hipower yanmar generators manual
TRANSCRIPT
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HIPOWER builds a
wide range of Power
Plants available for
standby or primer
power applications
providing a safe, relia-
ble and dependable
source of energy
where ever is needed.
Industrial Range Industrial Generator Sets
feature a robust construc-
tion with strict adherence
to quality, while maintai-
ning a minimal impact to
the environment.
Rental RangeHIPOWER Rental Gene-
rators Sets have been
developed from the user
and service point of view
thanks to the input of
the premium class rental
companies.
Generating SetsManualYanmar
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Contents
Forward .......................................................................................................2
1. Safety .....................................................................................................5
1.1 General Safety Information ........................................................................ 5
1.2 Installation And Transporting .................................................................... 6
Hazards ................................................................................................................. 6
2. Identication .........................................................................................8
2.1 Generator Identication View ..................................................................... 8
3. Installation..........................................................................................10
3.1 General Information ................................................................................... 10
3.2 Control Of Material ..................................................................................... 10
3.3 Outdoor Installations ................................................................................. 103.4 Indoor Installations .................................................................................... 10
3.4.2 Exhaust Installation ............................................................................................ 12
3.4.3 Ventilation ............................................................................................................ 1
3.4.4 Remote Fuel Tank ............................................................................................... 1
3.4.5 Heating ................................................................................................................. 1
3.4.6 Electrical Connections ....................................................................................... 1
3.3.7 Three Phase Generator Sets .............................................................................. 1
3.3.8 Single Phase Generator Sets ............................................................................. 1
4. Prestart Checks ..................................................................................19
4.1 Prestart Checks.......................................................................................... 19
5. CEM7 Control Panel ...........................................................................20
5.1 Introduction ................................................................................................ 20
5.1.1 Display Module (Control Panel) ......................................................................... 2
5.1.2 Measurements Module ....................................................................................... 2
5.2 Control Panel .............................................................................................. 215.3 Control Panel Push Buttons ..................................................................... 22
5.3.1 Operating Mode Buttons .................................................................................... 22
5.3.2 Command Buttons .............................................................................................. 22
5.3.3 Display Buttons ................................................................................................... 22
5.4 Data LED’s .................................................................................................. 23
5.4.1 Contactor Status LEDs ....................................................................................... 2
5.4.2 Engine Status LEDs ............................................................................................ 2
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Forward
5.4.3 Alarm LEDs .......................................................................................................... 23
5.5 Starting And Stopping Genset .................................................................. 24
5.5.1 Starting - Manual Mode ....................................................................................... 24
5.5.2 Stopping - Manual Mode ..................................................................................... 24
5.5.3 Starting And Stopping - Automatic Mode ......................................................... 24
5.6 Interruption Of Function Mode ................................................................. 24
5.7 Working Mode ............................................................................................ 24
5.8 Transfer Fuel Pump.................................................................................... 25
5.9 Alarms ......................................................................................................... 25
5.9.1 Reseting Alarms .................................................................................................. 26
5.10 Engine Alarms .......................................................................................... 27
5.11 Genset Alarms .......................................................................................... 28
5.12 Programmable Alarms And Inputs ......................................................... 28
6. M6 Control Panel ................................................................................30
6.1 Control Panel - M6...................................................................................... 30
6.2 Starting And Stopping Genset - M6 Control Panel ................................. 31
6.2.1 Starting - Manual Mode ....................................................................................... 31
6.2.2 Stopping - Manual Mode ..................................................................................... 32
6.2.3 Starting And Stopping - Automatic Mode ......................................................... 32
6.3 Engine Alarms ............................................................................................ 33
7. DSE3000 Series Control Panel ........................................................ 34
7.1 Description Of Controls............................................................................... 34
7.2 Quickstart Guide .......................................................................................... 34
7.1.1 Starting The Engine .............................................................................................. 34
7.1.2 Stopping The Engine ............................................................................................ 34
7.3 Graphical Display......................................................................................... 34
7.4 Controls ........................................................................................................ 35
7.5 Automatic Mode Of Operation .................................................................... 357.5.1 Waiting In Auto Mode ............................................................................................ 35
7.5.2 Starting Sequence ................................................................................................. 35
7.5.3 Stopping Sequence ............................................................................................... 36
7.6 Manual Operation ......................................................................................... 36
7.6.1 Waiting In Manual Mode ....................................................................................... 36
7.6.2 Starting Sequence ................................................................................................. 36
7.6.3 Stopping Sequence ............................................................................................... 36
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7.7 Warnings ....................................................................................................... 36
7.8 Shutdowns .................................................................................................... 37
7.9 Module Display ............................................................................................. 37
7.9.1 Timer Icon .............................................................................................................. 3
7.9.2 Stopped Icon ......................................................................................................... 3
7.9.3 Running Icon ......................................................................................................... 3
7.9.4 USB Icon ................................................................................................................ 3
7.9.5 Memory Corruption ............................................................................................... 3
7.9.6 Backlight ................................................................................................................ 3
7.10 Fault Icons .................................................................................................. 38
8. DSE5310 Series Control Panel .......................................................... 39
8.1 Description Of Controls............................................................................... 39
8.5 Typical LCD Display Screens ...................................................................... 488.5.1 Typical Status Display .......................................................................................... 4
8.5.2 Typical Instrument Display ................................................................................... 4
8.5.3 Typical Alarm Display ........................................................................................... 4
8.5.4 Typical Event Display ........................................................................................... 49
8.6 Viewing The Instruments ............................................................................. 49
8.6.1 Instrument Page Content ..................................................................................... 5
8.6.2 Manually Selecting An Instrument....................................................................... 5
8.7 User Congurable Indicators ...................................................................... 518.8 Controls ........................................................................................................ 51
8.7 User Congurable Indicators ...................................................................... 52
8.8 Controls ........................................................................................................ 52
8.9 Fault Finding................................................................................................. 53
8.10 Icons And LED Identication .................................................................... 54
7.10.1 Push Buttons ....................................................................................................... 54
8.10.2 Status / Measurement Units ............................................................................... 54
8.10.3 LED Indication ..................................................................................................... 5
9. Routine Maintenance ........................................................................55
9.1 Maintenance ............................................................................................... 55
9.2 Periodic Maintenance .................................................................................. 56
10. Alternator ......................................................................................... 57
10.1 Generator Designation ............................................................................ 57
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10.2 Serial Number Location ........................................................................... 57
10.3 Rating Plate .............................................................................................. 57
10.4 Lifting ........................................................................................................ 57
10.5 Automatic Voltage Regulators ................................................................ 58
10.5.1 Type AS440 ........................................................................................................ 5810.5.2 Type MX341 ........................................................................................................ 59
10.5.4 Type MX321 ........................................................................................................ 60
10.6 Electrical Protection ................................................................................ 60
10.7 Fault Finding............................................................................................. 61
10.7.1 SX460 AVR ......................................................................................................... 61
10.7.2 SX440 AVR ......................................................................................................... 61
10.7.3 SX421 AVR ......................................................................................................... 61
10.8 Alternator Maintenance ........................................................................... 6210.8.1 Winding Condition ............................................................................................ 62
10.8.2 Guidance Of Typical Insulation Resistance [IR] Values ................................ 62
10.8.3 Winding Condition Assessment ...................................................................... 62
10.9 Replacement Parts ................................................................................... 62
11. Specications ...................................................................................63
11.1 Generator Set Models .............................................................................. 63
11.2 Engine Models .......................................................................................... 64
11.2.1 3TNV76 ............................................................................................................... 64
1.2.2 3TNV88 ................................................................................................................. 64
11.2.3 4TNV84T ............................................................................................................. 65
11.2.4 4TNV88 ............................................................................................................... 65
11.2.5 4TNV98 ............................................................................................................... 66
11.2.6 4TNV98T ............................................................................................................. 66
Illustrations and technical detail provided courtesy of Cummins Generator Technologies.
Copyright 2010, Cummins Generator Technologies, All Rights Reserved.
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1. Safety
1.1 General Safety InformationThis manual provides information and procedures to safely
operate and maintain your Hipower Generator Set. Read,
understand and observe the safety instructions described
in this manual before installing, operating and servicing the
generator.
If you have questions about operation or service, pleasecontact Hipower Systems. The information contained in this
manual was based on machines in production at the time of
publication. Himoinsa Power Systems reserves the right to
change any portion of this information without notice.
All rights, especially copying and distribution rights are
reserved. Copyright© 2010 by Himoinsa Power Systems.
No part of this publication may be reproduced in any form
or by any means, electronic or mechanical, including
photocopying, without express written permission from
Himoinsa Power Systems.
This manual is provided to assist in the maintenance and
operation of the generator and is not to be used in any manner
detrimental to the interests of Himoinsa Power systems.
Information in this manual represents components installed
when product was manufactured based upon the best
available information. Modications made subsequent
to initial delivery are not included. Always verify the parts
required with Himoinsa Power Systems.
If you have any questions, please contact our Parts and
Service Department.
Do not operate generator without an Operators Manual.
Treat the Operators Manual as part of the generator. Replace
the Operators Manual if it is lost, damaged or becomes
unreadable.
All personnel that will be operating, maintaining and working
around the generator must review these documents before
interacting with the generator.
If you have any safety concerns or questions that are not
covered by this manual, please contact Himoinsa Power
Systems at 1-913-495-5557.
^ California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
Battery posts, terminals and related accessories contain
lead and leads compounds, chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm. Wash hands after handling.
The safety information in this manual is denoted by th
safety alert symbol: ^
The level of risk is indicated by the following signal words
^ DANGER
Indicates a hazardous situation, which, if not
avoided, will result in death or serious injury.
^ WARNING
Indicates a hazardous situation, which, if not
avoided, could result in death or serious injury.
^ CAUTION
Indicates a hazardous situation, which, if not
avoided, could result in minor or moderate injury
NOTICE
Indicates a situation that could result in damage
to the equipment or other property.
Never go under raise equipment unless properly supporte
Use properly rated lifting equipment to lift heavy objects.
Extinguish all smoking material when adding fuel or workin
around generator. Engine must be stopped before addin
fuel.
Clean up spilt uids and dispose of uids, contaminate
material etc. in accordance with local regulations.
Disconnect negative (-) battery cable before performi
maintenance on generator set.
Allow components to cool before attempting a
maintenance.
Do not operate generator set with safety guard(s) remove
Seek medical attention immediately if your skin contacts
high pressure fuel.
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1.2 Installation And Transporting
Hazards
^ WARNING
Crushing hazard.
Generator set is heavy.
Use properly rated lifting devices to move
generator set.
Never enter the area under a raised generator set.
^ WARNING
The generator lifting points are designed to lift thegenerator only.
Do not lift the complete generating set by the
generator lifting points.
^ WARNING
Incorrect installation and/or protective systems
can result in injury and/or equipment damage.
Installers must be qualied to perform electrical
installation work.
1.3 Operational Hazards
^ WARNING
Risk of death or serious injury.
Do not operate, work on or around this machinewhile under the inuence of alcohol, drugs or if
feeling ill.
^ WARNING
Entanglement hazard.
Loose tting clothing and long hair can be
come entangled in moving or rotating parts.
Do not wear loose tting clothing.
Long hair must be tied back or netted.
Remove neck ties.
Do not operate generator with a guard removed
or access panel removed.
^ WARNING
Carbon monoxide hazard.
Do not operate the generator in an enclosed
building or conned area.
Avoid actions or areas that expose you and
others to carbon monoxide.
^ WARNING
Risk of death or serious injury.
Do not operate, work on or around this machine
while under the inuence of alcohol, drugs or if
feeling ill.
^You must adhere to local codes and regulations whereyour generator is being used.
1. Safety
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1. Safety
^ Do not smoke while refueling. Do not refuel near sparksor an open ame.
^ Clean up uid spills and contaminated material inaccordance with local regulations.
^ WARNING
Ensure that all personnel operating, servicing,
maintaining or working near this equipment
are wearing appropriate Personal Protective
Equipment (PPE) including eye and ear protection
and are fully aware of the emergency procedures
in case of any accidents.
^ WARNING
Generators emit noise.
Ensure appropriate ear protection is worn at all
times. Maximum A-weighted emissions levels may
reach 104 db.
1.4 Maintenance Hazards
^ Service and maintenance procedures must be carried
out by experienced, qualied engineers, familiar withthe procedures and the equipment. Before any intrusive
procedures are carried out, ensure that the engine is inhibited
and the generator is electrically isolated.
^ All electrical equipment can be dangerous if notoperated correctly. Always service and maintain the
generator in accordance with this manual. Always use
genuine replacement parts.
^ WARNING
Hot engine and exhaust system can cause severe
injury.
Do not touch hot engine parts.
Do not perform service or maintenance on
generator until cool to the touch.
^ WARNING
Risk of severed digits or limbs.
Generator can be started from a remote switch.
Disconnect the negative (-) battery cable from
generator battery before performing service or
maintenance on generator set.
^ WARNING
Electrical shock can cause injury or death.
Ensure that all personnel operating, servicing,
maintaining or working near this equipment are
fully aware of the emergency procedures in caseof accidents.
^ WARNING
Do not handle Permanent Magnet Generators
(PMGs) if you have mechanically implanted
devices; ie pacemakers.
^ WARNING
Service and fault nding procedures present
hazards which can result in injury or death.
Only personnel qualied to perform electrical
and mechanical service should carry out these
procedures. Ensure engine starting circuits
are disabled before commencing service or
maintenance procedures. Isolate any anti-
condensation heater supply.
^California Proposition 65 Warning
Diesel engine exhaust and some of its constituents a
known to the State of California to cause cancer, bir
defects and other reproductive harm.
Battery posts, terminals and related accessories conta
lead and leads compounds, chemicals known to th
State of California to cause cancer, birth defects an
other reproductive harm. Wash hands after handling.
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2. Identication
1 - Alternator 2 - Control Box 3 - Engine Turbocharger 4 - Radiator 5 - Fuel Fill
2.1 Generator Identication View
Open Skid Model HYW 45 T6
1
2
3
4
5
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2. Identication
2.2 Data Plate The genset data plate contains the following information:
Manufacturer
Model
Serial Number
Frequency
R.P.M.
Rated Power (KW)Rated Voltage (V)
Phase
Rated Current
Rated Power Factor
Insulation Class
Dimensions
Weight
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3. Installation
3.1 General Information
^ WARNING
Crushing hazard.
Generator set is heavy.
Use properly rated lifting devices to lift generator
set.
Lift only by the generator devices designed
for lifting.
Never enter the area under a raised generator.
Use an adequate lifting device to unload and set the
generator in place. Lift only by the lifting devices on thegenerator designed for lifting.
The generator set must be placed on level site designed to
carry the weight of the generator set.
Electrical wiring to and from the generator set must be
performed by a qualied electrician and conform to all
national and local code requirements.
Fuel supply to the generator set must be installed by a
qualied technician. If a remote fuel tank is used, tank must
be properly located and correct size fuel lines are installed.
Contact the generator engine manufacturer for proper fueltank location and fuel line size specications.
3.2 Control Of MaterialWhen the genset is delivered, check that the received material
matches the order, and to compare it with the delivery note
that is enclosed with the set. Also, check that the material is
not damaged. Proceed to open the packaging.
If any damage detected, contact the shipping company
immediately in order to report the incident to the insurance
company.
Himoinsa species that all deliveries are made at the
customer’s complete risk.
Operations prior to the installation of the automatic
genset.
During the operations prior to the installation of the
automatically-driven gensets, or when connecting the
electrical connections, or in order to avoid unfortunate
startups, etc. the battery/batteries must be disconnected and
the control panel switch must be set to the OFF position.
Safety rules for diesel gensets
The engine room and installation of the set (foundations, air
intake, gas exhaust) must match the “Safety rules” that exist
in the country where the genset will be installed.
Installation
For stationary gensets, two types of installation can be
considered:Outdoor assembly
Indoor assembly
3.3 Outdoor InstallationsThe generator set can be temporarily placed on a rm level
surface. If possible, avoid direct exposure to the sun, rain
and dirty conditions. It is recommended that the area around
generator set be fenced to prevent unauthorized access.
For long-term installations, a concrete foundation designed
by an engineer for the generator set is required. Foundation
must be constructed to prevent generator set noise and
vibration from surround areas and buildings.
Airow is critical for the proper operation of the generator.
Outdoor installation must allow adequate clearance to
maintain the proper ventilation for generator cooling.
Minimum clearance around generator set is 5 ft (1.5m).
^ WARNING
Carbon monoxide hazard.
Engine exhaust pipe(s) must be installed tocarry exhaust gases to an area where they pose
no danger.
Avoid actions or areas that expose you and
others to carbon monoxide.
Engine exhaust pipe(s) must be installed to carry exhaust
gases to an area where they pose no danger.
3.4 Indoor InstallationsFor the correct installation of a genset in closed premises,
the size of the room must allow:• The regular operation of the genset.
• An easy access to its components for maintenance and
possible repairs.
• The possibility of installing the genset using the available
means of transport. The door through which the genset
will be installed must be centered, so that the set remains
centered once it is inside, and there is no need of moving
it.
• The existence of holes that allow oil replacement.
• The installation of the exhaust pipe with the minimum
possible number of pipe elbows.
• The genset to be placed in the middle of the premises,
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3. Installation
with respect to perimeter walls, in order
to facilitate access.
• The layout of the command panel (in case it is an automatic
set) to be in a position that allows the operator to have
complete visibility over the instruments when operating it.
The recommended room dimensions are displayed in the
following pictures:
Sound Attenuated Generator
1. Generating set.
2. Control panel.
3. Air intake gap.
4. Air outlet tunnel.
5. Cable wireway.6. Access door.
7. Reinforced concrete base.
8. Exhaust pipe.
9. Flexible pipe.
10. Exhaust silencer.
* May vary depending on the function of the outlet section of
the model (see plans of the specic model to be installed).
Open Skid Set
1. Generator set.
2. Control panel.
3. Air intake gap.
4. Air outlet tunnel.
5. Tray for cable-running.
6. Access door.
7. Concrete base.
8. Exhaust pipe.
9. Flexible sleeve.
10. Exhaust silencer.
* May vary depending on the function of the outlet section
the model (see plans of the specic model to be installed)
The basic elements to be considered are:
• Foundations
• Exhaust installations• Ventilation
• Fuel installation.
• Electrical connections
• Grounding.
• Heating
3.4.1 FoundationThe foundation must be designed by an engineer experience
in generator foundation design. The foundation must suppo
the weight of the generator set and all uids, and preve
the transmission of vibration and noise to other parts of th
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building.
The surface on which the set will be placed must be levelled
in order to allow its correct operation.
For cleaning reasons, it is recommended that the foundations
are approximately 10cm above the oor level, and covered
with gres industrial sandstone tiles.
3.4.2 Exhaust Installation
^ DANGER
Carbon monoxide hazard.
Generator exhaust gases must be routed to an
outdoor area where they pose no danger.
Exhaust installation must be performed by
a qualied technician, experienced in indoor
generator installation.
Avoid actions or areas that expose you and
others to carbon monoxide.
Exhaust pipe(s) must be routed to an outdoor area where
exhaust gases pose no danger.
Exhaust pipe that passes through walls, must prevent the
transmission of heat to the walls. Exhaust pipe connections
must be sealed tight to prevent exhaust gas leaks and must
end with a protection cap to protect them from water entry, or
with a similar system (1) and (2).
In the part where they run through the walls, it is recommended
2
1
6 0 °
DX2
D
D x 0 . 3
5
4 5 °
R = D
x 2 , 5
to perform a thermal insulation of the pipes, in order to
prevent heat expansion to the walls. (3)
The joints between the different pipes must be perfectly
sealed so that there are no gas leaks. The connection
between ange and gasket is the most critical one. It is also
recommended to place a condensation collector, with drain
valve, on the bottoms point of the pipes.
The connection between the engine’s collector outlet (or the
turbocharger) and the pipe must be made by means of a
exible tube, so that the engine movement and the thermal
expansions of the pipe are absorbed by the engine without
damaging any elements.
The use of exible pipe also requires the placement of
anges in the exhaust pipe, independent of the genset.
Therefore, the pipelines must be xed to the walls or ceiling
of the engine room, with supports that can bear the weight
of the pipe to the engine outlet, so that it does not rest on
the parts of the engine (collector, turbocharger), and allow
its expansion.
When dealing with very long pipes, it is necessary to insert
expansion joints made of sealed exible pipes.
3
D
D
+ 4 m m .
D x 1 . 5
NO NO NO YES
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When establishing the trajectory of the exhaust pipe, it is
necessary that the pipe is not near the engine air lters,
in order to prevent the machine from drawing in hot air.
Otherwise, it will be necessary to insulate it.
Whenever there are several gensets, it is advisable that
all exhausts do not converge on a common pipe, as therecan be problems when some gensets are in operation and
others are not. The produced exhaust gases can penetrate
in the conduits of the sets that are not in operation and may
cause damage.
A. Exhaust pipes measurement for Standard Static Gensets
The engine’s exhaust backpressure has a remarkable
inuence on the produced power and on the thermal
charge.
Excessive backpressure values (measured at the exhaust
collector outlet for non-turbocharged engines, and at theturbine outlet on turbocharged engines) cause reductions in
power, rise in temperature of exhaust gases, fumes, high fuel
consumption, cooling water overheat, lubricant degradation,
and the ensuing consequences on the engine parts.
The limits that must not be exceeded (referred to the delivery
conditions of maximum power at full throttle) in HIMOINSA
genets must be consulted with the factory.
Such limits can be observed considering the dimensions that
are suitable for the exhaust installation, that is, the diameter
of the pipe and type of silencer.
The pipes must be as short as possible, and with as few pipe
elbows as possible. Whenever pipe elbows are necessary,
they must be used with a very wide angle of curvature (from
2.5 to 3 times the diameter of the pipe).
Pipes with bends of angles lower than 2.5 times the diameter
pose difculties so they must be avoided.
In order to calculate the total length of the pipe (which is
crucial for the exhaust’s backpressure), the following
considerations must be taken into account:
The rectied length of the pipe elbows must be determined
according to the chart and pictures:
6.7
300Pipe I.D. (mm)
Pipe Length 5.4
250
4.0
200
2.8
150
2.2
125
1.7
100
1.2
80
0.9
65
0.7
50
0.5
40
010xId
d
05xIC
d
04xIb
r = 2 , 5
x d
d
01xIa
r = 2 , 5
x d
d
The backpressure values due to the exhaust silencers ma
vary within a wide range, depending on the type of buildin
dimensions and noise abatement characteristics:
- If it is the one supplied by HIMOINSA, the length must b
multiplied by a coefcient of safety, so that the total length
be considered due to backpressure will be: L=2 X l.
- If it has been provided by another supplier, it is recommende
to check the value of backpressure derived from the silenc
with the supplier.
Example: The exhaust pipe consists of the following parts
- 5 metres of straight pipe stretches.
- Two pipe elbows type a)
- Three pipe elbows type c)
- A 1m long silencer.
If the inner diameter of the engine exhaust is 80mm, the to
length of the exhaust pipe is calculated as follows:
a) for the inner diameter 80mm, according to the chart,
l=1.2m.
b) total length of the pipe elbows type (a) is, 1l=1X1.2=1.2m. as there are two pipe elbows, 2 x 1.2=2.4m
c) the total length of the pipe elbows type c) is 5 X l=5 x 1.2
6m. as there are three pipe elbows, 3 x 6 = 18m.
d) the total length of the exhaust silencer is L=2X l = 2X1
2m.
e) the total length of the exhaust pipe is: 5+2.4+18+2
27.4metres
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• In order to calculate the diameter of the exhaust pipe it is
possible to use the normogram below:
• For calculation purposes, in this normogram we will use the
following backpressure values:
- 800 mm H2O, for aspirated engines.
- 400 mm H2O, for supercharged engines.
• Exhaust gases airow in kg/h. In order to convert into m3/h,
the data must be divided by the exhaust gases density.
Request these data to the manufacturer.
Example: If we take the exhaust pipe from the previousexample, with a total length of 27.4 metres (taking into
account the rectied length of the pipe elbows and the length
equivalent to the exhaust silencer). From the following data
of the installation:
- 5 pipe elbows at 90º (2x type A and 3x type C).
- Set model: HIW-210
- Working rate: 50 Hz
- Motor: 8361 SRi 26 (supercharged).
- Insulated pipe.
a) Start from the lower part, with a total pipe length of 27.4m
Longitud de la tubería en m
Contrapresión en la tubería en mm H2O(sin silenciador)
200
300
400
500
600
700
800
Diámetro tubo en mm
100 130 160
Aislado
No Aislado
3600
3200
2800
2400
2000
1600
1200
800
400
C a u d a
l d e g a s e s d e e s c a p e m
3 / h
15
10
5
0
15
10
5
0
Números de codos a 90º - r=2,5xd
5 6 7 8 9 1 0
1 5
2 0
2 5
3 0
4 0
5 0
6 0
7 0
8 0
9 0
1 0 0
1 5 0
2 0 0
Números de codos a 90º - r=2,5xd
(straight stretches + rectied elbow length), until crossing
the straight line relative to the total number of pipe elbows in
the installation (5 elbows).
b) Continue and follow a horizontal direction to the right until
crossing again the straight line relative to the number of pipe
elbows (5 elbows).
c) Continue upwards until crossing the straight line relativeto the ow of the exhaust gases, which according to the
chart is 1120 kg/h. To convert kg/h into m3/h divide the ow
expressed in kg/h by the density of the exhaust gases. As a
rst approximation we can take the density of the exhaust
gases with a value of 0.42 kg/ m3 1120x0.42=2667 m 3/h.
d) Continue horizontally to the left. After crossing the straight
line, continue upwards until crossing the straight line relative
to the overpressure of the pipe, 400 mmH2O.
e) Continue upwards until crossing the straight line.
f) Continue to the right until the straight line relative to theinsulated pipe. After crossing this last straight line, the
pipe diameter, 122 mm, is determined on the right top
part. The commercial diameter right above is the one to be
considered.
The exhaust pipe cannot have a lower diameter than the
collector pipe of the engine exhaust, and also, the straight
stretches must have a slight inclination in order to prevent
the return of condensates, as shown on the location plan of
the genset in the room.
When the diameter of the pipe is higher, the engine joint
must have a conic connection element with a conicity below30º in order to avoid excessive load losses.
B. Exhaust pipes measuring for Sound Attenuated Static
Gensets.
Check with the HIMOINSA engineering department. There is
backpressure in the outlet of the genset which is caused by
the internal pipes. It is necessary to know this value so as not
to exceed the recommended backpressure when designing
the rest of the installation.
• Exhaust silencer
The exhaust silencer is usually attached to the stretch of pipe
that remains inside the room where the genset is located.
Whenever possible, it can be separated from the genset.
The silencer used in industrial applications performs a 15 to
20 decibels noise reduction.
In order to reduce the noise, the position of the silencer can
be altered, by reducing the length of the tube that goes into
the engine. For example, for a 10m long pipe, the optimal
position would be half-way through the distance in relation
to the outlet. In the cases of private installations, such as
hospitals or residential areas, where a higher noise reduction
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is required, special silencers can be used, with a reduction
of 25 to 30 decibels, and whenever possible, using special
quiet chambers.
3.4.3 Ventilation Adequate ventilation is essential for proper operation and
durability of the generator set.
The generator set room must:
1. Allow the dissipation of the heat produced when the genset
is in operation by irradiation and convection.
2. Provide sufcient air ow for combustion and engine
cooling.
3. Allow the engine cooling by means of the radiator, keeping
the operating room temperature within the safety limits in
order to guarantee a good aspiration of the supply air.
A good ventilation solution applicable to most cases is theone indicated in the charts of the sections of the installation,
in which the engine fan draws in the cooling air from the
engine room, whereas the hot air is expelled through the
expulsion tunnel placed between the radiator and the room
window.
The expulsion window must be bigger or same size as the
radiator in case of standard static gensets, and bigger or
same as the expulsion grid in case of sound attenuated
sets.
Prevent the radiator exhaust hot air from coming back to the
engine room, making sure the expulsion conducts are leak-proof. Therefore, the air in the engine room is constantly
renovated, and the dimensions of intake grilles must be big
enough for the cooling and combustion.
In order to achieve a correct air ow, the cool air must be
introduced through the grilles that are located on the lower
part of the engine room wall. This wall should be the one
located opposite the radiator, so that the air ows all over the
set before being expelled through the fan.
Make sure there are no areas in the engine room where the
air is deposited. This usually happens in rooms with several
engines. In those cases, and whenever possible, each groupshould have its own air intake grille.
In case you need more details about the air ow required for
the different types of HIMOINSA gensets, please contact to
the manufacturer.
For safety reasons, in those premises where there are
sets in continuous operation, or in those areas where the
room temperature is high, it is advisable to use an auxiliary
extractor fan that has enough power to achieve a suitable
ventilation. Such extractor fan must be located on top of the
room, as close to the radiator as possible.
3.4.4 Remote Fuel TankThe generator set is supplied with an integrated fuel tank.
In some situations, a remote fuel tank may be required. Th
remote fuel tank must be properly connected to the engin
so the fuel transfer pump can draw fuel properly.
The remote tank must be located no more than 65.5 ft (2
m) from the engine and no more than 16.5 ft (5 m) below th
engine.
Generator sets supplied by HIMOINSA include a comple
fuel installation, since the fuel tank is located on the bedpla
of the genset.
The fuel tank is connected through exible tubes in ord
to guarantee their operating durability, depending on thmodel.
For longer run times, and in order to satisfy special demand
it may necessary to use a special tank that is tted separate
It will be necessary to connect the engine to the new tan
and install exible connections and new suitable pipes th
must be rmly connected. The new fuel tank must be locate
according to the following criteria, so that the engine injectio
pump is able to draw in fuel from the new tank:
• Closer than 20m from the engine, in case they are both
the same level.
• Less than 5m deep.
The usual connections are:
• For fuel injections to the engine injection pump.
• For fuel excess returns from the injection pump.
• For drain return of the injectors.
The pipes must not have any welds. They can be madof steel, iron or cast iron. Galvanized steel pipelines mu
not be used. Flexible connections must be tted in order
isolate the static parts of the plant from the new fuel tank,
order to avoid the possible vibrations caused by the engin
Depending on the type of engine, these can be made usinthe following:
Stretches with a suitable length made of reinforced rubb
pipes with exible insertions that are resistant to gas oil. F
the connections with the terminal rubber holders with edge
and screw clamps.
Flexible low-pressure type tubes, suitable for gas o
protected with metal mesh and with screwed terminals f
tightly-sealing. Synthetic resins must be avoided.
In complementary areas of the plant, maximum attentio
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must be paid to the following issues:
- Fix pipes by means of holders, at regular intervals in a
way that vibrations and inexions caused by pipes weight
are avoided, especially those made of copper tube.
- Couplings must be avoided. In case of using them they
must be tightly-sealed, especially in depression conditions
parts (fuel aspiration intake), in order to avoid air ltrationsthat make the startup more difcult.
- Aspiration pipes below the fuel level must be placed at
a distance of 20-30mm from the bottom, in order to avoid
a possible deactivation of the circuit due to insufcient air.
Also, these must be conveniently separated from each other,
in a way that the fuel return ow does not block the supply
due to the gas oil impurities from the bottom of the tank or
mixed air.
- Thorough cleaning of the used pipes.
- Avoid abrupt variations in the tube section and the use ofelbows with a wide angles in pipes.
3.4.5 HeatingIn cold climates, automatic starting generator sets may need
an engine room heater to keep the engine room above 50° F
(10° C) to ensure the generator starts when needed.
Electric heaters with thermostatic controls ranging from 500
to 1500W, depending on the genset, have also been supplied
with those sets. They maintain the water temperature within
acceptable values in case a sudden start or power input may
damage the engine.
3.4.6 Electrical Connections
^ WARNING
Electrical shock hazard.
Electrical connections must be performed by
a qualied electrician and conform to local
electrical codes.
Refer to the following electrical schematics for your generator
for the proper electrical connection. The generator frame
must be grounded.
The gensets are ready for user connections. When making
the connections, you must comply with the conditions
specied in the diagrams enclosed with the genset.
Manual Genset
The user cables must be connected to the line terminals
which, for standard static gensets, are located inside the
electrical panel, on the rail terminals or at the bottom of the
magnetothermal switch, either inside the panel or in the
moldeada box (check the electrical diagrams included in
the manual of the panel). For sound attenuated sets, the
connection to the grounding terminals is easily accessible
and protected with a methacrylate sheet.
Automatic GensetThe cables that come from the genset, the external power
supply and user shall be connected to their respective
terminals, located in the command panel. The power cables
of the genset shall be connected directly to alternator
terminals of the genset.
The connection to auxiliary services between the set and
the command panel shall be made with a multiple cable and
using the multiple connectors plugs provided with the set.
Cable dimensions
The choice and dimensions of the cables is responsibility of
the person who carries out the installation.
Cable positioning
Power cables, for both manual and automatic sets, must be
placed in suitable channelling, tunnels or protective conduct-
holder. Do not include 400V and 12V (or 24V) cables in the
same channelling.
Grounding
Metal parts of installations which are exposed to human
contact, and due to an insulation aw or other reasons,
may get in contact with voltage, must be connected to land-
dispersion device.
The gensets and panels have been equipped with their
respective grounding terminals. The connection of these
to the land-dispersion must be made with bare copper
wires conductors with a minimum section of 16mm2, or
if not available, galvanized iron with a 50 mm2 section.
The resistance of such conductor, including the contact
resistance, must not exceed 0.15 Ohm.
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3.3.7 Three Phase Generator Sets
3. Installation
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3.3.8 Single Phase Generator Sets
3. Installation
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4. Prestart Checks
4.1 Prestart ChecksBefore starting the generator set engine, perform the
following prestart checks:
Verify all guards and covers are in place and fasten tight.
Check entire machine for loose hardware. Tighten all loose
hardware.
Fill fuel tank with fuel.
Check engine coolant hoses for damage and loose clamps.
Check level of engine oil on dipstick (1). Oil must be between
the min and max levels on dipstick. Add the recommended
oil if necessary.
Check coolant level in radiator (2). Add coolant to proper
level if low.
Check the engine and alternator for any signs of damage,
water, oil or fuel leaks.
Verify intake and outlet air vents and grills are not obstructedor blocked.
Verify that there are no obstructions in engine intake air lter
tube.
Check fuel lter/water separator (3) (if equipped) for water or
contaminants. Drain if necessary.
Verify battery cables are properly connected and tight.
Once engine is started, warm engine with a reduced load
before applying full load. This does not apply to emergency
power generators.
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5. CEM7 Control Panel
5.1 IntroductionThe CEM7 digital control panel is a monitoring system for
the genset electrical signal and also manages the genset
engine.
The control panel consists of 2 different modules:
5.1.1 Display Module (Control Panel)The display module provides information about the status of
the device and, at the same time, allows the user to interact
with it. The user is able to control, program and congure the
functions of the unit. This module allows checking of the last
10 failures registered in the control unit (fault history).
5.1.2 Measurements ModuleThe measurements module controls and monitors the control
board. Every signal, sensor and actuator is connected to this
module.
NOTE: An optional programming timer module can be addedto the display module, which would allow it to carry out start-
up, locking, and programmed maintenance functions.
The control panel provides the following readings of the
electric mains supply:
• Phase to neutral voltage.
• Phase to phase voltage.
• Phase amperage.
• Frequency.
• Real, apparent and reactive powers.
• Power factor and cos phi.
• Instant power (Kwh) and historical power (day, month,year) of the genset (with option programming timer).
The control panel provides the following engine information:
•Engine alarm inputs:
- Fuel reserve.
- Oil pressure.
- Coolant temperature.
- Coolant level.
- Emergency stop (stop button).
• Analogic engine inputs:
- Fuel level. - Pressure.
- Temperature.
- Congurable input (i.e. Oil temperature).
- Battery charger alternator voltage
• Congurable inputs:
The measurements device has 5 inputs that can be
programmed to carry on the following functions:
Default conguration applied in the factory:
- Start disabling.
- External start.
Consult conguration with your distributor or authorized
technical service:
- Mains contactor conrmation - Genset contactor conrmation.
- Rate change notice.
- Rate change.
- Start disabling.
- External start.
- Test.
- Manual override.
- 5 programmable alarms.
- Self-programming (S1-S2)
• Engine statistics:
- Number of working hours.
- Number of starts.
• Functions of the engine:
- Pre-heating or glow plug.
- Stop.
- Start.
- Coolant heater.
- Fuel Transfer pump.
- Alternator excitation.
The measurements module has outputs which allow
monitoring of the operative conditions of the generating set:
• Engine running (on).
• General alarm.
• 3 programmable outputs which monitor the control board
alarm conditions or the inputs about the engine data.
The measurements module commands ouputs to relays
for the activation of the genset contactor and the electronic
overload and short-circuit protection that trip the genset´s
general circuit breaker.
The connection between the measurements and visualization
modules is made by the CAN bus communication, which
allows the interconnection of additional modules, allowingthe expansion of the CEM7 device.
With the bus CAN, additional modules can be added. If
interested, please contact your distributor.
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5.2 Control PanelThe control panel has a backlit display and different LED’s to control the device status. Different push buttons allow the
user to command and program the control panel.
1
2 3 4 5 6
7
8 9 10
NOTE: The display turns off the backlighting (low consumption mode) after 10 minutes without any detectable pulse on th
keyboard.
1 - Backlit Display
2 - Start Button
3 - Stop Button
4 - Reset Button
5 - Diesel Transfer Button
6 - Auto Button
7 - Display Buttons
8 - Contactor Status LEDs
9 - Engine Status LEDs
10 - Engine Alarm LEDs
5. CEM7 Control Panel
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5.3 Control Panel Push Buttons
5.3.1 Operating Mode Buttons Automatic mode.
The CEM7 device monitors the status of the generating set and controls its working process and the
programmable inputs.
LED On: Automatic mode running.
LED Flashing: Automatic mode blocked.
LED Off: Manual mode running.
5.3.2 Command Buttons Start engine push button (manual mode only).
Control Starts with only one push down.
LED on: Engine running.
Stop engine push button (manual mode only).
Press once, a cooling phase begins and then the engine stops.
Press twice, the engine stops immediately.
LED on: The engine is in stopping phase (with or without cooling down).
Reset push button.
Allows the user to acknowledge and clear the alarm condition.
LED ashing: There are alarms to check up.
LED on: Active alarms.
Transfer fuel pump push buttons.
In manual mode, this button activates the transfer pump if the fuel level is under the programmed levels.
LED on: Fuel transfer pumps working.
5.3.3 Display Buttons
Conrmation button (V). Allows access to menu and validates and store the entered data.
Cancellation button (X). Go back in the menu and cancels the entered data.
Up button (+). Moves along the selection displays and maintenance menus, also
increases the programmed values.
Down button (-). Moves back in the selection display and maintenance menus, it also
reduces the programmed values.
5. CEM7 Control Panel
DIESEL
TRANSF
RESET
START
STOP
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5. CEM7 Control Panel
5.4 Data LED’s
5.4.1 Contactor Status LEDs
Mains contactor status.
On: Contactor activated.
Flashing: Alarm, conrming the contactor is activated. Off: Contactor deactivated.
Generating set contactor status.
5.4.2 Engine Status LEDs Engine started
On: Engine running detected.
Off: Engine stopped.
Engine starting
On: Engine starting activated.
Off: Engine starting not activated.
Pre-heatingOn: Pre-heating function activated.
Off: Pre-heating function not activated.
Battery charger and alternator status
On: The voltage supplied by the battery charger alternator is detected when the engine is running.
Off: Engine stopped or started without voltage signals in the battery charger alternator.
5.4.3 Alarm LEDs Fuel level
Battery levels
High temperature
Overspeed
Low oil pressure
Starting failure
Aux1 (Free to program)
Aux2 (Free to program)
On: Alarm caused by analogic sensors.
Flashing: Alarm caused by digital inputs.
Off: No alarms. NOTE: See alarms section for more details.
M
G
M
G
-B
W
+D +B
M
Aux. 1
Aux. 2
M
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5.5 Starting And Stopping Genset
Perform pre-start checks. See Section 4 in this manual.
NOTICE
Avoid electrical system damage.
Turn genset main circuit breaker off before
starting generator engine.
5.5.1 Starting - Manual Mode Push START button to activate the engine
starting process. The start button LED
will be illuminated. If the engine is
equipped with a starting aid, the appropriate
LED will be illuminated and there may be a delay before the
engine starts.
If the engine fails to start at the rst crank, the control panel
will wait for 5 seconds before attempting another start cycle.
It is not necessary to press start button again. The generator
will attempt to start 4 times. If the engine is still not running,
the control panel will trigger the start failure alarm.
To stop the start cycle, press the stop button.
Readings about the engine condition are shown on the
display panel and the start sequence details can be seen.
The sequence is as follows:
– Genset: Stop
– Genset: Starting
– Genset: Started
– Genset: Stabilized
– Genset: Loading
The starting process in an automatic system by means
of timer, ATS signal, etc. and works in the same way as a
starting cycle in manual mode.
5.5.2 Stopping - Manual Mode
NOTICE
Avoid electrical system damage.
Turn genset main circuit breaker off before
stopping generator engine.
The generator engine can be stopped
using one of two methods. Pressing the
stop button once will stop the engine
after a 20 second cool down cycle. This is
START
STOP
the recommended procedure. Pressing the stop button twice
will stop the engine immediately. This is not recommended.
Use this procedure only in an emergency situation.
Push the STOP button once to stop the engine after a 20
second cool down cycle.
Push the STOP button twice to stop the engine immediately,
without cooling down cycle.
5.5.3 Starting And Stopping - Automatic
Mode In automatic mode, the control panel
constantly controls the Gen-set operation.
In some situations, the gen-set can be
programmed to supply power, the controller
starts the generator set activating the gen-set contactor.
Programmable operational modes to start the Gen-Set:
• External start.
• Start controlled by timer.
• Forced start.
• Rate change notice.
• Engine test.
• Controlled by the transfer switch control board
The gen-set will stop after a 20 second cooling down cycle
after the deactivation of the command which automatically
started the genset.
5.6 Interruption Of Function Mode When the control panel is in manual mode,
the automatic mode can be initiated bypressing the AUTO button for 5 seconds.
This blocking function does not allow the
change of modes and the button of the mode running at that
moment will ash. To deactivate the automatic interruption
mode and allow the change of operational modes, press the
AUTO button for 5 seconds.
5.7 Working ModeThe generator engine works in the following way, once the
control panel detects an activation condition:
1. Delay in the starting: Once an activation conditionis detected, and before going on with the engine
starting process, a delay in the engine starting can be
programmed.
2. Engine pre-heating phase: The control board activates
the pre-heating output for a programmed time.
3. Engine Start Enabling (run signal): The engine run
signal is made by means of the PC (B+) output from the
measurements module. The output allows a no-excitation
stop (energized to-run) or an excitation stop (energized
5. CEM7 Control Panel
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to-stop). This output is congurable.
4. Engine starting: For a programmed period of time, the
starting output of the measurements module is activated,
waiting to detect, at least, one of the programmed starting
conditions. The possible engine starting conditions could
be:
• Generator voltage: The engine would be considered
started (running) when its voltage exceeds a given value.
• Alternator voltage: The engine would be considered
started (running) when the battery charger alternator
voltage exceeds a given value.
• Pick up frequency: The engine would be considered
started (running) when the pick up frequency exceeds a
given value. To activate the pick up calculation through the
engine ring gear, the number of teeth of the gear must be
introduced. In case the number of teeth is “0”, the frequency
of the pick up will be calculated through the generatorfrequency as per the equivalence-ratio 50Hz/1500 rpm or
50Hz/3000 rpm and 60 Hz/1800 rpm.
• Low oil pressure: It is not advisable to use the low oil
pressure signal as a way to detect if the engine is working,
but it is useful as a protection, in order to avoid engaging
the starter while the engine is running.
If in the programmed time the starting of the engine is not
detected, the control board waits for a short time before
attempting a new start. The start failure alarm will be raised
after a specied number of attempts without detecting any
starting condition.
In the starting cycle, the excitation of the battery charger
alternator is activated temporarily through the D+ output. Once
the excitation of the alternator is nished, the measurements
module checks if the battery charge alternator is working
properly. The battery charge alternator failure alarm is raised
in case of an output failure.
• Genset stabilization: Once any of the starting conditions
is detected, the controller waits for a programmed
stabilization-time of the generator output, before monitoring
output parameters.
• Nominal condition: Once the stabilization of the engine
is reached, the next step is the checking of the signal
produced by the generator. In this way, the quality of the
signal produced by the generator set is monitored (voltage
levels, frequency).
5.8 Transfer Fuel PumpThe fuel transfer pump function can be activated in the
control panel by linking its working service to the BT relay in
the measurements module.
Once the transfer pump option is activate
its operation modes are as follows:
Inhibited mode: The transfer pump is blocked fro
operation.
Manual mode: The transfer pump is operated by pressingthe diesel transfer button, provided that the fuel level is und
the maximum threshold parameters.
Automatic mode: The transfer pump becomes operative
• According to the minimum activation parameters, und
which the relay BT is activated.
• According to the maximum deactivation parameters, ov
which the relay BT is deactivated.
Control board mode: The transfer pump operation is carrie
out as follows:
• When the controller is in automatic or test-mode, th
transfer pump is operated automatically.
• When the controller is manual-mode, the transfer pum
operation is carried out in manual mode.
• When the controller is in a blocked-mode, the transf
pump operation is inhibited (CEM7+CEC7).
5.9 AlarmsThe CEM7 distinguishes between anomalies which caus
the stop of the engine (alarms) and errors, which do not sto
the engine (warnings).
When an alarm or warning is detected, the controller produc
an acoustic alarm, at the same time the digital alarm outp
(AL) activates and the LED of the reset button ashes; th
status will remain the same as long as the failure conditio
continues for a programmable period of time.
The LED of the reset button lights when alarms or warning
are active or in need of acknowledgement. Pressing res
button once allows the user to see a record of alarms an
warnings that are active and needing to be acknowledge
The up and down buttons of the display are used to go ba
and forward in the failure record. A second press of res
silences the alarm.
The record of warnings that are active or
need of acknowledgement has the
following format:
*A L A R M* E N 1 / 3
M I N F R E Q U E N C Y G E N S E T
E: Alarm or A: Warning
N: To be checked
DIESEL
TRANSF
RESET
5. CEM7 Control Panel
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1: Number of position in the total record of errors
3: Number of errors in the record
The LEDs on the control panel indicate alarms detected by
the sensors.
The alarms which cause the engine to stop are not auto-
resetting. They must be acknowledged and re-set by theuser in order for the engine to start again, but only if the
alarm does not remain active.
The warning alarms do not stop the engine. They need to be
reset to erase them from the display, but only if the warning
does not remain active. The fuel level alarm is an exception,
as it is automatically reset.
5.9.1 Reseting AlarmsEN - Alarm with engine stop.
AN - Warning that needs to be reset, engine does not stop.
A - Warning that automatically resets.
EN Alarm with engine stop.
When an alarm is detected, the controller produces an
acoustic signal, the LED of the RESET button ashes, the
display blinks and the appropriate digital alarm output (AL)
is activated. In this case the engine stops.
The acoustic alarm is silenced by pressing the reset button
once. The reset LED turns into xed light and the display
(which stops ashing) shows the kind of alarm.
Determine the cause of the alarm. Once the alarm is no
longer active “N”, press reset button and the engine can berestarted.
AN Warning.
When an alarm is detected, the controller produces an
acoustic signal, the LED of the reset button ashes, the
display blinks and the appropriate digital alarm output (AL)
is activated.
The acoustic alarm is silenced by pressing once the RESET
button. Once the RESET LED turns into xed light and
the display (which stops ashing) shows the kind of Active
warning “AN”.
Determine the cause of the alarm. Once the alarm is no
longer active “N”, press reset button to reset alarm.
A Warning.
When an alarm is detected, the controller produces an
acoustic signal, the LED of the reset button ashes, the
display blinks and the appropriate digital alarm output (AL)
is activated.
The acoustic alarm is silenced by pressing the RESET
button once. The RESET LED turns into xed light and the
display (which stops ashing) shows the kind of warning.
Warning “A”.
This kind of warning is automatically reset as long as nominal
working conditions are restored. It is focused on the type of
alarms related to fuel level and the alarms related with the
mains threshold.
5. CEM7 Control Panel
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DESCRIPTIONLED ON CONTROL
PANELTYPE
High water temperature (ATA) (HCT)
Immediate engine stop with no cooling.LED ashes Alarm
Low oil pressure (BPA) (LOP)Immediate engine stop with no cooling.
LED ashes Alarm
Emergency stop (PEM) (EMS)
Immediate engine stop with no cooling. Alarm
Battery charge alternator failure (engine running)
Engine does not stop.LED off Warning
Start failure LED ashes
Low coolant level (CL)
Immediate engine stop with no cooling.LED ashes Alarm
Fuel level
Engine does not stop. LED ashes Warning
Overspeed
Immediate engine stop with no cooling.LED on Alarm
Loss of speed
Engine stops with cooling. Alarm
Low battery voltage
Engine does not stop.Warning
High water temperature by sensor
Engine does not stop.LED on Warning
Low oil pressure by sensor
Engine does not stop.LED on Warning
Low fuel level by sensor Engine does not stop.
LED on Warning
Unexpected shutdown
Stop failure
Low engine temperature
Engine does not stop.Warning
Genset voltage drops
Engine stops with cooling. Alarm
M
G
-BW
+D +B
5.10 Engine Alarms
5. CEM7 Control Panel
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DESCRIPTION TYPE
Overload.
Engine stop with cooling. Alarm
Genset voltage asymmetry.
Engine stop with cooling. Alarm
Maximum voltage of the genset.
Immediate engine stop with no cooling. Alarm
Maximum genset frequency.
Immediate engine stop with no cooling. Alarm
Erroneous phase sequence of the genset.
Immediate engine stop with no cooling. Alarm
Inverse power
Immediate engine stop with no cooling. Alarm
Short circuit.
Immediate engine stop with no cooling. Alarm
Minimum genset voltage.Immediate engine stop with no cooling.
Alarm
Minimum genset frequency.
Immediate engine stop with no cooling. Alarm
5.12 Programmable Alarms And Inputs
DESCRIPTION TYPE
Related with programmable inputs.
According to conguration. Alarm
5.11 Genset Alarms
5. CEM7 Control Panel
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5. CEM7 Control Panel
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6.1 Control Panel - M6
1 2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6. M6 Control Panel
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1. On/Off Switch: Used to connect and disconnect the
controller.
2. Mode Selection Key: (MAN/STOP/AUTO). In “MAN”
position, the control panel will initiate a start engine
sequence (1 attempt to start ). In “STOP” position, the
controller will stop the genset. In “AUT” position, controller
will remain in automatic mode and will do as follows: if freevoltage contact closes, the controller will start the genset.
If the contact opens, the genset will stop.
3. Emergency Stop: Press to stop engine immediately. The
LED will be illuminated until the emergency stop button
has been reset.
4. Overspeed Indicator (Red). The LED will illuminate if
one of the following conditions occur: During the over
speed programming, to indicate that the programming
was successful, and also when the internal overspeed
protection device trips. When the overspeed protection
device trips, the controller initiates a stop cycle and thewarning indicator will be illuminated until reset.
5. Low Oil Pressure Indicator (red). Indicates that the
engine oil pressure switch has detected an anomaly. This
protection activates an engine stop cycle. The LED will
remain illuminated until the alarm condition is reset.
6. High Water Temperature Indicator (red). Indicates that
the engine coolant temperature sensor has detected an
anomaly. This signal activates an engine stop cycle. The
LED will remain illuminated until the alarm condition is
reset.
7. Engine Failure Indicator (red). Indicates that the engine
has stopped without a stop signal from the controller.
8. Fail To Start Indicator (red). Indicates that the controller
completed 5 attempts to start the engine, but the engine
did not start.
9. Power Supply On Indicator (green). Indicates that the
controller is on when illuminated.
10. Reset Button. Push to restart the operation cycle of the
controller.
11. Engine Running Indicator (green). Indicates that the
engine is running when illuminated.
12. Activated “LT” Contactor (green). This LED is illuminated
when the free-voltage contact is closed. The LED goes
out when the contact is opened.
13. Cooling Stop Indicator (yellow). This led starts blinking
in 1 second intervals when the controller initiates a stop
engine cycle. The LED will stop blinking when the engine
has stopped.
14. Pre-Heating Indicator (yellow). The LED starts blinking
1 second intervals during the engine pre-heating cycle
15. Auxiliary Alarm Indicator (yellow). Indicates that th
alarm condition established in the auxiliary input
the controller has been detected. The LED will rema
illuminated while the alarm condition is active.
16. Battery Charger Failure Indicator (D+) (yellow). Indicat
that the generator battery charger is not charging th
battery. The LED will remain illuminated while the alar
condition is active.
17. Fuel Reserve Indicator (yellow). Indicates low fuel lev
in the tank. The LED will remain illuminated while th
alarm condition is active.
6.2 Starting And Stopping Genset - M
Control Panel
6.2.1 Starting - Manual ModeMove on/off switch to the on position (1). The controller will ru
an internal diagnosis and lamp checking program, lighting
LEDs on the control panel. The controller remains on hol
as long as the mode operation key is in the stop position.
Move mode section key (2) to the man position. The controll
initiates an immediate start of the engine. After a programme
warm up cycle, the genset contactors automatically close.
1
2
6. M6 Control Panel
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6.2.2 Stopping - Manual ModeMove mode selection key (2) to the stop position. The
controller initiates the stop of the genset and holds for a
mode change. Move on/off switch to the off position (1)
Note: Under no circumstances can the generator be stopped
by switching the controller off or by pushing the reset button.
The only way to stop the engine is by turning the key to thestop position.
6.2.3 Starting And Stopping - Automatic
ModeMove on/off switch to the on position (1). The controller will run
an internal diagnosis and lamp checking program, lighting all
LEDs on the control panel. The controller remains on hold,
as long as the mode operation key is in the stop position.
Move mode section key (2) to the auto position. In this mode,the engine start is co-ordinated with the closing of the free-
voltage contact. When this contact is closed, the controller
initiates up to 5 attempts to start in sequence as long as there
is no engine running detection. Every attempt is 5 seconds
long and the time in between attempts is 10 seconds.
When the free-voltage contacts opens, the controller initiates
to stop, and holds before the contact closes again or waiting
for a change of operation mode.
1
2
1
2
NOTE: If the controller disconnects, resets, or fails power
supply, once it is restored, if set to manual or automatic mode
with the free-voltage contact closed, the genset will start.
6. M6 Control Panel
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DESCRIPTIONLED ON CONTROL
PANELTYPE
High water temperature
Engine stops.LED ashes Alarm
Low oil pressureEngine stops
LED on Alarm
Emergency stop
Engine stops. Alarm
Battery charge alternator failure (engine running)
Engine does not stop.LED on Warning
Start failure LED ashes
Fuel level
Engine does not stop.LED ashes Warning
Overspeed
Immediate engine stop with no cooling.LED on Alarm
Unexpected shutdown LED ashes
High coolant temperature
Engine stops.LED ashes Warning
6.3 Engine Alarms
6. M6 Control Panel
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7. DSE3000 Series Control Panel
7.1 Description Of Controls
The following section details the function and meaning of the
various controls on the module.
1 - Navigation Buttons 2 - Main Status Display
3 - Common Alarm Indicator 4 - Start engine.
5 - Select Auto Mode 6 - Select Stop Mode
7.2 Quickstart GuideThis section provides a quick start guide to the module’s
operation.
7.1.1 Starting The Engine1. First press Stop/Reset (1).
2. Then, press the Start button to crank the engine. Depending
upon module conguration, two presses may be required.
7.1.2 Stopping The Engine1. Select Stop/Reset mode (1). The generator is stopped.
7.3 Graphical Display A 32x132 pixel LCD (35mm / 1.4”) is available for the display
of generator instrumentation and alarm conditions. The
display is segmented into areas for instrumentation, unit,
alarm icons and for Front Panel Editor (FPE) use.
When not in the Front Panel Editor (FPE) mode the FPE
area of the display is used to display the currently active
conguration. The letter ‘M’ is displayed for main conguration
active, the letter ‘A’ for alternative conguration active.
VIEWING THE INSTRUMENTSIt is possible to scroll to display the different pages of
information by repeatedly operating the scroll button.
Once selected the page will remain on the LCD display until
the user selects a different page or after an extended period
of inactivity, the module will revert to the status display.
When scrolling manually, the display will automatically return
to the Status page if no buttons are pressed for the duration
of the congurable LCD Page Timer.
If an alarm becomes active while viewing the status page,
the display shows the Alarms page to draw the operator’sattention to the alarm condition.
Page order:
Engine Speed
Generator Volts
Generator Frequency
Engine Run Time
Battery Volts
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7.4 ControlsStop / Reset
This button places the module into its Stop/Reset mode.
This will clear any alarm conditions for which the triggering
criteria have been removed. If the engine is running and
the module is in Stop mode, the module will automatically
instruct the changeover device to unload the generator
(‘Close Generator’ becomes inactive (if used)). The fuelsupply de-energizes and the engine comes to a standstill.
Should a remote start signal be present while operating in
this mode, a remote start will not occur.
Auto
This button places the module into its
‘Automatic’ mode. This mode allows the
module to control the function of the generator
automatically. The module will monitor the
remote start input and once a start request
is made, the set will be automatically started
and laced on load. Upon removal of the starting signal,
the module will automatically transfer the load from thegenerator and shut the set down observing the stop delay
timer and cooling timer as necessary. The module will then
await the next start event.
Start
Pressing this button in auto mode will start the
engine and run off load. Pressing this button
in STOP/RESET mode will turn on the CAN
engine ECU (when correctly congured and
tted to a compatible engine ECU)
PagePressing this button scrolls the display to show
the various instruments.
7.5 Automatic Mode Of Operation
NOTE:- If a digital input congured to panel lock is active,
changing module modes will not be possible. Viewing the
instruments and event logs is NOT affected by panel lock.
Activate auto mode by pressing the AUTOpushbutton. The line/arrow icon around AUTO
is displayed to indicate Auto Mode operation if
no alarms are present.
Auto mode will allow the generator to operate fully
automatically, starting and stopping as required with no user
interv