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Greaves POWER GENSET GPWII-35 User Manual

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  • Page 2 Please feel free to speak with any of our Regional offices or HO for additional information. Once again we thank you for buying a Greaves Power DG set and will look forward to hearing your valuable feedback in near future.
  • Page 3 Name of the Company • Your Name, Detailed Address, and Phone / Mobile Number • General Description of Assistance required Greaves Toll Free No. 1800-266-0670 For Emergency Contact AGM-Service, HO Greaves Cotton Limited, Engine Business, Chinchwad, Pune-411 019 Phone: +91-20-67308260 Mobile: +91-9923201928...
  • Page 4 Engine Model and Sr. No: ……………………………………………………………………………………………………………………………………………………………. Alternator Sr. No. Make & Type: ……………………………………………………………………………………………………………………………………………………………. Control Panel Sr. No. Make & Type: ……………………………………………………………………………………………………………………………………………………………. First Service Check Details: ……………………………………………………………………………………………………………………………………………………………. Second Service Check Details: ……………………………………………………………………………………………………………………………………………………………. Service Dealer Stamp & Signature: ……………………………………………………………………………………………………………………………………………………………. Greaves Cotton Limited Page 3 of 319...
  • Page 5 Business division of Greaves Cotton Limited. Before commissioning of the said GENSET, please go through the contents of this section carefully. 2. For details of Greaves authorised service dealer for your GENSET, please contact either your supplier of GENSET or nearest Greaves area office.
  • Page 6 GENSET Model and Serial No: …………………………………………………………………….. Engine Serial No. …………………………………………………………………….. …………………………………………………………………….. Detailed Site Address …………………………………………………………………….. …………………………………………………………………….. Contact Person Name & Telephone/ Mobile No. …………………………………………………………………….. No. of Hrs. ran till date …………………………………………………………………….. …………………………………………………………………….. …………………………………………………………………….. Nature of Failure …………………………………………………………………….. Greaves Cotton Limited Page 5 of 319...
  • Page 7 Auxiliary Power Business Revisions in User Manual #P21190060197 Revision No. Modification Summary Date New Release 10-10-2014 Greaves Cotton Limited Page 6 of 319...
  • Page 8 Greaves Cotton Diesel GENSET 1. Warranty Policy (Diesel GENSET): Greaves Cotton Ltd. warranty for the GENSET is limited to its defective materials/ components and/or workman-ship and is valid until a period of 30 months from the date of invoice OR a period of 24 months from the date of commissioning at site or completion of 5000 hours of operation, whichever event shall occur first provided the user of the GENSET uses recommended genuine spare parts including “Greaves...
  • Page 9 Greaves Cotton Ltd. shall not be responsible for replacement of the complete unit under any circumstances. In case of any warranty claim, the responsibility of Greaves Cotton Ltd. shall be limited to the extent of replacement or supply of defective parts.
  • Page 10 Air Filter element and Lube Oil Filter element purchased only from Authorized Dealers of Greaves Cotton Ltd. Our above warranty policy for engines / DG Sets operated on Producer Gas, Bio Gas, and CNG like gaseous fuel should have minimum of following characteristics.
  • Page 11 Lube Oil added (Cubic Cms.) No Load Engine (RPM) Full Load Current (Amp) 3-phase Voltage (Volts) Frequency (Hz) PF & kW if provided kWH meter reading if provided Remarks – Record events of maintenance/repairs Greaves Cotton Limited Page 10 of 319...
  • Page 12 Lube Oil added (Cubic Cms.) No Load Engine (RPM) Full Load Current (Amp) 3-phase Voltage (Volts) Frequency (Hz) PF & kW if provided kWH meter reading if provided Remarks – Record events of maintenance/repairs Greaves Cotton Limited Page 11 of 319...
  • Page 13 Lube Oil added (Cubic Cms.) No Load Engine (RPM) Full Load Current (Amp) 3-phase Voltage (Volts) Frequency (Hz) PF & kW if provided kWH meter reading if provided Remarks – Record events of maintenance/repairs Greaves Cotton Limited Page 12 of 319...
  • Page 14 Lube Oil added (Cubic Cms.) No Load Engine (RPM) Full Load Current (Amp) 3-phase Voltage (Volts) Frequency (Hz) PF & kW if provided kWH meter reading if provided Remarks – Record events of maintenance/repairs Greaves Cotton Limited Page 13 of 319...
  • Page 15 Lube Oil added (Cubic Cms.) No Load Engine (RPM) Full Load Current (Amp) 3-phase Voltage (Volts) Frequency (Hz) PF & kW if provided kWH meter reading if provided Remarks – Record events of maintenance/repairs Greaves Cotton Limited Page 14 of 319...
  • Page 16 Auxiliary Power Business INDEX SECTION A GENERAL SECTION B GENSET SECTION C DIESEL ENGINE SECTION D ALTERNATOR SECTION E CONTROL PANEL SECTION F DRAWINGS Greaves Cotton Limited Page 15 of 319...
  • Page 17 Auxiliary Power Business Greaves Cotton Limited Page 16 of 319...
  • Page 18 Explanation of the Symbols Limitation on Liability Copyright Warranty Terms Customer Service Safety Customer’s Responsibility Personnel Requirements Appropriate Use Personnel Protective Equipment’s Specific Dangers Behaviour in the Case of Emergency & Accident Environmental Protection Greaves Cotton Limited Page 17 of 319...

  • Page 19: Chapter 1 Introduction

    WARNING! Points out a potentially dangerous situation which can result in death or severe injuries if it is not avoided. CAUTION! Points out a potentially dangerous situation which can result in minor/slight injuries or damage to property if it is not avoided. Table A1.1 Greaves Cotton Limited Page 18 of 319...
  • Page 20 Violations oblige to compensation. The right for further claims remains reserved. 1.4 Warranty Terms The warranty terms are provided in the manufacturer's terms and conditions. Greaves Cotton Limited Page 19 of 319...

  • Page 21: Customer Service

    9923201928 for a list of our sales and service partners. Also, we request you in sharing the new information and experience arising out of usage of the product, which can be valuable for the development of the same. Greaves Cotton Limited Page 20 of 319...
  • Page 22 The owner must ensure that antifreeze is filled for engines with radiators. Explosive and easily flammable substances must always be kept away from the engine as the engine can become very hot during operation. Greaves Cotton Limited Page 21 of 319...

  • Page 23: Personnel Requirements

    The system must only be operated if it is in proper working condition. In the case of doubt, always contact the nearest Greaves Diesel service dealer before starting the GENSET. Only regular maintenance in accordance with the information in this operator's manual maintains the operational readiness of the GENSET.
  • Page 24 The system is designed and constructed exclusively for the intended purpose described in this manual. Any other use is considered to be improper. Greaves Cotton Ltd. accepts no liability for any danger and damage resulting out of misuse. The risk would be solely borne by the user / owner of the GENSET.
  • Page 25 Pay attention to the run-on time after switching off the GENSET. • Ensure that there are no parts still moving or the GENSET is not running before opening the covers. • Wear close-fitting clothing / apron while operating or servicing. Greaves Cotton Limited Page 24 of 319...
  • Page 26 Report suspicious materials, liquids or gases immediately to the person in charge. • Suspend any work activities in case of fire. • Leave the danger zone until the all clear signal is given by authorized means. Greaves Cotton Limited Page 25 of 319...
  • Page 27 Warning! Risk of injury due to non-functional safety devices: Safety is only ensured if the safety devices are intact. Therefore: • Check whether the safety devices are functional and correctly installed before starting work. • Never deactivate safety devices. Greaves Cotton Limited Page 26 of 319...
  • Page 28 The following environmentally hazardous substances are used in GENSET: Lubricant, Coolant, Antifreeze, and Diesel contain toxic substances. They must not reach the environment. The disposal of the same must be performed by a specialist disposal company. Greaves Cotton Limited Page 27 of 319...
  • Page 29 Auxiliary Power Business Greaves Cotton Limited Page 28 of 319...
  • Page 30 Brief Description of the GENSET Package Installation of G Series GENSET Location Foundation Cooling & Ventilation Exhaust Piping Arrangement Fuel System Fire Precautions Starter Batteries Electrical Connections Noise Control Maintenance General Alternator Unit Cleaning Radiator Maintenance Greaves Cotton Limited Page 29 of 319...

  • Page 31: Chapter 1 General Description Of Genset

    Auxiliary Power Business Chapter 1 General Description of GENSET Your new Greaves Power GENSET is a high performance and low maintenance product. It is ruggedly designed so as to minimize breakdowns and interruption in the supply of power to your applications.
  • Page 32 E: INS Panel 040: 40 kVA Phase 250: 250 kVA 1: Single Phase Alternator Make 3: Three Phase Controller C: Crompton Greaves Limited S: Stamford D: Deep Sea L: LEROY SOMER K: DATAKOM M: MECCALTE E: EMS Engine Make P: PROCOM...
  • Page 33 The GENSET package includes an engine, alternator, exhaust system, cooling system and a control system. The GENSET consists of an Engine closely coupled with an Alternator along with a Control Panel, all housed inside a canopy. The engine is Greaves make G11 series, water-cooled, four-stroke, multi-cylinder and direct injection compression ignition. In addition to the performance parameters, the engine designers have paid special attention to ease of maintenance, ease of assembly and dis-assembly, reliability and standardization.
  • Page 34 The silencer is of residential type fitted in the canopy with flange fitting at the outlet to enable discharge of exhaust gases at desired location, through extension piping, as required. Fig. B1.3 Exhaust Piping Arrangement Greaves Cotton Limited Page 33 of 319...
  • Page 35 Fig. B1.4 below shows the radiator cooling system arrangement. Fig. B1.4 Radiator Cooling System (b) Heat Exchanger The engine cooling system comprises of heat exchanger, and a thermostat. Fig. B1.5 below shows the heat exchanger cooling system arrangement. Greaves Cotton Limited Page 34 of 319...
  • Page 36 GENSET to the foundation on which the GENSET is mounted. The anti-vibration mountings selected to suit the particular duty and are fitted between with the engine, alternator feet and the base frame. Greaves Cotton Limited Page 35 of 319...
  • Page 37 The Control Panel is mounted inside the canopy. The canopy is provided with toughened glass cover opening for viewing the controls on the Control Panel. The Control Panel is fitted with an Electronic Controller and suitable switchgear and controls to operate and control the GENSET. Greaves Cotton Limited Page 36 of 319...

  • Page 38: Chapter 2 Installation Of G Series Genset

    • The concrete block should be extended by at least one meter on all sides. For GENSET dimensions, refer GENSET Ratings Matrix. • Surface of concrete block should be in one water level Greaves Cotton Limited Page 37 of 319...
  • Page 39 It is necessary to ensure that building structures are capable of supporting the GENSET, fuel storage and accessories. 2.2.3 Grounding (Indian Electricity Rules) Grounding should be done in accordance with applicable National, Local Code or Regulation. Greaves Cotton Limited Page 38 of 319...

  • Page 40: Air Inlet

    & canopy. Recommended window size = 1.5 X Frontal area of air passage of the canopy. Fig. B2.3 shows typical exhaust fan arrangement. Greaves Cotton Limited Page 39 of 319...
  • Page 41 When length of pipe is more, calculate the exhaust pipe ID by following method. a. Before actually doing installation of exhaust piping, decide how it should be routed and number of bends required? Greaves Cotton Limited Page 40 of 319...
  • Page 42 Table B2.1 CAUTION! Total exhaust system assessment should be done by competent personnel. If planned exhaust piping length is crossing 50 meters, then we recommend the use of soot arrestor blower. Fig. B2.4 Greaves Cotton Limited Page 41 of 319...
  • Page 43 Coarse wire mesh at the end of the pipe should be provided otherwise birds can build nest. Refer Fig. B2.6 Fig. B2.6 Greaves Cotton Limited Page 42 of 319...
  • Page 44 2.5.1 Diesel Fuel Bulk Storage Bulk fuel storage is the most preferable method of providing fuel supply. This method allows bulk fuel purchases which will minimize dirt and contamination possibilities, especially when Greaves Cotton Limited Page 43 of 319...
  • Page 45 Auxiliary tanks or day tanks as they are commonly referred to are recommended. Refer figure B2.6 for typical fuel tank installation. All standard GENSETS with acoustic enclosure are provided with tank fitted in the base frame. This day tank will produce a ready fuel supply. Greaves Cotton Limited Page 44 of 319...
  • Page 46 If it is not convenient to use flexible cable throughout then a link box can be installed close to the set with a flexible connection between it and the set. Greaves Cotton Limited Page 45 of 319...
  • Page 47 Load impedance is always constant regardless of the applied voltage. The load current increases proportionately as the voltage increases and decreases as the voltage decreases. Examples of linear loads are motor, incandescent lighting and heating loads. Greaves Cotton Limited Page 46 of 319...
  • Page 48 The information needed to select acoustic equipment is: The model and capacity of the GENSET The location and overall site plan iii. The designed noise level at a fixed distance, normally 1m or 7m Environmental conditions, ambient temperature, etc. Greaves Cotton Limited Page 47 of 319...
  • Page 49 Noise emissions from diesel GENSET (without acoustic treatment) are at sound pressure levels of between 100 dB (A) and 110 dB (A) at 1m. Greaves GENSET with acoustic enclosures have a typical noise pressure level of 75 dB (A) or less (average) at a distance of 1 meter from the enclosure.

  • Page 50: Chapter 3 Maintenance

    Check all the hose connections and hose conditions. Check the engine oil level. Check the battery terminals for corrosion. xii. Check the battery electrolyte level and fill it with distilled water if necessary. Greaves Cotton Limited Page 49 of 319...
  • Page 51 All of these materials can work their way into the windings and may cause overheating or insulation breakdown. Remove these same materials from the ventilation screens around the circumferences of the unit. Greaves Cotton Limited Page 50 of 319...
  • Page 52 3.3.2.1 External Cleaning of Radiator In dusty or dirty conditions the radiator fins can get blocked with loose debris, insects, etc. and this fouling will have an effect on the performance of the radiator. Greaves Cotton Limited Page 51 of 319...
  • Page 53 If, due to leaky joints for instance, or indiscriminate topping up with hard water has been carried out for some time, or if the generator set has been run without inhibitors the system may become fouled by scale. To descale the radiator call GREAVES authorised service dealer. The procedure for the same is as follows: Drain the water system and disconnect and bank off the pipe connections to the engine.
  • Page 54 Auxiliary Power Business Greaves Cotton Limited Page 53 of 319...

  • Page 55: Table Of Contents

    Engine Nomenclature Technical Data Engine Illustrations Engine Systems Lubrication System Cooling System Fuel System Electrical System Engine Operation Standard and Typical Operating Conditions Starting the Engine Stopping the Engine Safety Stop Running In Greaves Cotton Limited Page 54 of 319...
  • Page 56 Flywheel Run Out Timing Gear Maintenance of Cooling System Battery Checking Instructions Some Assorted Maintenance Jobs 5.10 Electronic Governor and Actuator Fitment 5.11 Maintenance Schedule Engine Preservation Engine Preservation Engine De-Preservation Installation Do’s and Don’ts Greaves Cotton Limited Page 55 of 319...

  • Page 57: Chapter 1 General

    Read the instructions carefully before installation of the engine or equipment. iii. In case of any doubt or difficulty, seek help from authorized Greaves service dealers. Your engine needs clean air, clean fuel, clean lube oil and clean coolant. Greaves Cotton Limited...

  • Page 58: Maintenance Guidelines

    Giving attention to these factors improves the life of your equipment, reduces the running costs, and also increases the mean time between failures. 1.3 Maintenance Guidelines Please read the maintenance instructions. Seek services of authorized Greaves service dealers if needed. Follow maintenance schedules.

  • Page 59: Engine Description

    Auxiliary Power Business Chapter 2 Engine Description 2.1 Engine Orientation Fig. C2.1 Engine Orientation 2.2 Engine Nameplate Fig. C2.2 Engine Nameplate 2.3 Location of the Nameplate Fig. C2.3 Location of Nameplate Greaves Cotton Limited Page 58 of 319...

  • Page 60: Cylinder Nomenclature

    Auxiliary Power Business 2.4 Cylinder Nomenclature Fig. C2.4 Typical Cylinder Nomenclature 2.5 Engine Nomenclature System Fig. C2.5 Engine Nomenclature System Greaves Cotton Limited Page 59 of 319...

  • Page 61: Technical Data

    Turbocharged After Cooled Cooling Water Cooled 1:17 1:17 1 : 16.8 Starting Electric start ( 12 VDC ) BMEP in 7.84 9.03 10.02 14.48 13.24 16.36 19.82 17.1 19.30 21.19 24.84 bar @ Rt. Greaves Cotton Limited Page 60 of 319...
  • Page 62 93.0 Efficiency Fan Power & Other 11.4 Losses kW 10 % Overload (1 hour in 12 hours) as per (ISO 3046) Overload 1500 Governing Class A1- IS 10000, less than 4.5% Droop Standard Greaves Cotton Limited Page 61 of 319...
  • Page 63 Pressurized (7 PSI) water cooled with radiator, with thermostat (74-82ºC), pusher fan OR Cooling Pressurized (7 PSI) water cooled with Heat Exchanger, with thermostat (74-82ºC) Water Flow (LPM) Pressure Drop of Water 0.3 to 0.4 Bar across Engine Greaves Cotton Limited Page 62 of 319...
  • Page 64 Max. Pressure Drop of 50 mm of Hg Water across CAC Radiator 7 PSI Pressure Heat Lost by Water 27622 27622 27622 46472 46472 58950 58950 111016 111016 111016 111016 in Radiator (kCal/hr.) Greaves Cotton Limited Page 63 of 319...
  • Page 65 Lube Oil 5 to 7 bar Cold Kick Lube Oil Spin on type single element Filter with filtration capacity 10 to 20 micron Lube Oil After 500 Hrs. of Operation / Running Change Greaves Cotton Limited Page 64 of 319...
  • Page 66 High Speed Diesel (BIS 1460) Fuel Inline Fuel pump BOSCH, Injector BOSCH Injection Fuel Filter Twin bowl, screwed type Typical Fuel 30-38 30-38 30-38 36-38 36-38 38-42 38-42 38-42 38-42 38-42 38-42 Temp. °C Greaves Cotton Limited Page 65 of 319...
  • Page 67 SFC in LPH 12.0 12.0 12.0 20.01 20.01 25.4 30.71 47.53 47.53 47.53 60.35 (G) AIR INTAKE SYSTEM Air Filter Dry Type, with filtration capacity 10 micron Air Suction Depression (Max-New) mm WC Greaves Cotton Limited Page 66 of 319...
  • Page 68 200 KVA 250 KVA (G) AIR INTAKE SYSTEM [continued] Air Suction Depression (Max-Clog) mm WC (H) EXHAUST SYSTEM Exhaust Outlet Temp. °C (Max.) after Turbine Exhaust Back 50 mm of Hg Pressure (Max) Greaves Cotton Limited Page 67 of 319...
  • Page 69 Inlet Valve Tappet 0.4 mm Clearance Cold Exhaust Valve Tappet 0.4 mm Clearance Cold Bumping 0.8 - 1.2 mm Clearance Crankshaft 0.1 - 0.35 mm End Play CON Rod 0.4 mm End Play Greaves Cotton Limited Page 68 of 319...
  • Page 70 Out w.r.t. Crank Shaft Axis Flywheel Housing Bore Run- 0.25 mm Max. Out w.r.t. Crank Shaft Axis (J) VALVE / FUEL INJECTION TIMING Inlet Valve 3° BTDC Opens Inlet Valve 23° ABDC Closes Greaves Cotton Limited Page 69 of 319...
  • Page 71 6 +/-1° BTDC 9 +/-1° BTDC Timing (K) BOLT TORQUE TIGHTNING DATA M B Cap 7-14-20 kgf (Torque in step) bolts Cylinder head 5-9-15 kgf (Torque in Step) bolts Inlet, exhaust 6 kgf manifold Greaves Cotton Limited Page 70 of 319...
  • Page 72 Injector 5 kgf Oil Sump 2.5 Kgf Idler Gear 6 kgf on line Pulley 17 kgf M 12 8.5 kgf M 10 5 kgf 2.5 kgf Table C2.1 Technical Data of G Series Greaves Cotton Limited Page 71 of 319...

  • Page 73: Engine Illustrations

    Water manifold Oil Header Air Manifold Turbocharger to CAC in connection pipe Exhaust manifold Gear casing Lube. Oil filter Turbocharger Flywheel Housing Oil supply to turbocharger Flywheel Exhaust Bellow Engine Foot Exhaust Outlet Greaves Cotton Limited Page 72 of 319...
  • Page 74 Engine Foot Exhaust Outlet Fuel Filter Exhaust Bellow Starter CAC to inlet manifold connection Fuel Feed Pump High pressure pipe Fuel Pump Oil filler Cap Cylinder Head 10 Belts 11 CAC air in pipe Greaves Cotton Limited Page 73 of 319...
  • Page 75 323 454 812 1115 343.2 228.029 SAE3/11.5” 451 454 804 1025 SAE3/11.5” 1635 665 454 832 1091 SAE1/14” Table C2.2 Engine Dimensions & Weight 2.7.4 Engine Lifting Instructions Fig. C2.9 Lifting Hook Illustration Greaves Cotton Limited Page 74 of 319...
  • Page 76 Take all safety precautions while lifting and moving the engine. Only trained personnel should handle the engine. You can consult Greaves service dealers, if necessary. Firstly, remove water and oil from the engine before lifting. If your engine has cast iron sump then the engine can be rested on the sump.

  • Page 77: Chapter 3 Systems

    Recommended Oil for G11 series engines Company Oil brand name Greaves Cotton Ltd Greaves Maxtherm (API CF-4 15W-40) Table C3.1 Engine Dimensions & Weight Greaves Cotton Limited Page 76 of 319...
  • Page 78 Table C3.2 If at any operating condition the lube oil pressure drops below 2.5 bar, then change lube oil filter element. If the problem persists then contact Greaves authorized service agent or dealer. Greaves Cotton Limited Page 77 of 319...
  • Page 79 Fig. C3.2 G Series Lubrication System (Lube Oil Filter Side) Intermediate gear support Main oil gallery Nozzle gear lubrication Pressure regulating valve Lube oil pump Lube oil filter Lube oil suction strainer Lube oil cooler Lube oil sump Push rods Greaves Cotton Limited Page 78 of 319...
  • Page 80 Auxiliary Power Business Fig. C3.3 G Series Lubrication System (FIP Side) Piston cooling nozzle Lube oil sump Piston cooling nozzle gallery Main bearings Crank pins Cam bores Oil holes on crank shaft Greaves Cotton Limited Page 79 of 319...
  • Page 81 Auxiliary Power Business 3.1.3 Permissible Engine Inclination Permissible Engine Inclination is 1 deg. However for continuous or intermittent operation at an inclination contact our technical team for approval. Fig. C3.4 Engine Inclination Greaves Cotton Limited Page 80 of 319...

  • Page 82: Cooling System

    Pump Centrifugal Drive Engine driven gear drive Static water pressure (radiator cap) 7 psi Typical steady state water temp 72 – 90 ° C Max allowable water temp 95 - 96 ° C Greaves Cotton Limited Page 81 of 319...
  • Page 83 Auxiliary Power Business Fig. C3.6 Illustration of G-Series Cooling System Lube Oil Side Water out to radiator Oil cooler cavity Thermostat Cylinder head Bypass Water manifold Water pump Weeping hole Water in from radiator Greaves Cotton Limited Page 82 of 319...
  • Page 84 Auxiliary Power Business Fig. C3.7 Illustration of G-Series Cooling System FIP Side Water outlet manifold Bypass Cylinder water cavity Water pump Water core Water in Water out Greaves Cotton Limited Page 83 of 319...
  • Page 85 TDS (Total Dissolved Solids) Less than 400 ppm 3.2.4 Coolant Additive Specification Fill requisite quantity of cooling water duly mixed with Greaves MAXTHERM specialty summer coolant / anti-freeze compounds about 20% by volume or cooling conditioner with anti-freeze, if required.
  • Page 86 The drain plug on crankcase is for draining the entire engine. The drain plug on the radiator is for draining the entire system. Drain the coolant in a tray. Dispose-off the coolant safely in an environmentally friendly way. Greaves Cotton Limited Page 85 of 319...
  • Page 87 In an unlikely event of water coming out of weeping hole, immediately stop the engine and inform service dealer for changing of pump seal or sealing ring. Refer Fig. C3.14 Greaves Cotton Limited Page 86 of 319...
  • Page 88 Do not use water or chemicals. These can harden the deposits into very hard cake-like formations, which are very difficult to dislodge. Fig. C3.15 Cleaning the Radiator Greaves Cotton Limited Page 87 of 319...

  • Page 89: Fuel System

    FIP provided suction head is up to one meter. FIP and injectors are supplied by BOSCH and warranty is covered. Servicing the fuel system must be carried out by highly skilled personnel. This has to be done by authorized service agency or shop. Greaves Cotton Limited Page 88 of 319...
  • Page 90 Auxiliary Power Business Fig. C3.17 Circuit Diagram of Fuel System Fig. C3.18 Illustration of Fuel System Greaves Cotton Limited Page 89 of 319...
  • Page 91 Unscrew feed pump knob. Loosen fuel inlet banjo. iii. Pump manually, till fuel comes through the screw free of air, later on Knob may be relocked. Fig. C3.19 Illustration of Air Removal from Fuel System Greaves Cotton Limited Page 90 of 319...

  • Page 92: Electrical System

    For details, please refer Section E of this manual. 3.4.2 Battery Even though battery is an optional item during purchase, but recommended specification of the same is 12 Volt / 24 Volt (optional), 88 Amp-Hrs. Fig. C3.22 Typical Battery Greaves Cotton Limited Page 91 of 319...

  • Page 93: Engine Operation

    At 1.5 m above ground in normal cleanliness mg/m3 industrial area or agricultural standard dry air cleaner land on a wind less conditions Inclination both Degree < 1 For GENSET Application directions Table C4.1 Greaves Cotton Limited Page 92 of 319...

  • Page 94: Starting The Engine

    The engine may only be operated or maintained by trained staff. iii. Ensure sufficient ventilation in engine room. Cleaning maintenance and repair should be done when engine is stopped and secured. Fig. C4.1 Greaves Cotton Limited Page 93 of 319...
  • Page 95 During the normal running of the engine, the charging lamp should be OFF. vii. If the battery-charging lamp turns ON during engine running, it is an indication that the battery is not getting charged. Check the circuit and take corrective actions. Greaves Cotton Limited Page 94 of 319...
  • Page 96 Auxiliary Power Business Fig. C4.2 (a) Fig. C4.2 (b) Fig. C4.3 Inspection & Checking of V Belt Tension 4.2.3 In Case of Key Start Fig. C4.4 Engine Control Panel Greaves Cotton Limited Page 95 of 319...

  • Page 97: Stopping The Engine

    The engine can also be stopped manually by turning the stop lever on the fuel pump (Refer Fig. C4.5). Turn the key to “Off” mode so that battery does not get depleted / discharged. Greaves Cotton Limited Page 96 of 319...

  • Page 98: Safety Stop

    Check tappet clearance and correct it, if required, vii. Check engine for leakages and tighten the fasteners, if required. Take corrective action if abnormal noise, vibrations are observed. Now the engine is ready for its long life. Greaves Cotton Limited Page 97 of 319...

  • Page 99: Chapter 5 Service & Maintenance

    For lube oil viscosity recommendation, refer table C5.3 Ambient Temperature (Deg. C) Grade of oil -20 to + 20 SAE 10 W 30 -10 to +55 SAE 15 W 40 -5 to +45 SAE 20 W 40 Table C5.3 Greaves Cotton Limited Page 98 of 319...
  • Page 100 (Refer figure C5.3) and fit back the oil filler cap. (Refer Fig. C5.2) Dispose-off the used oil in an eco-friendly way. Greaves Cotton Limited Page 99 of 319...
  • Page 101 Auxiliary Power Business Fig. C5.2 Illustration of Lube Oil Cap Refitting Fig. C5.3 Illustration of Checking Oil Level with Dip-Stick Fig. C5.4 Illustration of Replacing Lube Oil Filter Greaves Cotton Limited Page 100 of 319...

  • Page 102: Changing Oil Filter

    Take a new genuine oil filter cartridge. Fill up fresh specified oil from sealed package into the oil filter cartridge. Fit it as per instructions given on filter. Note: Never try to clean up a cartridge and re-use. This causes severe injury to the engine. Greaves Cotton Limited Page 101 of 319...
  • Page 103 Fuel feed pump is mounted on FIP. It has a fuel strainer, which needs cleaning periodically. Remove banjo bolt below feed pump at the inlet. Unplug screw to take out the strainer. Clean the strainer with diesel and refit the assembly. Greaves Cotton Limited Page 102 of 319...
  • Page 104 5.2.3 Fuel Injection Pump It is recommended that Fuel Injection pump servicing is done by BOSCH authorized service agent / personnel at authorized service center preferably through Greaves service personnel. 5.2.4 Injector NOP (Nozzle Opening Pressure) Adjustment Injector servicing needs to be done by authorized service personnel. Hence this needs to be brought to the authorized service station for servicing and setting.
  • Page 105 Adjust the valve clearance when engine is in cold condition. Adjust the clearance with piston at top dead center and ensure that both valves are closed. Clearance is 0.4 mm for both inlet and exhaust valves. (Refer Fig. C5.9) Fig. C5.9 Checking & Adjustment of Valve Clearance Greaves Cotton Limited Page 104 of 319...
  • Page 106 Match idler gear mark ‘0’ with crank gear mark ‘0’. Locate cam gear in dowel & ensure matching of mark ‘1’ on cam gear with mark ‘1- 1’ on idler gear. Greaves Cotton Limited Page 105 of 319...
  • Page 107 The water used should be clean, free from dirt or dust, floating matter, colorless, without smell. Add Greaves supplied coolant in correct proportion for efficient cooling of the system. Bad water can cause severe corrosion. These corrosion products can block cooling system and severely damage the engine.
  • Page 108 Engine speed is sensed by magnetic pickup sensor. This sensor is used by electronic control unit to give signal to rotary actuator to control speed regulating lever of fuel injection unit to control the speed of engine at 1500 rpm for 50Hz GENSET. Greaves Cotton Limited Page 107 of 319...
  • Page 109 Check water level in radiator Check Battery condition Clean coarse fuel filter Every 500 Hrs. Change air filter element Every 500 Hrs. Change filter on the feed pump Change oil filter cartridge Change fuel filter cartridge Greaves Cotton Limited Page 108 of 319...
  • Page 110 Cleaning up fuel tank Or at least once in a year Cleaning up exhaust silencer Checking exhaust bellows and change if After 3500 Hrs. necessary Checking valve and insert condition, change if necessary Greaves Cotton Limited Page 109 of 319...
  • Page 111 Changing thermostat element Changing cylinder head gaskets Changing air / exhaust / water manifold / thermostat housing gaskets Checking sensors and change if necessary Overhauling starter and alternator Checking and changing AV mounts if required Greaves Cotton Limited Page 110 of 319...
  • Page 112 Changing set of gaskets and O rings Changing water pump if required Changing valves, valve guides and valve seat inserts if required Changing high pressure pipes Changing injectors if required Changing liners if required Changing piston assembly if required Greaves Cotton Limited Page 111 of 319...
  • Page 113 To be procured from Bosch authorized dealer Checking all critical fasteners and replace if necessary Checking fan drive assembly Add coolant additive Every 500 hrs. Replace cooling water and additive Change belt Check engine protection system Greaves Cotton Limited Page 112 of 319...
  • Page 114 Auxiliary Power Business Note: This schedule is applicable only when Greaves Maxtherm oil and coolant are used. Typical or usual change periods are maximum periods. Depending on the local conditions, these may have to be shortened. Set up your own maintenance frequency with experience, based on the site conditions.
  • Page 115 6.1 Engine Preservation during Prolonged Period of Non-usage If the period between engine dispatch from Greaves and the installation is more than six months or if engine is to be non-operational for more than twelve months, the engine has to be preserved to avoid damage due to corrosion, dust, and other factors.
  • Page 116 If some irregular behavior is observed take corrective actions or call authorized service dealer. j. If everything found operative and functional then start the engine and put it into service. Greaves Cotton Limited Page 115 of 319...
  • Page 117 . Check fire hazard possibility near fuel, oil storage. Plan release direction of the exhaust. Judge engine size properly. Seek help from Greaves service dealers or area offices for this purpose. vii. Provide adequate safety measures around installation area.
  • Page 118 Auxiliary Power Business Greaves Cotton Limited Page 117 of 319...
  • Page 119 Auxiliary Power Business SECTION D – ALTERNATOR Chapter Topic Description Page No. Crompton Greaves Alternator General Information Specifications Operating Conditions Rating Chart Features Safety Requirements Electrical Checks Do’s & Don’ts Maintenance 1.10 Troubleshooting Chart Stamford Alternator General Information Specifications Ratings Chart...

  • Page 120: Chapter 1 Crompton Greaves Alternator

    Chapter 1 Crompton Greaves Alternator 1.1 General Information The Crompton Greaves Alternator’s incorporate advanced European technology and are designed for optimum performance using the most accurate methods of design, manufacturing and testing. If the alternators are used as per recommendations in this manual, you are ensured with a continuous working and a prolonged trouble-free life of the alternator.

  • Page 121: Specifications

    If the ambient temperature exceeds 40°C, a deration factor of 4% should be applied for every 5°C rise in temperature. If the altitude is higher than 1000 meters, a deration factor of 4% should be applied for every 500 meters increase in altitude. Greaves Cotton Limited Page 120 of 319...

  • Page 122: Ratings Chart

    200MDX 91.5 92.0 250SB 90.8 91.2 250SD 92.5 93.0 250SD 92.3 92.8 250MA 92.3 92.8 250MB 92.3 92.9 250MB 92.5 93.0 250LB 92.9 93.6 250LD 93.1 93.7 315SE 93.3 93.8 315SE 93.2 93.9 Greaves Cotton Limited Page 121 of 319...

  • Page 123: Features

    Anti-loosening fasteners ensure stable cable terminations. Standard 6 leads for rated voltage and optional reconnectable 12 leads for different voltages in three phase AC Generators. 1.5.3 Automatic Voltage Regulator (AVR) Fig. D1.1 Automatic Voltage Regulator (AVR) Greaves Cotton Limited Page 122 of 319...

  • Page 124: Radio Interference

    The alternator is designed to give an excellent output waveform. The total harmonic content of line-to-line voltage waveform on no load is less than 5%, as per the limits specified by IEC/IS standards. Greaves Cotton Limited Page 123 of 319...

  • Page 125: Safety Requirements

    (max. 30 cm.) The alternator should be securely connected and perfectly aligned with the engine; otherwise unsafe vibrations may occur resulting in alternator bearing failure. Greaves Cotton Limited Page 124 of 319...

  • Page 126: Electrical Checks

    There is no short circuit due to wrong connections either/or in between the terminals of the alternator and the power switch or breaker (this part of the circuit is not protected by the breaker). Greaves Cotton Limited Page 125 of 319...

  • Page 127: Do's & Don'ts

    All covers and guards should be fitted before starting the generator. viii. After servicing the alternator, make sure the connections are as per connection diagram. Maintain and operate the GENSET correctly. Run the GENSET daily for at least 5-10 minutes on no load. Greaves Cotton Limited Page 126 of 319...

  • Page 128: Maintenance

    All fasteners, especially the connectors should be inspected for tightness at regular intervals. Greaves Cotton Limited Page 127 of 319...

  • Page 129: Troubleshooting Chart

    Faulty AVR Replace the AVR Low speed Reset the speed to nominal Faulty rotating rectifier Replace the rotating rectifier Low Voltage on No Load Check the winding resistance Faulty winding and rewind if required Greaves Cotton Limited Page 128 of 319...
  • Page 130 Excessive overheating of Set misalignment Align the set properly both bearings (temperature of bearings Bearing loose in end shield Replace the faulty end shield over 80°C) (with housing without noise) Greaves Cotton Limited Page 129 of 319...
  • Page 131 Stop the set immediately and alternator alternator causing short remove the object and check the circuit or flash in the stator alternator for further problems winding caused by the object Table D1.2 Alternator (CG Make) Troubleshooting Greaves Cotton Limited Page 130 of 319...

  • Page 132: Stamford Alternator

    Double bearing b. Brush type c. Transformer controlled d. Class ‘F’ winding e. With PMG Fig. D2.1 Stamford Alternator Greaves Cotton Limited Page 131 of 319...

  • Page 133: Specifications

    1 Hr. in 12 Hrs. Harmonic Distortion Factor < 3% NL L-L Max. Unbalanced Load TVD at Full Load 0.8 p.f. 15% max at linear load TVR at Full Load 0.8 p.f. 15% max at linear load Greaves Cotton Limited Page 132 of 319...

  • Page 134: Ratings Chart

    88.5 55.0 UCI224E 89.1 62.5 UCI224F 90.1 75.0 UCI224G 90.4 82.5 UCI224G 90.4 UCI274C 90.0 UCI274D 90.5 UCI274V 91.0 UCI274E 92.0 UCI274F 92.5 UCI274G 92.5 UCI274H 93.5 HCI 434C/444C 93.0 HCI 434C/444C 93.0 Greaves Cotton Limited Page 133 of 319...

  • Page 135: Construction

    The Rotor core is made of high quality low content silicon steel stampings. The poles carry continuous damper windings to facilitate parallel operation. 2.4.6 End Shields End shields are of cast iron construction and are fixed by easily accessible high tensile bolts. Greaves Cotton Limited Page 134 of 319...
  • Page 136 2.4.13 Radio Interference The absence of brush gear and the high quality of AVR design ensure low levels of interference with radio transmission. Additional RFI suppression kit can be supplied if required. Greaves Cotton Limited Page 135 of 319...

  • Page 137: Operating Principle

    (Hz) setting, preventing over-excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine. Greaves Cotton Limited Page 136 of 319...
  • Page 138 Set Point 97% of 50 Hz Build up voltage 4 V @ AVR Terminals Environmental Parameters Description / Value Operating Temperature -40° to +70°C Storage Temperature -55° to +80°C Relative Humidity 0 – 70°C Greaves Cotton Limited Page 137 of 319...
  • Page 139 External hand trimmer – REMOVE LINK 1-2 & connect trimmer across terminals 1 & 2 AVR Input Selection iii. a. High Voltage (220/240 V) – INPUT No Link b. Low Voltage (110/120 V) – INPUT Link 3-4 Greaves Cotton Limited Page 138 of 319...
  • Page 140 (i.e. the machine volts are stable but close to the unstable region) iii. Under Frequency Roll Off (UFRO) Fig. D2.4 Graph Illustrating Under Frequency Roll Off Greaves Cotton Limited Page 139 of 319...
  • Page 141 Clockwise adjustment lowers the frequency (speed) setting of the “Knee point” and extinguishes the LED. For optimum setting the LED should illuminate as the frequency falls just below the nominal frequency, i.e. 47 Hz on a 50 Hz generator. Greaves Cotton Limited Page 140 of 319...

  • Page 142: Automatic Voltage Regulator (Avr

    Note: Below mentioned is the description of acronym used in the part list of single bearing alternator. 1. N.D.E. – Non Driven End 2. D.E. – Driven End 3. AVR – Automatic Voltage Regulator Greaves Cotton Limited Page 141 of 319...
  • Page 143 Air Inlet Cover Cap Screw Terminal Box Lid AVR Access Cover End Panel D.E. AVR Anti Vibration Mounting Assembly End Panel N.D.E. Auxiliary Terminal Assembly Table D2.1 Part List of Typical Single Bearing Generator Greaves Cotton Limited Page 142 of 319...

  • Page 144: Maintenance

    The measured value of insulation resistance for all windings to earth and phase to phase should be minimum 1 MΩ. 2. Voltage and Frequency: Check that the voltage and frequency levels required for the GENSET application are as indicated on the alternator nameplate. Greaves Cotton Limited Page 143 of 319...
  • Page 145 If no voltage builds up is obtained it can be assumed that a fault exists either in the alternator of AVR circuit. Follow separate excitation procedure to check the alternator windings, rotating diodes and AVR. Greaves Cotton Limited Page 144 of 319...
  • Page 146 The recommended torque tightening is 4.06 – 4.74 Nm (36-42 lb-in). Greaves Cotton Limited Page 145 of 319...
  • Page 147 Important Note! Faults on the stator winding or cables may also cause noticeable load increase on the engine when excitation is applied. Disconnect the main cables and separate the winding leads U1-U2, U4-U6, V1-V2, V5-V6, W1-W2, and W5-W6 to isolate each winding section. Greaves Cotton Limited Page 146 of 319...
  • Page 148 Turning the ‘VOLTS’ control potentiometer fully anti-clockwise should turn off the lamp. If the lamp failed to light, the AVR is faulty and must be replaced. Important Note! After excitation control test turn the VOLTS control potentiometer anti-clockwise. Greaves Cotton Limited Page 147 of 319...

  • Page 149: Troubleshooting Chart

    High voltage on load Faulty AVR setting or Correct the setting/Replace the faulty AVR Check speed, Check link 1-2 or Low voltage on no load Low speed external hand trimmer leads continuity Greaves Cotton Limited Page 148 of 319...

  • Page 150: Standard Reference Conditions

    For altitudes above 1000 m, outputs must be multiplied by the following factors. (Refer table D3.2) Altitude in Meters Multiplier 1500 0.97 2000 0.94 2500 0.91 3000 0.88 3500 0.85 4000 0.82 Table D3.2 Greaves Cotton Limited Page 149 of 319...

  • Page 151: Optional Equipment

    The sizing of these air filters is important to avoid airflow restrictions and advice should be sought from authorized Greaves Sales and Service dealer. Greaves Cotton Limited Page 150 of 319...

  • Page 152: Chapter 5 General Comments On The Load Conditions

    For this, a suitable rating generator selection is very important. The types of loads that generally exist at sites can be broadly classified under following categories: Linear Loads Motor Loads (Part of Linear load, considered separately) iii. Non-Linear Loads Special Loads Greaves Cotton Limited Page 151 of 319...
  • Page 153 Leading Power Factor: For Capacitor loads, the power factor is leading. iii. The Crompton Greaves alternators are designed for 0.8 lag operating power factor of load. Also, these alternators can operate satisfactorily at any power factor in the range of 0.8 to unity, but care should be taken for engine rating for pure resistive loads to operate the GENSET on its full capacity.
  • Page 154 Any restriction on Transient Voltage Dip (Details of the same) vii. Frequency of starting viii. Base load at the time of starting induction motor Any other load apart from the motor loads (Details thereof) Sequence of starting the motors Greaves Cotton Limited Page 153 of 319...
  • Page 155 UPS & Telecom load controlled by a 3 pulse Non-Linear Load should not exceed 66% of thyristor bridge plus a filter alternator rating Variable speed pulse thyristor bridge Non-Linear Load should not exceed 50% of controlled drive alternator rating Table D5.1 Greaves Cotton Limited Page 154 of 319...
  • Page 156 Following information should be supplied for selecting a suitable alternator for computer loads: Total kVA rating of the computer load and its operating power factor. Acceptable steady state and transient state voltage and frequency variation. iii. Details of other types of loads existing. Greaves Cotton Limited Page 155 of 319...
  • Page 157 Following information should be supplied for selecting a suitable alternator for welding loads: kVA rating (Name plate details) Rated power factor iii. Whether single phase (240 V) or two phase (415 V) Primary rated transient current Details of other voltage sensitive loads, if any. Greaves Cotton Limited Page 156 of 319...
  • Page 158 Auxiliary Power Business Greaves Cotton Limited Page 157 of 319...
  • Page 159 2.13 Terminal Description 2.14 Specifications Deep Sea 4520 Controller Introduction Major Parts of Deep Sea (DSE4520) Controller Specifications Installation Description of Controls Operation Front Panel Configuration Fault Finding Maintenance, Spares, Repair, and Servicing Greaves Cotton Limited Page 158 of 319...
  • Page 160 Description of Controls 5.10 Waveform Display & Harmonic Analysis 5.11 Operation of the Unit 5.12 Protection and Alarms 5.13 Program Parameter List 5.14 SMS Commands 5.15 Data Recording 5.16 Data Features 5.17 MODBUS Communications Greaves Cotton Limited Page 159 of 319...
  • Page 161 Auto Mains Failure (AMF) Panel Battery Trickle Chargers Fuel Transfer Pumps Meters Gauges Speed / Voltage Control Alarm Signalling Remote Start Batteries Safety Charger and Battery Connections Charger Operation Battery Maintenance Fault Finding Greaves Cotton Limited Page 160 of 319...

  • Page 162: Control System And Operation

    Local and national regulations for the grounding of GENSET should be adhered to, as well as those regulations which describe the methods of connection and minimum sizes of grounding conductors based on the size of the load cables. Greaves Cotton Limited Page 161 of 319...

  • Page 163: Initial Start-Up

    These steps are critical and must be followed closely to avoid complications in operating the GENSET. To start-up the GENSET follow the procedure as mentioned below: Check the engine oil and coolant levels and replenish if necessary. Fill the fuel tank. Greaves Cotton Limited Page 162 of 319...
  • Page 164 When the engine starts, the display shows ‘Run Up’ with a countdown in seconds. This allows the engine measurement system to stabilize. Over speed and loss of speed signal are the only parameters checked during Run Up. Greaves Cotton Limited Page 163 of 319...

  • Page 165: Normal Start-Up

    Check the engine oil, fuel and coolant levels, replenish if necessary. Check the battery terminals for corrosion, clean them if necessary. Also check the battery electrolyte level and if necessary, fill it with distilled water. Turn the Control switch to ON position. Greaves Cotton Limited Page 164 of 319...
  • Page 166 Run Up. d. WARM UP i. Allows the engine to stabilize at full speed before putting on load. Oil pressure and Over-speed are monitored. ii. The display shows ‘Warm Up’ with a countdown time. Greaves Cotton Limited Page 165 of 319...
  • Page 167 ‘Stop Time’. The speed must remain zero and the oil pressure must be below the alarm set point for the ‘Stop Rest Time’ before the engine is considered stopped. Greaves Cotton Limited Page 166 of 319...
  • Page 168 If the GENSET does not stop then the alarm output is activated and ‘STOP FAIL’ is displayed on the LCD. b. READY i. Once the engine stops, READY icon will be displayed on the LCD indicating the engine is ready to start again. Greaves Cotton Limited Page 167 of 319...

  • Page 169: Procom Controller

    2.2 Major Parts of PROCOM Controller The major parts of PROCOM controller are explained in two aspects, which are as mentioned below. 2.2.1 Components on the Door of Control Panel Fig. E2.1 Exterior Illustration of PROCOM Control Panel Greaves Cotton Limited Page 168 of 319...
  • Page 170 The breaker will carry the rated current continuously. In case of a short circuit or even if over current flows for specified amount of time, the breaker will trip. The breaker must then be moved to “OFF” position before re-closing. Greaves Cotton Limited Page 169 of 319...
  • Page 171 3) Current Transformers: Three current transformers, one for each phase, are provided for sensing current. 4) Hooter: The hooter operates in case of any fault is sensed by the controller. Greaves Cotton Limited Page 170 of 319...

  • Page 172: Protection & Supervision Salient Features

    2.5 Annunciations PROCOM’s DES-11 controller is equipped with the following annunciations for system status and faults finding: LLOP HWT(Model A) iii. HCT (Model B) Greaves Cotton Limited Page 171 of 319...

  • Page 173: Contacts

    HWT supervision time (Model-A) viii. RWL supervision time (Model-A) HCT supervision time (Model-B) Canopy Temperature Time (Model-B) Hooter Reset Time xii. Service Time xiii. Charging Alternator contact on time xiv. Crank Timer Greaves Cotton Limited Page 172 of 319...

  • Page 174: Switches Description

    LLOP, HWT and emergency faults. On detection of any of these faults for the pre-programmed duration the engine is automatically shut down and fault along with run hour is recorded in non-volatile memory. The run hour time of engine is recorded in internal non-volatile memory. Greaves Cotton Limited Page 173 of 319...

  • Page 175: Setting Procedure

    6 (For /5 A CT) 1-999 Max permissible current, above this 42A (For (For /5 A CT) Generator O/C* the Current is treated unhealthy & Procom CT) 1-199 A (For the Generator is stopped. Procom CT) Greaves Cotton Limited Page 174 of 319...
  • Page 176 E.g. If Oil HWT Only, pressure sensor is not installed the LLOP Only, unit shall provide protection for No sensor LLOP through oil pressure switch and not through the oil pressure sensor (linear measurement) Greaves Cotton Limited Page 175 of 319...
  • Page 177 This setting is to protect the fuel solenoid in case the Stop button or Emergency Emergency key is kept pressed. In 40 Sec 1-100 Sec Solenoid Time such a case the solenoid shall be released after this time. Greaves Cotton Limited Page 176 of 319...
  • Page 178 Disable Disable / disabling the SMS communication Crank Cut Only Voltage based / Voltage or LOP Voltage/ LOP Voltage Method based Or Voltage Table E2.4 * This parameter can be disabled while programming. Greaves Cotton Limited Page 177 of 319...

  • Page 179: Fault History

    There are two categories of faults, v.i.z. Internal Faults External Faults 2.11.1 Internal Faults Internal faults are the faults, which do not need any external signals and are detected by the system itself. They are: Greaves Cotton Limited Page 178 of 319...

  • Page 180: Communication Setup

    The owner of the first 2 telephone numbers can, on demand, access the above information through SMS by sending an SMS to AC3. The SMS is “STATUS”, without quotes and all capital. Greaves Cotton Limited Page 179 of 319...
  • Page 181 Make sure that the last digit after the valid number is a blank. To go to next telephone number press Key. The process can be terminated and all previous programmed numbers can be stored by pressing R (Reset) Key Greaves Cotton Limited Page 180 of 319...

  • Page 182: Terminal Description

    B Phase CT ( For Whole Current Unit with Procom Make CT’s) Common Point Of CTs ( For Whole Current Unit with Procom Make CT’s) 20-22 Fan Current input for Single Phase Model-B Table E2.5 Terminal Description Greaves Cotton Limited Page 181 of 319...

  • Page 183: Specifications

    Max. Battery Voltage DC Interruption time 1 Sec. Digital Output + 12V Cut out Dimensions 92mm X 92mm Depth 120mm Digital Input Level which is battery supply Battery Voltage (Negative) except Charging Alt, Table E2.6 Greaves Cotton Limited Page 182 of 319...

  • Page 184: Deep Sea 4520 Controller

    Module access can also be protected by PIN code. Selected parameters can be changed from the module’s front panel. The module is housed in a robust plastic case suitable for panel mounting. Connections to the module are via locking plug and sockets. Greaves Cotton Limited Page 183 of 319...

  • Page 185: Major Parts Of Deep Sea (Dse4520) Controller

    Description of Part Load ON GENSET Canopy Light Switch Deep Sea (DSE4520) Controller Power MCB / MCCB Control Switch (ON/OFF) Table E3.1 Part List for External Components of DSE4520 Control Panel & Power Panel Greaves Cotton Limited Page 184 of 319...
  • Page 186 The breaker must then be moved to “OFF” position before re-closing. 3.2.2 Components inside the Control Panel & Power Panel Fig. E3.2 Interior Illustration of DSE4520 Control Panel Greaves Cotton Limited Page 185 of 319...

  • Page 187: Specifications

    4) Hooter: The hooter operates in case of any fault is sensed by the controller. 3.3 Specifications 3.3.1 Short Names DSE4500, DSE45xx All modules in the DSE4500 range DSE4520 DSE4520 module/controller 3.3.2 Operating Temperature DSE45xx -30ºC to +70ºC (-40ºC to +70ºC for variants fitted with display heaters) Greaves Cotton Limited Page 186 of 319...
  • Page 188 Table E3.3 Power Supply Requirements 3.3.3.1 Module Supply Instrumentation Display Range 0V-70V DC (note Maximum continuous operating voltage of 35V DC) Resolution 0.1V Accuracy 1% full scale (±0.7V) Table E3.4 Module Supply Instrumentation Display Greaves Cotton Limited Page 187 of 319...
  • Page 189 3.5 Hz Maximum Frequency 75.0 Hz Frequency Resolution 0.1 Hz Frequency Accuracy ±0.2 Hz Table E3.5 Voltage & Frequency Sensing 3.3.5 Current Sensing Important Note! Current Sensing is not available on the DSE45xx-01 variant. Greaves Cotton Limited Page 188 of 319...

  • Page 190: Digital Inputs

    +60 V DC with respect to plant supply negative Minimum Input Voltage -24 V DC with respect to plant supply negative Contact Wetting Current 6 mA typical Open Circuit Voltage 15 V typical Table E3.7 Digital Inputs Greaves Cotton Limited Page 189 of 319...

  • Page 191: Coolant Temperature

    1°C (2°F) +/-2% of full scale resistance (±9.6 Ω) excluding transducer error Accuracy Max Common Mode Voltage ±2V Display Range 0°C - 250°C (32°F - 482°F) subject to limits of the sensor Table E3.9 Greaves Cotton Limited Page 190 of 319...

  • Page 192: Fuel Level Sensor

    0% - 250%, 0°C - 250°C (32°F - 482°F) or 0 bar - 17.2 bar (0 PSI - Display Range 250 PSI) subject to limits of the sensor and sensor configuration Table E3.11 Greaves Cotton Limited Page 191 of 319...
  • Page 193 Normally used as Fuel & Start outputs. Fully configurable for other purposes if the module is configured to control an electronic engine. Rating 10A resistive for 10secs, 5A resistive continuous at 35V Table E3.13 Greaves Cotton Limited Page 192 of 319...
  • Page 194 2A resistive continuous at 35V Table E3.15 3.3.8 Dimensions and Mounting Fig. E3.5 3.3.8.1 Dimensions 140.0mm x 113mm x 43mm (5.5” x 4.4” x 1.7”) 3.3.8.2 Panel Cut-out 118mm x 92mm (4.6” x 3.6”) Greaves Cotton Limited Page 193 of 319...
  • Page 195 Turn the screws a little more to secure the module into the panel fascia. Care should be taken not to over tighten the fixing clip screws. Fig. E3.6 Important Note! In conditions of excessive vibration, mount the module on suitable anti-vibration mountings. Greaves Cotton Limited Page 194 of 319...
  • Page 196 The gasket is fitted to the module before installation into the panel fascia. Take care to ensure the gasket is correctly fitted to the module to maintain the integrity of the seal. Fig. E3.7 Greaves Cotton Limited Page 195 of 319...

  • Page 197: Installation

    Specifications, Dimension and mounting in this chapter. 3.4.1 Terminal Description To aid user connection, icons are used on the rear of the module to help identify terminal functions. An example of this is shown below. Fig. E3.8 Greaves Cotton Limited Page 196 of 319...

  • Page 198: Description Of Controls

    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. Greaves Cotton Limited Page 197 of 319...
  • Page 199 2, 3 & 4’ become inactive at once (if used)). The module will then await the next start event. For further details, please see the more detailed description of ‘Auto operation’ elsewhere in this manual. Menu Navigation Used for navigating the instrumentation, event log and configuration screens. Greaves Cotton Limited Page 198 of 319...
  • Page 200 ‘Delayed Load Output 1, 2, 3 & 4’ becomes active (if used)). Upon removal of the Remote Start Signal, the generator remains on load until either selection of the Stop/Reset Mode or Auto Mode. Table E3.16 3.5.2 Instrumentation Icons Exhibit Table E3.17 Instrumentation Icons Greaves Cotton Limited Page 199 of 319...
  • Page 201 Exhibit Table E3.18 Mode Icons 3.5.4 Load Switching Icons An icon is displayed in the Load Switching Icon section to indicate the current operation status of the controller. Exhibit Table E3.19 Load Switching Icons Greaves Cotton Limited Page 200 of 319...
  • Page 202 ‘all warnings are latched’ will cause warning alarms to latch until reset manually. This is enabled using the DSE Configuration Suite in conjunction with a compatible PC. Exhibit Table E3.20 (a) Warning Alarm Icons Greaves Cotton Limited Page 201 of 319...
  • Page 203 (The exception to this is the Low Lube Oil Pressure alarm and similar ‘active from safety on’ alarms, as the oil pressure is low with the engine at rest). Greaves Cotton Limited Page 202 of 319...
  • Page 204 Shutdowns are latching alarms and to remove the fault, press the Stop/Reset Mode button on the module. Exhibit Table E3.22 (a) Shutdown Alarm Icons Greaves Cotton Limited Page 203 of 319...
  • Page 205 Auxiliary Power Business Exhibit Table E3.22 (b) Shutdown Alarm Icons Greaves Cotton Limited Page 204 of 319...
  • Page 206 Hence, the log always contains the most recent shutdown alarms. The module logs the alarm, along with the engine running hours. Greaves Cotton Limited Page 205 of 319...

  • Page 207: Operation

    Auxiliary Power Business 3.6 Operation 3.6.1 Quick Start Guide This sub-topic provides a quick start guide to the module’s/controller’s operation. 3.6.1.1 Starting the Engine Fig. E3.10 3.6.1.2 Stopping the Engine Fig. E3.11 Greaves Cotton Limited Page 206 of 319...
  • Page 208 Power Save Mode, the module enters Power Save Mode. To ‘wake’ the module, press any fascia control buttons or activate Digital Input A. The same is true for Deep Sleep Mode. Greaves Cotton Limited Page 207 of 319...

  • Page 209: Automatic Mode

    If this sequence continues beyond the set number of attempts, the start sequence is terminated and the display shows fail to start Greaves Cotton Limited Page 208 of 319...

  • Page 210: Engine Running

    After the cooling timer has expired, the set is stopped. 3.6.4 Manual/Start Mode 3.6.4.1 Waiting in Manual Mode To begin the starting sequence, press the Manual/Start Mode button. If ‘protected start’ is disabled, the start sequence begins immediately. Greaves Cotton Limited Page 209 of 319...
  • Page 211 After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Greaves Cotton Limited Page 210 of 319...
  • Page 212 – The delayed load outputs are de-activated immediately and the set immediately stops. The Auto Mode button is pressed. The set observes all auto mode start requests and stopping timers before beginning the Auto Mode Stopping Sequence. Greaves Cotton Limited Page 211 of 319...

  • Page 213: Front Panel Configuration

    ( ) button, the value begins to flash. Press the (+) or (-) buttons to adjust the value to the required setting. Press the ( ) button the save the current value, the value ceases flashing. Greaves Cotton Limited Page 212 of 319...
  • Page 214 (manually or automatically) to ensure security. Important Note! More comprehensive module configuration is possible via PC configuration software. For further details of module configuration, refer to DSE Publication: 057-172 DSE45xx configuration software manual. Greaves Cotton Limited Page 213 of 319...

  • Page 215: Fault Finding

    Starter motor inoperative battery supply is present on the Starter output of module. Ensure oil pressure switch or sensor is indicating the “low oil pressure” state to the controller. Table E3.25 Fault Finding during Starting Greaves Cotton Limited Page 214 of 319...
  • Page 216 This indicates a fault condition detected by the engine ECU and CAN ECU SHUTDOWN transmitted to the DSE controller. Indicates failure of the CAN data link to the engine ECU. Check all CAN DATA FAIL wiring and termination resistors (if required). Greaves Cotton Limited Page 215 of 319...
  • Page 217 Accuracy of the controller is better than 1% of full scale. Generator voltage full scale is 415V ph-N, accuracy is ±4.15V (1% of 415V). Table E3.29 Fault Finding in Instruments Greaves Cotton Limited Page 216 of 319...

  • Page 218: Maintenance, Spares, Repair And Servicing

    Greaves authorized service personnel. 3.9 Maintenance, Spares, Repair and Servicing The controller is Fit and Forget. As such, there are no user serviceable parts within the controller.
  • Page 219 3.9.2 Purchasing Additional Fixing Clips from DSE Item Description Part No. Module Fixing Clips (Packet Of 2) 020-406 Table E3.33 3.9.3 Purchasing Additional Sealing Gasket from DSE Item Description Part No. Module Silicon Sealing Gasket 020-282 Table E3.34 Greaves Cotton Limited Page 218 of 319...

  • Page 220: Deep Sea 6123 Controller

    Additionally, the module’s / controller’s integral fascia configuration editor allows adjustment of this information. A robust plastic case designed for front panel mounting houses the module. Connections are via locking plug and sockets. Greaves Cotton Limited Page 219 of 319...

  • Page 221: Major Parts Of Deep Sea (Dse6123) Controller

    The major parts of Deep Sea (DSE6123) control panel & power panel are explained in two aspects, which are as mentioned below. 4.2.1 Components on the Door of Control Panel & Power Panel Fig. E4.1 Exterior Illustration of DSE6123 Control Panel Greaves Cotton Limited Page 220 of 319...
  • Page 222 The breaker will carry the rated current continuously. In case of a short circuit or if over current flows for specified amount of time, the breaker will trip. The breaker must then be moved to “OFF” position before re-closing. Greaves Cotton Limited Page 221 of 319...
  • Page 223 Ref. No. Description of Part Ref. No. Description of Part Control MCB/Fuse Power MCCB Power Relay Board Hooter Current Transformers Table E4.2 Part List for Internal Components of DSE6123 Control Panel & Power Panel Greaves Cotton Limited Page 222 of 319...

  • Page 224: Specifications

    Reverse polarity protection -35V continuous Maximum operating current 160mA at 24V; 340mA at 12V Maximum standby current 80mA at 24V; 160mA at 12V Current when in Sleep Mode 50mA @ 12V; 32mA @ 24V Greaves Cotton Limited Page 223 of 319...

  • Page 225: Generator Voltage/Frequency Sensing

    60% of DC supply voltage Maximum input voltage DC supply voltage positive terminal Minimum input voltage DC supply voltage negative terminal Contact wetting current 2.5mA @12V typical; 5mA @ 24V typical Open circuit voltage Plant supply Greaves Cotton Limited Page 224 of 319...

  • Page 226: Charge Fail Input

    Magnetic Pickup devices can often be ‘shared’ between two or more devices. For example, one device can often supply the signal to both the DSE6100 series module and the engine governor. The possibility of this depends upon the amount of current that the magnetic pickup can supply. Greaves Cotton Limited Page 225 of 319...

  • Page 227: Accumulated Instrumentation

    The number of logged Engine Hours and Number of Starts can be set/reset using the DSE Configuration Suite PC software. Depending upon module configuration, this may have been PIN number locked by your generator supplier. Greaves Cotton Limited Page 226 of 319...
  • Page 228 Turn the fixing clip screws clockwise until they make contact with the panel fascia. Turn the screws a little more to secure the module into the panel fascia. Care should be taken not to over tighten the fixing clip screws. Fig. E4.5 Fixing Clips Greaves Cotton Limited Page 227 of 319...

  • Page 229: Installation

    4.4.1.1 DC Supply, Fuel, and Start Outputs Important Note! When the module/controller is configured for operation with an electronic engine, FUEL and START output requirements may be different. Avail advice in this regard from Greaves expert technical team. Greaves Cotton Limited Page 228 of 319...
  • Page 230 Auxiliary Power Business Exhibit Table E4.3 4.4.1.2 Generator / Mains Voltage Sensing Exhibit Table E4.4 Greaves Cotton Limited Page 229 of 319...

  • Page 231: Description Of Controls

    Auxiliary Power Business 4.4.1.3 Digital Inputs Exhibit Table E4.5 4.5 Description of Controls The following section details the function and meaning of the various controls on the module. Fig. E4.7 Greaves Cotton Limited Page 230 of 319...
  • Page 232 Auxiliary Power Business 4.5.1 Quick Start Guide This topic provides a quick start guide to the module’s operation. 4.5.1.1 Starting the Engine Fig. E4.8 4.5.1.2 Stopping the Engine Fig. E4.9 Greaves Cotton Limited Page 231 of 319...
  • Page 233 (if used)). Upon removal of the remote start signal, the generator remains on load until either selection of the ‘STOP/RESET’ or ‘AUTO’ modes. For further details, please see the more detailed description of ‘Manual operation’ elsewhere in this chapter. Greaves Cotton Limited Page 232 of 319...
  • Page 234 ECU, pressing this button in STOP/RESET mode after pressing the START button (to power the ECU) will cancel any “passive” alarms on the engine ECU. Scroll This buttons scrolls through the instrument display pages. Greaves Cotton Limited Page 233 of 319...

  • Page 235: Operation

    When configured to do so, when left in STOP mode for five minutes with no presses of the fascia buttons, the module enters low power mode. To ‘wake’ the module, press the button or any other fascia control button. Fig. E4.10 Greaves Cotton Limited Page 234 of 319...
  • Page 236 4.6.2 Automatic Mode Important Note! If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock. Greaves Cotton Limited Page 235 of 319...
  • Page 237 If this sequence continues beyond the set number of attempts, the start sequence will be terminated and the display shows fail to Start. Greaves Cotton Limited Page 236 of 319...
  • Page 238 The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is particularly important where turbo chargers are fitted to the engine. After the cooling timer has expired, the set is stopped. Greaves Cotton Limited Page 237 of 319...
  • Page 239 Important Note! If the unit has been configured for CAN, compatible ECU’s will receive the start command via CAN. Important Note! If the unit has been configured for CAN, speed sensing is via CAN. Greaves Cotton Limited Page 238 of 319...
  • Page 240 Press the auto mode button to return to automatic mode. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence. Greaves Cotton Limited Page 239 of 319...

  • Page 241: Front Panel Configuration

    4.7 Front Panel Configuration Fig. E4.11 This configuration mode allows the operator limited customising of the way the module operates. Use the module’s navigation buttons to traverse the menu and make value changes to the parameters. Greaves Cotton Limited Page 240 of 319...
  • Page 242 PIN number. Press when the fourth digit is correctly entered. The entered digit will turn back to a * to maintain security. Table E4.6 Greaves Cotton Limited Page 241 of 319...
  • Page 243 (+) to select the next parameter or (-) to select the previous parameter within the current page. When viewing the parameter to be changed, press the ) button. The value begins to flash. Greaves Cotton Limited Page 242 of 319...
  • Page 244 (min to max) in less than 20 seconds. Important Note! When the editor is visible, it is exited after 5 minutes of inactivity to ensure security. Greaves Cotton Limited Page 243 of 319...

  • Page 245: Fault Finding

    Check relevant switch and wiring of fault indicated Shutdown fault operates on LCD display. Check configuration of input. Check relevant switch and wiring of fault indicated Warning fault operates on LCD display. Check configuration of input. Greaves Cotton Limited Page 244 of 319...
  • Page 246 Engine runs but generator will not take module inputs. Check connections to the switching load device. Note that the set will not take load in manual mode unless there is an active remote start on load signal. Greaves Cotton Limited Page 245 of 319...
  • Page 247 Important 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 or avail assistance from Greaves Technical Team. Greaves Cotton Limited Page 246 of 319...

  • Page 248: Maintenance, Spares, Repair, And Servicing

    6000 series fixing clips (packet of 4) 020-294 4.9.3 Purchasing Additional Sealing from DSE The optional sealing gasket is not supplied with the controller but can be purchased separately. Item Description Part No. 6000 series silicon sealing gasket 020-389 Greaves Cotton Limited Page 247 of 319...

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