up the electrolyte level. PROCEDURE FOR TESTING STARTER BATTERIES CHECK THAT THE REPLACE THE...
- Page 44 For Inquires, Please Contact: Trade Tested Limited PO Box 9117, Newmarket, Auckland 1149, New Zealand 0800 800 880 support@tradetested.co.nz www.tradetested.co.nz Imported/Distributed by Trade Tested Limited Licensed by Hyundai Corporation Holdings, Korea...
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