General and safety manual

GGeenneerraattiinngg sseett

GGEENNEERRAALL –– SSAAFFEETTYY –– IINNSSTTAALLLLAATTIIOONN

All brands

C_3_EN

15/07/2012 33522926801_2_1

RAMIRENT

RAMIRENT

1

CONTENTS

1. Preface .................................................................................................................................................................................................. 5

1.1. Introduction .............................................................................................................................................................................. 5

1.2. Description of the documentation for generating sets .............................................................................................................. 5

1.3. Warnings .................................................................................................................................................................................. 6

2. General recommendations..................................................................................................................................................................... 6

2.1. Safety ....................................................................................................................................................................................... 7 2.1.1 Pictograms and their meanings ................................................................................................................................................ 7 2.1.2 Safety instructions .................................................................................................................................................................... 9

2.1.2.1. General guidelines ...................................................................................................................................................... 9 2.1.2.2. Electrical safety precautions ..................................................................................................................................... 12 2.1.2.3. Safety precautions in case of electrical shock .......................................................................................................... 12 2.1.2.4. Safety precautions relating to fire, burns and explosions .......................................................................................... 13 2.1.2.5. Toxic risk safety precautions ..................................................................................................................................... 14 2.1.2.6. Precautions for risks relating to handling phases ...................................................................................................... 16 2.1.2.7. Precautions for risks relating to noise ....................................................................................................................... 16

2.2. Fuels, lubricants and coolants ................................................................................................................................................ 16 2.2.1 Specifications ......................................................................................................................................................................... 17

2.2.1.1. Fuel specifications .................................................................................................................................................... 17 2.2.1.2. Lubricant specifications ............................................................................................................................................. 19 2.2.1.3. Coolant specifications ............................................................................................................................................... 20

2.3. Protecting the environment .................................................................................................................................................... 21

3. General description of the equipment .................................................................................................................................................. 21

3.1. Fixed generating set .............................................................................................................................................................. 22 3.1.1 Generating set without protective cover ................................................................................................................................. 22 3.1.2 Generating set with protective cover ...................................................................................................................................... 23

3.2. Mobile generating set ............................................................................................................................................................. 24 3.2.1 Generating set without trailer .................................................................................................................................................. 24 3.2.2 Trailer-mounted generating set............................................................................................................................................... 25 3.2.3 Lighting column ...................................................................................................................................................................... 25

3.3. Containerised generating set ................................................................................................................................................. 26 3.3.1 ISO 20 and ISO 40 containers ................................................................................................................................................ 26 3.3.2 CIR 20 containers ................................................................................................................................................................... 27 3.3.3 EUR 40 container ................................................................................................................................................................... 28 3.3.4 Trailer-mounted container ...................................................................................................................................................... 28

3.4. Identification plates ................................................................................................................................................................ 29 3.4.1 Identifying sets ........................................................................................................................................................................ 29 3.4.2 Location of plates on generating sets with and without an enclosure ..................................................................................... 30 3.4.3 Location of plates on containerised generating sets ............................................................................................................... 30 3.4.4 Identifying generating set components ................................................................................................................................... 31

4. Installation............................................................................................................................................................................................ 32

4.1. Unloading the equipment ....................................................................................................................................................... 32

4.2. Handling the equipment ......................................................................................................................................................... 32 4.2.1 Warnings concerning handling ............................................................................................................................................... 32 4.2.2 Moving the equipment using slings ......................................................................................................................................... 33

4.2.2.1. Fitting slings to generating sets without an enclosure ............................................................................................... 33 4.2.2.2. Fitting slings to generating sets with an enclosure .................................................................................................... 33 4.2.2.3. Fitting slings to containerised generating sets .......................................................................................................... 34

4.2.3 Moving the equipment using a forklift truck ............................................................................................................................ 36 4.2.3.1. Handling generating sets with and without an enclosure .......................................................................................... 36 4.2.3.2. Handling containerised generating sets .................................................................................................................... 37

4.2.4 Moving the equipment using a mobile winch .......................................................................................................................... 37 4.2.5 Moving the equipment using rollers ........................................................................................................................................ 38

RAMIRENT

2

4.3. Transporting the equipment ................................................................................................................................................... 39 4.3.1 Warnings concerning transport ............................................................................................................................................... 39 4.3.2 Preparing for transport ............................................................................................................................................................ 39 4.3.3 Road transport ........................................................................................................................................................................ 39

4.3.3.1. Generating sets with and without an enclosure ........................................................................................................ 39 4.3.3.2. Containerised generating sets .................................................................................................................................. 39 4.3.3.3. Generating sets on trailers ........................................................................................................................................ 40

4.3.4 Rail transport .......................................................................................................................................................................... 46 4.3.4.1. Generating sets with and without an enclosure ........................................................................................................ 46 4.3.4.2. Containerised generating sets .................................................................................................................................. 46

4.3.5 Shipping ................................................................................................................................................................................. 46 4.3.5.1. Generating sets with and without an enclosure ........................................................................................................ 46 4.3.5.2. Containerised generating sets .................................................................................................................................. 46

4.3.6 Air transport ............................................................................................................................................................................ 47 4.4. Installing a generating set indoors ......................................................................................................................................... 48

4.4.1 Introduction ............................................................................................................................................................................. 48 4.4.2 Determining the installation location ....................................................................................................................................... 49 4.4.3 Selecting the type of premises................................................................................................................................................ 50 4.4.4 Determining the dimensions and layout of the premises ........................................................................................................ 50 4.4.5 Creating the base for the generating set ................................................................................................................................ 51 4.4.6 Opening the premises for access and ventilation ................................................................................................................... 51 4.4.7 Preparing a lifting system ....................................................................................................................................................... 52 4.4.8 Soundproofing the premises ................................................................................................................................................... 52

4.4.8.1. Reminder of applicable regulations: Acoustics ......................................................................................................... 52 4.4.8.2. Description of the installation .................................................................................................................................... 53

4.4.9 Fuel management ................................................................................................................................................................... 54 4.4.9.1. Reminder of applicable regulations ........................................................................................................................... 54 4.4.9.2. Description of the installation .................................................................................................................................... 55 4.4.9.3. Built-in fluid retention container (option) .................................................................................................................... 56

4.4.10 Defining the exhaust circuit ................................................................................................................................................... 57 4.4.10.1. Reminder of applicable regulations: Exhaust emissions ........................................................................................... 57 4.4.10.2. Description of the installation .................................................................................................................................... 57

4.4.11 Cooling ................................................................................................................................................................................. 64 4.5. Installing a containerised generating set ................................................................................................................................ 65

4.5.1 Determining the installation location ....................................................................................................................................... 66 4.5.2 Limiting noise pollution ........................................................................................................................................................... 67 4.5.3 Fuel management ................................................................................................................................................................... 67

4.5.3.1. Reminder of applicable regulations ........................................................................................................................... 67 4.5.3.2. Description of the installation .................................................................................................................................... 68

4.5.4 Ensuring correct ventilation .................................................................................................................................................... 70 4.5.5 Guaranteeing a correct exhaust system ................................................................................................................................. 70

4.6. Installing a mobile generating set ........................................................................................................................................... 71 4.6.1 Trailer-mounted generating set............................................................................................................................................... 71

4.7. Connecting the generating set electrics ................................................................................................................................. 72 4.7.1 Wiring ..................................................................................................................................................................................... 72 4.7.2 Neutral system ........................................................................................................................................................................ 75

4.7.2.1. TT system ................................................................................................................................................................. 76 4.7.2.2. TNS system .............................................................................................................................................................. 76 4.7.2.3. IT system .................................................................................................................................................................. 77

4.7.3 Overvoltage ............................................................................................................................................................................ 78

5. Installation............................................................................................................................................................................................ 78

5.1. Warnings concerning commissioning ..................................................................................................................................... 78

5.2. Checking the generating set installation ................................................................................................................................ 78

5.3. Preparing for operation of the generating set ......................................................................................................................... 78

5.4. Checking the generating set before startup ........................................................................................................................... 79

5.5. Checking the generating set after startup .............................................................................................................................. 79

RAMIRENT

3

6. Maintenance ........................................................................................................................................................................................ 81

6.1. Maintenance plans ................................................................................................................................................................. 81

6.2. Cleaning a generating set with an enclosure ......................................................................................................................... 82 6.2.1 Cleaning frequency ................................................................................................................................................................. 82 6.2.2 Cleaning procedure ................................................................................................................................................................ 83

6.3. Cleaning a containerised generating set ................................................................................................................................ 84 6.3.1 Cleaning frequency ................................................................................................................................................................. 84 6.3.2 Cleaning procedure ................................................................................................................................................................ 84

6.4. Exhaust silencer maintenance ............................................................................................................................................... 85

6.5. Testing generating sets .......................................................................................................................................................... 86

7. Storage/Removal from storage ............................................................................................................................................................ 87

8. Additional equipment ........................................................................................................................................................................... 87

8.1. JAPY manual pump ............................................................................................................................................................... 88 8.1.1 Technical specifications .......................................................................................................................................................... 88 8.1.2 Maintenance ........................................................................................................................................................................... 88

8.2. JAPY electric pump ................................................................................................................................................................ 90 8.2.1 Technical specifications .......................................................................................................................................................... 90 8.2.2 Maintenance ........................................................................................................................................................................... 91

8.3. REN-RAB automatic oil auxiliary adjuster .............................................................................................................................. 92 8.3.1 Technical specifications .......................................................................................................................................................... 92 8.3.2 Operation ................................................................................................................................................................................ 92

8.4. Air filter for dusty atmospheres .............................................................................................................................................. 93

8.5. Additional fuel filters ............................................................................................................................................................... 95 8.5.1 Diesel filters ............................................................................................................................................................................ 95

8.5.1.1. Filter maintenance .................................................................................................................................................... 95 8.5.1.2. Bleeding .................................................................................................................................................................... 95 8.5.1.3. Filter replacement ..................................................................................................................................................... 95

8.5.2 Separ diesel filters .................................................................................................................................................................. 96 8.5.2.1. Filter maintenance .................................................................................................................................................... 96 8.5.2.2. Bleeding .................................................................................................................................................................... 96 8.5.2.3. Filter replacement ..................................................................................................................................................... 97

8.6. Starter batteries ..................................................................................................................................................................... 98 8.6.1 Checking the electrolyte level ................................................................................................................................................. 99 8.6.2 Checking the voltage/acid density .......................................................................................................................................... 99 8.6.3 Connecting/disconnecting the battery ..................................................................................................................................... 99 8.6.4 Charging the battery ............................................................................................................................................................. 100 8.6.5 Cleaning the battery ............................................................................................................................................................. 100 8.6.6 Fault finding .......................................................................................................................................................................... 101

8.7. AEES battery charger .......................................................................................................................................................... 102 8.7.1 Function ................................................................................................................................................................................ 102 8.7.2 Locating and resolving faults ................................................................................................................................................ 102

8.8. Shut-off valve ....................................................................................................................................................................... 104

8.9. Air coolers ............................................................................................................................................................................ 105

9. Glossary ............................................................................................................................................................................................ 107

RAMIRENT

4

TABLE OF ILLUSTRATIONS Figure 1: Warning pictograms ................................................................................................................................................................... 7 Figure 2: Pictograms indicating prohibited activities .................................................................................................................................. 7 Figure 3: Pictograms indicating compulsory operations ............................................................................................................................ 7 Figure 4: Information pictograms ............................................................................................................................................................... 8 Figure 5: Specific pictograms .................................................................................................................................................................... 8 Figure 6: Pictograms relating to battery operations ................................................................................................................................... 9 Figure 7: General description of a generating set without a protective cover .......................................................................................... 22 Figure 8: General description of a generating set with a protective cover ............................................................................................... 23 Figure 9: General description of a generating set with a protective cover ............................................................................................... 24 Figure 10: Example of a mobile generating set on a trailer ..................................................................................................................... 25 Figure 11: Example of a lighting column .................................................................................................................................................. 25 Figure 12: Example of an ISO 20 container ............................................................................................................................................. 26 Figure 13: Example of an ISO 40 container ............................................................................................................................................. 27 Figure 14: Example of a CIR 20 container ............................................................................................................................................... 27 Figure 15: Example of a EUR 40 container ............................................................................................................................................. 28 Figure 16: Example of a container on a trailer ......................................................................................................................................... 28 Figure 17: Example of a generating set identification plate ..................................................................................................................... 29 Figure 18: Position of the identification plate for generating sets with and without protective covers ...................................................... 30 Figure 19: Position of the identification plate for generating sets in a container ...................................................................................... 30 Figure 20: Examples of engine identification plates ................................................................................................................................ 31 Figure 21: Examples of alternator identification plates ............................................................................................................................ 31 Figure 22: Example of an electrical cabinet identification plate ............................................................................................................... 31 Figure 23: Slinging a generating set without a cover ............................................................................................................................... 33 Figure 24: Sling attachment points on a generating with a protective cover ............................................................................................ 34 Figure 25: Examples of handling equipment ........................................................................................................................................... 35 Figure 26: Examples of container lifting methods .................................................................................................................................... 35 Figure 27: Examples of prohibited lifting methods ................................................................................................................................... 36 Figure 28: Examples of handling using forklift trucks .............................................................................................................................. 36 Figure 29: Handling a generating set using a mobile winch .................................................................................................................... 37 Figure 30: Handling a generating set using rollers .................................................................................................................................. 38 Figure 31: Release cable ......................................................................................................................................................................... 40 Figure 32: Example of coupling head ...................................................................................................................................................... 41 Figure 33: Wear indicator ........................................................................................................................................................................ 42 Figure 34: Example of French signalling ................................................................................................................................................. 45 Figure 35: Example of a generating set room .......................................................................................................................................... 48 Figure 36: Examples of problems that may be encountered ................................................................................................................... 49 Figure 37: Example of the size of a room ................................................................................................................................................ 50 Figure 38: Example of a lifting system ..................................................................................................................................................... 52 Figure 39: Example of an installation....................................................................................................................................................... 53 Figure 40: Example of a fuel tank installation in France .......................................................................................................................... 54 Figure 41: Example of an installation....................................................................................................................................................... 55 Figure 42: Integrated fluid retention container ......................................................................................................................................... 56 Figure 43: Example of a burnt gas exhaust circuit ................................................................................................................................... 58 Figure 44: Examples of pipes and elbows ............................................................................................................................................... 59 Figure 45: Example of a compensator and hose ..................................................................................................................................... 59 Figure 46: Examples of bleeds ................................................................................................................................................................ 59 Figure 47: Examples of bulkhead crossings ............................................................................................................................................ 59 Figure 48: Examples of exhaust outlets ................................................................................................................................................... 59 Figure 49: Examples of suspension lines ................................................................................................................................................ 60 Figure 50: Examples of needle frames .................................................................................................................................................... 60 Figure 51: Examples of column bases..................................................................................................................................................... 60 Figure 52: Examples of suspension lines ................................................................................................................................................ 60 Figure 53: Example of an absorption silencer ......................................................................................................................................... 61 Figure 54: Example of an absorbent reactive silencer ............................................................................................................................. 61 Figure 55: Example of an adapted silencer ............................................................................................................................................. 61

RAMIRENT

5

Figure 56: Schematic diagram for calculating the chimney height ........................................................................................................... 62 Figure 57: Examples of exhaust chimneys .............................................................................................................................................. 63 Figure 58: Condensate receptacle .......................................................................................................................................................... 64 Figure 59: Installation of containers on the ground .................................................................................................................................. 66 Figure 60: : Examples of an increase in sound level caused by reverberations and sound directivity ..................................................... 67 Figure 61: Example of a fuel tank installation in France .......................................................................................................................... 68 Figure 62: Example of an installation....................................................................................................................................................... 69 Figure 63: Positioning constraints ........................................................................................................................................................... 70 Figure 64: Removing the blanking cover ................................................................................................................................................. 70 Figure 65: Example of a container installation with a free-standing chimney .......................................................................................... 71 Figure 66: Neutral TT system .................................................................................................................................................................. 76 Figure 67: Neutral TN-S system (separate earth and neutral) ................................................................................................................. 76 Figure 68: Neutral IT system ................................................................................................................................................................... 77 Figure 69: Drainage holes for generating sets with enclosure ................................................................................................................. 84 Figure 70: JAPY manual pump ................................................................................................................................................................ 88 Figure 71: JAPY JEV pump assembly ..................................................................................................................................................... 90 Figure 72: General view of the regulator ................................................................................................................................................. 92 Figure 73: Simplified diagram of valve action .......................................................................................................................................... 92 Figure 74: Damper valve models ........................................................................................................................................................... 104

1. Preface 1.1. Introduction

Thank you for choosing a generating set from our company.

This manual has been designed to help you operate and maintain your generating set correctly.

1.2. Description of the documentation for generating sets

The documentation supplied with the generating sets gives all the user and maintenance operations for the generating set or power station.

This documentation allows you to get to know the equipment, operate it and maintain it, both on a daily basis and periodically. The documentation for the engines and alternators fitted to the generating sets consists of engine user and maintenance manuals (from the manufacturer) or alternator user and maintenance manuals (from the manufacturer).

The documentation for the generating sets is composed of the following:

- The general and safety manual containing, amongst others:

the general recommendations and safety regulations to respect;

the general rules for installing generating sets;

the general instructions for preparing generating sets prior to commissioning;

the specifications for the fuels, lubricants, coolants to use;

specific maintenance instructions;

descriptions and/or instructions relating to the maintenance of certain optional equipment.

- The user manual for the control unit (if equipped).

- The user and maintenance manual for the generating set engine.

- The maintenance manual for the generating set alternator.

- Wiring diagrams (these diagrams are supplied with the documentation or with the generating set).

Note: the abbreviations and words defined in the glossary and references to figures and sections are shown in italics in the document.

RAMIRENT

6

1.3. Warnings

In this manual, the warning messages are used as follows:

Immediate danger.

Indicates an imminent danger which may result in death or serious injury. Failure to follow the instruction shown may pose serious risks to the health and life of those concerned.

DANGER

Potential danger.

Indicates a dangerous situation if the warning is not heeded. Failure to follow the instruction indicated may cause minor injuries to those concerned or damage to equipment.

IMPORTANT

2. General recommendations

The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning.

Read the safety instructions attentively in order to prevent any accident, incident or damage. These instructions must be adhered to constantly.

In order to obtain optimum efficiency and the longest possible service life for the generating sets, maintenance operations must be carried out according to the periods indicated in the attached maintenance tables. If the generating set is used under dusty or unfavourable conditions, some of these periods will be shorter.

Ensure that all adjustments and repairs are carried out by personnel who have received appropriate training. Our agents possess this qualification, and can answer all of your questions. They can also supply you with spare parts and other services and they have qualified staff to carry out preventive and corrective maintenance or even total reconditioning of generating sets.

The left and right sides can be seen from the back of the generating set (the radiator is at the front).

Note: some user and maintenance manuals for engines fitted to generating sets cover control units and include the start-up and shut down procedures for the engines.

As our generating sets are fitted with control units that are specific to the generating sets; only the information that appears in the documentation for the generating set control units should be taken into consideration.

In addition, depending on the manufacturing criteria of the generating sets, some engines may be fitted with specific electrical wiring different to that described in the engine documentation.

RAMIRENT

7

2.1. Safety 2.1.1 Pictograms and their meanings

The aim of the pictograms is as follows:

- To draw the attention of the operator or maintenance technician to the potential dangers.

- To explain how to act in the interest of personal safety and to avoid damaging the equipment.

The safety pictograms present on the equipment are explained below.

Warning: danger

Important, Electrical risk

Important, risk of explosion

Important, toxic materials

Important, rotating or moving parts

Important, pressurised fluids

Important, high temperature

Important, corrosive product

Danger: automatic start-up

Figure 1: Warning pictograms

Entry prohibited to unauthorised persons

Jet washing prohibited

Figure 2: Pictograms indicating prohibited activities

Reading the manual for the equipment is compulsory

Wearing suitable protective clothing is compulsory

Wearing suitable protective goggles and ear defenders is compulsory

Lifting point required

Forklift required for lifting

Battery charge must be checked

Periodic maintenance compulsory

Figure 3: Pictograms indicating compulsory operations

RAMIRENT

8

Earth

Battery isolating switch

External fuel connections

Diesel fuel

Drain the fuel

Inspection flap

Fill the coolant

Drain the coolant

Mains supply connection prohibited before filling with water

Fill the oil

Drain the oil

Retention container high level

Drain the retention container

Figure 4: Information pictograms

Flammable product, Do not smoke or create sparks or

flames

Reading the manual for the equipment is compulsory

Fuel supply

- Selection valve - Securing straps routing point

Figure 5: Specific pictograms

RAMIRENT

9

Wearing suitable protective clothing and goggles is

compulsory

Rinse any splashes of acid on the skin or in the eyes using clean

water.

Consult a doctor immediately.

Wash contaminated clothing with water.

Figure 6: Pictograms relating to battery operations

2.1.2 Safety instructions

RETAIN THIS MANUAL

This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set and batteries.

IMPORTANT - SAFETY ADVICE

If any parts of this manual are not understood, or in case of doubt, contact your nearest agent in order to receive an explanation or demonstration to allow the equipment to be used correctly. The guidelines listed below must always be respected to ensure the safety of personnel and equipment. In addition to this information, it is essential to refer to the local and national regulations applicable according to the jurisdiction.

2.1.2.1. General guidelines

Installing the equipment

The installer of the equipment must create a document describing any modifications made to the equipment during installation.

Using the equipment

- Before starting any operations on the equipment:

Nominate an operations manager.

The role of the operations manager is to monitor, either directly or indirectly, any operations performed on the equipment and to ensure that the safety and operating instructions are respected.

The operations manager should read and understand all the documentation supplied with the equipment.

- Information for personnel:

Regularly reiterate the safety and operating instructions to the operating personnel.

Contact your dealer if you have any questions regarding the equipment and any training requests for personnel.

Make the manufacturer's instructions available to the users (if possible on site).

RAMIRENT

10

- Protection for individuals and equipment:

Wear suitable clothing.

Move away from equipment in operation.

Ensure that persons who are not authorised to intervene as well as animals are kept away from the equipment. Observe this guideline regardless of whether the equipment is in operation or stopped.

Protect the equipment from any fluid splashes and bad weather.

Before starting the equipment, refit the enclosures and close all the access doors.

Before starting the engine, check that the air filter is present and the correct extraction circuit for the exhaust gas.

Respect the current regulations relating to fuel use.

Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.

Adjust the equipment according to the manufacturer's prescriptions.

Check that the equipment operates correctly.

Engage the parking brake when the equipment is installed on the operating site on its trailer. When chocking the trailer on a slope, ensure that there is nobody in the path of the trailer.

Maintaining the equipment

- Personnel skills:

Ensure that the maintenance operations are performed on the equipment by appropriately trained personnel.

- Personnel protection:

Wear suitable clothing and protective goggles.

Remove any personal belongings that may hinder the operation: watch, bracelet, etc.

Fit a panel over the controls of the equipment to prevent any attempt to start.

Disconnect the battery (and pneumatic starter if fitted) before beginning any maintenance operation.

Handle the equipment according to best practices, using techniques which do not endanger the personnel.

It is essential to wear gloves when detecting leaks.

Regularly check that the safety devices are operating correctly.

- Equipment protection:

Use tools in good condition and suited to the work to be done. Ensure you have understood the instructions before beginning any operation.

Respect the maintenance table and its recommendations. In dusty or unfavourable conditions, certain maintenance intervals will need to be reduced.

Check that the spare parts fitted on the equipment are supplied only by the dealer.

Handle the equipment according to best practices, using techniques which do not risk damaging the equipment.

Replace any safety pictograms that are missing or illegible on the equipment.

Note: the mounting bolts on the protective devices of the rotating parts are captive bolts equipped with retaining washers. Also, in order to ensure the integrity of this assembly, it is prohibited to use electric or pneumatic screwdrivers to undo these mounting bolts.

RAMIRENT

11

- Cleaning the equipment:

Clean off any trace of oil, fuel or coolant using a clean cloth.

Use only approved cleaning solvents.

Cleaning products and methods that are strictly prohibited:

petrol or other flammable substances;

soapy solution containing chlorine or ammonia;

high pressure cleaner.

- Additional instruction:

If necessary, contact the dealer for the following reasons:

answers to any questions relating to the equipment;

training requests for personnel;

supplying the relevant documentation for maintenance operations;

supplying spare parts;

corrective or preventive maintenance operations.

Operating site

- Maintenance:

Clean the entire operating site regularly with suitable cleaning materials.

The presence of dangerous or combustible materials inside premises must be limited to the operating requirements.

- Access:

Prohibit free access to persons who are not part of the establishment, except for those designated by the user.

- Respecting the environment:

Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).

Burning of waste in the open air is prohibited.

Remove waste water, sludge and other waste in a specialised processing centre.

RAMIRENT

12

2.1.2.2. Electrical safety precautions

ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS

DANGER

- Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that these values match the installation being supplied.

- The electrical connections must be made in accordance with current standards and regulations in the country of use and the neutral system sold.

- Ask a qualified electrician to intervene when there are specific cases requiring equipment to be connected to an existing electrical network.

- Disconnect the power to the equipment (equipment voltage, battery voltage and network voltage) before any installation or maintenance operation is performed.

- Connect the equipment wires by respecting the wiring diagram supplied by the manufacturer.

- Always handle the equipment with dry hands and feet.

- Take all the necessary precautions to avoid touching stripped cables or disconnected connectors.

- Use and maintain the cables in good condition, well insulated and connected correctly and securely.

- Only replace equipment that provides protection against electric shock with identical equipment (specifications and nominal values).

- Only use flexible durable cables with a rubber covering, which conform to ECI 245-4, or equivalent cables.

- Refit the protective plates (blanking covers) after each maintenance operation.

Note: The electrical equipment supplied with the equipment complies with standard NF C15.100 (France), or with the standards of the countries in question.

2.1.2.3. Safety precautions in case of electrical shock

In the event of an electric shock, observe the following instructions:

1. Avoid direct contact both with the live conductor and the victim's body.

2. Shut off the power immediately and activate the emergency stop for the equipment concerned. Note: the live wire may be cut with an axe. Take extreme care to avoid the electric arc that will be generated by this.

3. If it is impossible to access the equipment: move the victim away from the live conductor using a dry piece of wood, dry clothing or other non-conducting material.

4. Move the victim away from any situations where there is a danger of death.

5. Contact the emergency services.

6. If breathing has stopped, begin artificial respiration at once.

7. In the event of cardiac arrest, carry out cardiac massage.

RAMIRENT

13

2.1.2.4. Safety precautions relating to fire, burns and explosions

DANGER

FUELS / FLAMMABLE PRODUCTS / PRESSURISED FLUID

- RISK OF BURNS - - RISK OF FIRE -

- RISK OF EXPLOSION -

1. Before starting the equipment, move any flammable or explosive products away (petrol, oil, cloth, etc.).

2. It is prohibited to put combustible materials on the hot parts of the equipment (for example: exhaust pipe).

3. Avoid any contact with the hot parts of the equipment (for example: exhaust pipe).

4. Use appropriate ventilation to allow the equipment to cool correctly.

5. Wait for the engine to stop and cool down completely before removing the radiator cap.

6. Wait for the equipment to stop and cool down completely before covering the equipment (if necessary).

7. Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.

8. Ensure that the equipment in operation is fixed (in a stationary position).

When installing the equipment on a vehicle or other mobile equipment, a study must be conducted beforehand in order to take into account the various specific uses of the generating set.

IMPORTANT

Fuels

- Respect current local regulations regarding the equipment and fuel used (petrol, diesel and gas).

- Top up the engine with fuel when the engine has stopped (except for equipment with an automatic filling system).

- Smoking, using a flame or producing sparks are forbidden while the fuel tank is being filled.

- Use protection suitable against fires and explosions.

- Pipes must be replaced as soon as their condition demands it.

RAMIRENT

14

Oils

1. Check that the system is no longer pressurised before carrying out any procedures.

2. Avoid contact with hot oil.

3. Wait for the engine to stop and cool down completely before topping up the oil.

4. Before starting the engine, refit the oil filler cap.

5. It is prohibited to cover the generating set with a fine layer of oil for anti-rust protection.

Battery

- Smoking, using a flame or producing sparks are forbidden close to batteries (particularly when the batteries are being charged).

Supply gas (concerns generating sets running on gas)

- Request the user technical notes and LPG or NG safety data sheets from your gas supplier.

- For any operation on a gas installation, ask a recognised specialist to intervene.

- Gas supply procedures must be carried out in the open air (outside) in accordance with local regulations, in an area well away from fires, people or animals.

- Check the sealing of the gas supply circuit using soapy water with the circuit pressurised, or using a leak detector.

- It is forbidden to smoke, bring flames near or create sparks when the tank is being filled, and near to the generating set.

2.1.2.5. Toxic risk safety precautions

DANGER

EXHAUST GAS - TOXIC PRODUCTS

- TOXIC RISK -

Exhaust gas

- Use suitable ventilation to release the exhaust gas outside and prevent it from accumulating.

- Respect current local regulations regarding the equipment and fuel used (petrol, diesel and gas).

- Periodically examine the burnt gas exhaust.

- Pipes must be replaced as soon as their condition demands it.

Note: the carbon monoxide present in the exhaust gas may lead to death by inhalation if the concentration levels in the atmosphere are too high.

RAMIRENT

15

Corrosion inhibitor in the coolant (contains alkali)

- Read the instructions on the packaging.

- Keep the product out of the reach of children.

- Do not swallow it.

- Avoid prolonged or repeated contact with the skin.

- Never allow contact with the eyes.

In the event of contact with the eyes:

1. Rinse immediately with plenty of water for at least 15 minutes.

2. Consult a doctor immediately.

In the event of contact with the skin:

1. Wash thoroughly with water and soap.

2. Consult a doctor immediately.

Fuels and oils

- Do not swallow it.

- Ensure proper ventilation.

- Use a suitable protective mask.

Battery electrolyte

- Avoid all contact with the skin and eyes.

- Wear suitable protective goggles and clothing and strong alkali-resistant gloves for handling the electrolyte .

If splashes get into the eyes:

1. Rinse immediately with running water and/or a 10% diluted boric acid solution.

2. Consult a doctor immediately.

RAMIRENT

16

2.1.2.6. Precautions for risks relating to handling phases

DANGER

HANDLING PHASES - RISK OF DROPPING

1. Select the appropriate handling equipment and apparatus according to the type of equipment being handled. Check that there is sufficient handling capacity.

2. Check that the handling equipment and apparatus are in good operating condition.

3. Respect the handling instructions described in the present documentation and the pictograms displayed on the equipment to be handled.

4. Be sure never to stand under the load being handled.

Note: the lifting rings provided on the equipment are designed to handle the generating set alone. If additional equipment is fitted to the generating set, a study should be conducted in order to define the centre of gravity of the assembly and to check the correct mechanical performance of the structure and its lifting rings.

2.1.2.7. Precautions for risks relating to noise

HIGH SOUND LEVEL - RISK OF HEARING LOSS

DANGER

- Always use suitable ear defenders when working in close proximity to a generating set which is in operation.

Note: for generating sets used inside, for which the ambient noise levels are dependent upon the installation conditions, it is not possible to specify these ambient noise levels in the operating instructions. As prolonged exposure to high sound pressure levels can cause permanent damage to hearing, it is necessary to measure the acoustics after installation in order to determine the sound pressure level and, if necessary, to implement the appropriate preventive measures.

2.2. Fuels, lubricants and coolants

All specifications (product features) are given in the engine and alternator maintenance manuals attached to this manual.

In addition to these, we recommend the fuels, lubricants and coolants mentioned in the "Specifications" section.

RAMIRENT

17

2.2.1 Specifications

2.2.1.1. Fuel specifications

General quality requirements

The quality of the fuel is essential for engine performance. It affects the technical performances such as the service life, power supplied and fuel consumption as well as the ability to respect the requirements issued by authorities relating to pollutant emissions. Only fuels which conform to the current legal requirements and national and international standards should be used. Consult the local fuel distributor to find out the characteristics of the diesel fuel available in the area.

Examples of standards and requirements:

EN 590 European standard (CEN) for vehicle fuel - fuels for diesel engines (diesel fuel) - requirements and test methods

ASTM D 975 1-D and 2-D American Society for Testing and Materials: basic requirement in the United States and Canada

JIS KK 2204 Japanese Industrial Standards: Japanese industrial standards

Respecting pollutant emissions

The certification measures confirming that the legal emission value limits are respected are performed with certified fuels which conform to the standards and requirements stated above.

Resistance to low temperatures

When the external temperature is low, the fluidity of diesel fuel may no longer be sufficient due to paraffin deposits. Also, in the winter in order to avoid malfunctions (for example, clogged filters), use diesel fuels which are fluid enough in cold weather.

The requirements to respect for the various geographical regions and various seasons (winter/summer) are specified in the standards and/or national regulations. Petrol companies should always supply fuels with the correct flow properties regardless of the time of year. In general, diesel fuel is treated with additives so that the fuel can be used at low temperatures in the region where it is marketed.

Treating fuel with additives must respect the engine manufacturer's recommendations and maintain a suitable lubricity for the injection systems. It is recommended to favour fuels whose additives have been added in a refinery over those modified in the storage tank.

RAMIRENT

18

General specifications for diesel fuel

The fuel used must have the following characteristics (non-exhaustive list):

Sulphur content

The sulphur content must meet the current emissions regulations in the region where the generating set is used.

For the United States and countries respecting the EPA regulation

Only use Ultra Low Sulphur Diesel (ULSD) fuel with a maximum sulphur content of 15 mg/kg for Interim Tier 4 and Tier 4 certified engines.

For the European Union

Directive 2009/30/CE whose aim is to limit atmospheric pollution, imposes the use of a diesel fuel with a very low sulphur content of 10 mg/kg, for non road mobile machinery.

In France, this obligation has resulted in the development of a diesel fuel called "off road diesel fuel" or "GNR". The maximum admissible sulphur content is 10 mg/kg. However, member states allow these diesel fuels to contain up to 20 mg/kg of sulphur when they are distributed to the final users. It is recommendable to avoid storing off road diesel fuel for long periods of time (over 6 months).

Viscosity and density

The viscosity and density directly affect the performance (power and fuel consumption), emissions and service life of the engine. A low level of viscosity and density reduces engine power and increases fuel consumption. Too high a level of viscosity and density seriously reduces the service life and operation of the fuel injection system.

In order to maintain adequate technical and environmental performance, the viscosity and density must conform to the specifications indicated in the manufacturer's instructions for the engines fitted to our generating sets.

Lubricity (or capacity for lubrication or oiliness)

In order to protect the fuel injection system against excessive wear, the fuel must have satisfactory lubricity (refer to the manufacturer's instructions for the engines fitted to our generating sets).

Cetane index The ignition behaviour of diesel fuels is described by the cetane index. The cetane index is important for emissions, the ability to start in cold weather and engine noises. The minimum technical requirements are 45.

Water and contaminants

The fuel and tank must not contain any water. Water causes the engine parts to corrode and wear more rapidly, particularly the injection system parts. In addition, water promotes the growth of bacteria and fungi in the tank, which can clog the fuel filter. The fuel must not contain any type of residue. Organic contaminants (bacteria, fungi, etc.) can block the fuel filters; inorganic material in the fuel (dust, sand) can cause serious damage to the injection equipment.

RAMIRENT

19

2.2.1.2. Lubricant specifications

Essential for the correct operation of the engine. The oil should be selected according to its use. Besides the lubrication function, oil should also:

- cool certain parts; - protect metal parts against corrosion; - improve the sealing, in particular between pistons, piston rings and cylinders; - remove impurities (to the filter).

It is recommendable to use a top of the range lubricant for diesel engines. The table below lists the oils recommended for each engine manufacturer.

Engine

Make Type Make Type

Cummins All GenPARTS GENLUB TDX 15W40

John Deere All John Deere John Deere PLUS-50

GenPARTS GENLUB TDX 15W40

MTU All GenPARTS GENLUB TDX 15W40

Mitsubishi All GenPARTS GENLUB TDX 15W40

Perkins Fuel GenPARTS GENLUB TDX 15W40

Gas MOBIL PEGASUS 705

Volvo All GenPARTS GENLUB TDX 15W40

Doosan All GenPARTS GENLUB TDX 15W40

Lombardini

Kohler All

GenPARTS

or Kohler

GENLUB TDX 15W40 or Kohler 5W40, according to the model of the engine

Viscosity

Viscosity is a measure of the flow resistance of a fluid. The viscosity of an engine oil is expressed by 2 SAE (Society of Automotive Engineers) grades. One grade for cold weather and one grade for hot weather. The grade for cold weather appears before the letter W.

The 1st grade represents dynamic viscosity in cold weather, namely the ability to start the engine and to prime the oil pump (and therefore to lubricate the various components quickly). The lower the number, the more fluid the oil.

The 2nd grade represents the kinematic viscosity in hot weather. The higher the number, the thicker the film of oil when hot (which aids protection and sealing). The lower the number, the less friction there will be in hot weather (it helps to save fuel).

In order to ensure immediate protection when starting the engine, the choice of viscosity grade when cold is essential. More fluid oil is quicker to flow when oil begins to circulate through the engine. It should be selected according to the ambient temperature. See the table below.

RAMIRENT

20

Characteristics of GENLUB TDX 15W40 oil

Performance

GENLUB TDX oil is a 15W40 multigrade mineral oil which meets the following specifications: ACEA E3 and API CG-4.

ACEA E3: oil with superior viscosity stability, suited to extended oil change intervals and severe conditions of use.

API CG-4: oil particularly effective to meet the emissions requirements.

ACEA = European Automobile Manufacturers' Association

API = American Petroleum Institute

Specifications

Specifications Units Grade SAE 15W-40

Density at 15°C kg/m3 883

Kinematic viscosity at 100°C mm2/s (cSt) 14

Viscosity index – 130

Flow point °C - 27°

Flash point °C >200

TBN* mgKOH/g 9.7

Typical values given for information purposes

* TBN (Total Base Number – degree of alkalinity): a measure of a lubricant's reserve alkalinity according to standard ASTMD 2896. This check makes it possible to assess the ability of the product to remain in service and to check the ’capacity of the lubricant to neutralise the acidity contained in the oil, which may corrode the metallic elements of the lubricated component.

2.2.1.3. Coolant specifications

The engine's internal cooling system allows the engine to operate at a precise temperature.

The table below lists the coolants recommended for each engine manufacturer.

Engine

Make Type Make Type

Mitsubishi All Mitsubishi LLC

GenPARTS GENCOOL PC -26

MTU All GenPARTS GENCOOL PC -26

John Deere All GenPARTS GENCOOL PC -26

Volvo All GenPARTS GENCOOL PC -26

Doosan All GenPARTS GENCOOL PC -26

RAMIRENT

21

Specifications of GENCOOL PC -26 coolant

Performance

GENCOOL PC -26 coolant is a ready-to-use cooling fluid which provides a high level of protection and is produced from an antifreeze approved by the majority of manufacturers (Power Cooling concentrated antifreeze).

It offers the following:

- Improved anticorrosion: improves the effectiveness and service life of the cooling system. - High temperature feature: promotes heat exchange. - Long-term protection: against overheating and corrosion under extreme conditions of use. - Compatible with the original fluid (however, it is recommended to drain the entire cooling system when replacing the fluid).

Specifications

Specifications Units Characteristics

Density at 20°C kg/m3 1053 ± 3

pH pH 7.5 to 8.5

Alkalinity reserve ML ≥ 10

Boiling temperature °C 105 ± 2

Freezing temperature °C -26 ± 2

Typical values given for information purposes

2.3. Protecting the environment Oil, fuel and coolant are very toxic products for the environment and for people's health: they should never be tipped over or allowed to run into the ground (collect fluids in suitable containers and take them to a waste collection point). Once the generating set is no longer being used (end of product life), take it to a waste collection point. To prevent the risk of fire, allow a broad clearance around the generating set (risk of sparks). To reduce noise disturbance, as far as possible, prevent sound from reverberating through walls or buildings (the noise will be amplified). 3. General description of the equipment

There are 3 main types of generating set:

- Fixed generating set:

without a protective cover;

with a protective cover.

- Mobile generating set:

without a trailer;

with a trailer;

lighting column.

- Generating set in a container:

without a trailer;

with a trailer.

Note: mobile generating sets always have protection (cover or container).

RAMIRENT

22

3.1. Fixed generating set 3.1.1 Generating set without protective cover

Figure 7: General description of a generating set without a protective cover

1 Air filter 5 Engine 9 Frame

2 Alternator 6 Protective grille for rotating parts 10 Identification plate

3 Damper studs 7 Control unit 11 Circuit breaker

4 Starter battery 8 Radiator 12 Console

1

2

6

7

12

10

8

11

5

9

3

4

RAMIRENT

23

3.1.2 Generating set with protective cover

Figure 8: General description of a generating set with a protective cover

1 Lifting ring 6 Engine 11 Frame

2 Air filter 7 Protective grille for rotating parts 12 Identification plate

3 Alternator 8 Exhaust 13 Circuit breaker

4 Damper studs 9 Radiator 14 Console

5 Starter battery 10 Protective cover 15 Control unit

2

3

7

6

1

5

4

15

14

12

9

13

10

11

8

RAMIRENT

24

3.2. Mobile generating set 3.2.1 Generating set without trailer

Figure 9: General description of a generating set with a protective cover

1 Lifting ring 6 Engine 11 Frame

2 Air filter 7 Protective grille for rotating parts 12 Identification plate

3 Alternator 8 Exhaust 13 Circuit breaker

4 Damper studs 9 Radiator 14 Control unit

5 Starter battery 10 Protective cover 15 Forklift pockets

16 Tow bar

2

13

1

7

5

14

4

3

12

9

10

11

8

6

16 15 RAMIR

ENT

25

3.2.2 Trailer-mounted generating set

All mobile generating sets are available on a trailer.

Figure 10: Example of a mobile generating set on a trailer

3.2.3 Lighting column

Figure 11: Example of a lighting column

Lights

Column

Generating set with a protective cover

Trailer

RAMIRENT

26

3.3. Containerised generating set

The name "container" is a generic term used for a box1 designed to transport merchandise, sufficiently solid for repeated use and equipped with components (ISO corners) enabling transfers between different modes of transport.

The SDMO CONTENENERGY range comprises 3 types of container:

- ISO 20 and ISO 40.

- CIR 20.

- EUR 40.

The names ISO, CIR and EUR are SDMO trade names.

These containers are based on high capacity containers (HC: High Cube) meeting ISO standards:

- 1AAA: 40' container (12.192m x 2.438m x 2.896m), used for ISO 40 and EUR 40.

- 1CCC: 20' container (6.058m x 2.438m x 2.896m), used for ISO 20 and CIR 20.

3.3.1 ISO 20 and ISO 40 containers

ISO 20 and ISO 40 20' and 40' containers comply with the ISO/TC104 standards and are CSC2 certified, i.e. authorised for shipping.

Figure 12: Example of an ISO 20 container

1 In the "jargon" of international transport, a container is often referred to as a "box". 2 CSC: Container Safety Convention

AIPR Console

Sound trap

Silencer

Radiator Soundproofed air inlet grille

RAMIRENT

27

Figure 13: Example of an ISO 40 container

3.3.2 CIR 20 containers

CIR 20 containers (not CSC certified) are built based on ISO 20 containers (compliant with ISO/TC104 on request).

These low noise level containers are well-suited to mobile and rental applications.

Figure 14: Example of a CIR 20 container

Silencer

Sound trap

Soundproofed air inlet grille

Radiator

AIPR

Fuel tank

Silencer

Soundproofed air inlet grille

Radiator

Tank RAMIRENT

28

3.3.3 EUR 40 container

EUR 40 containers are only available in 40' (not CSC certified). These containers designed for generating sets equipped with series 4000 MTU engines come with 2 soundproofing versions: Silent and Supersilent.

Figure 15: Example of a EUR 40 container

3.3.4 Trailer-mounted container

All container generating sets (20' and 40') are available on a trailer.

Figure 16: Example of a container on a trailer

Silencer

AIPR

Soundproofed air inlet grille

Air cooler

RAMIRENT

29

3.4. Identification plates 3.4.1 Identifying sets

Generating sets and their components are identified by means of identification plates.

The precise rules for identifying each major component (engine, alternator, etc.) are set out in each manufacturer's documentation contained in the appendices of this manual.

1 - Generating set

2 - Manufacturer name

3 - Model

4 - Serial number

5 - Year of manufacture

6 - Rated output (kVA and kW) according to the ISO 8528-1 standard

PRP: main power

ESP: emergency power

7 - Rated power factor

8 - Maximum altitude of the site above sea level (m) for the rated power

9 - Maximum ambient temperature for the rated power (°C)

10 - Rated frequency (Hz)

11 - Generating set rotation speed (RPM)

12- Rated voltage (V)

13 - Rated current (A)

14 - Weight (kg)

15 - CE marking

16 - Non CE standard marking (e.g.: GOSSTANDART)

17 - Sound pressure

18 - Sound power

Figure 17: Example of a generating set identification plate

RAMIRENT

30

3.4.2 Location of plates on generating sets with and without an enclosure

The identification plate for generating sets with and without protective covers is affixed to the lower section of the base frame.

Figure 18: Position of the identification plate for generating sets with and without protective covers

3.4.3 Location of plates on containerised generating sets

The identification plate for containers is affixed by the emergency stop.

Figure 19: Position of the identification plate for generating sets in a container

Identification plate

Identification plate

RAMIRENT

31

3.4.4 Identifying generating set components

Figure 20: Examples of engine identification plates

Figure 21: Examples of alternator identification plates

Figure 22: Example of an electrical cabinet identification plate

RAMIRENT

32

4. Installation 4.1. Unloading the equipment

To unload the equipment from its transportation support, observe the following steps:

1. Select the unloading site and final position (of use) for the equipment, in accordance with the following criteria:

- the proximity between the unloading site and the final position of use;

- ease of access to the equipment for the movement stages;

- ease of movement between the unloading site and the location where the equipment will be used;

- the ability of the ground to withstand the load of the equipment and its handling apparatus.

2. If the ground does not have the prerequisites to withstand the load of the equipment and its handling apparatus, fit beams that are designed to support the load of the assembly.

3. Select the appropriate method, handling equipment and apparatus according to the type of equipment being handled. Check that there is sufficient handling capacity.

4. Carefully read the instructions relating to the handling methods in the section entitled "Equipment handling" in this document.

4.2. Handling the equipment 4.2.1 Warnings concerning handling

Only ISO 20 and ISO 40 containers can be stacked.

It is prohibited to stack other generating set models.

IMPORTANT

Some generating sets are equipped with transport brackets, which are red, facilitating their movement and transportation.

It is essential to remove the transport brackets before the generating set concerned is installed in its final position.

IMPORTANT

It is prohibited to lift a lighting column with the lifting ring fixed to the generating set; use the 4 lifting rings fixed to the trailer.

IMPORTANT

RAMIRENT

33

4.2.2 Moving the equipment using slings

4.2.2.1. Fitting slings to generating sets without an enclosure

Each lifting ring on the generating set is marked by a pictogram

IMPORTANT

1. Attach the lifting machine's slings to the rings on the generating set designed for this operation.

2. Slightly tension the slings without lifting the generating set.

3. Check that the slings are correctly attached and that the equipment is secure.

4. Lift the generating set carefully and without jerking.

5. Direct the generating set towards the chosen location and stabilise it.

6. Carefully set down the generating set while continuing to position it.

7. Slacken the slings, then remove them from the lifting rings.

The slings must be perpendicular to the frame to ensure that they do not rub against the generating set.

IMPORTANT

Figure 23: Slinging a generating set without a cover

4.2.2.2. Fitting slings to generating sets with an enclosure

Each lifting ring or bracket on the generating set is marked by a pictogram.

IMPORTANT

1. Attach the lifting machine's slings to the rings or brackets on the generating set provided for this operation.

2. Slightly tension the slings without lifting the generating set.

3. Ensure that the slings are correctly fastened, the equipment is secure and the angle of the slings to vertical does not exceed 30° if the generating set is fitted with several lifting points.

4. Lift the generating set carefully and without jerking.

5. Direct the generating set towards the chosen location and stabilise it.

6. Carefully set down the generating set while continuing to position it.

7. Slacken the slings, then detach and remove the lifting rings.

RAMIRENT

34

The sling attachment points vary according to the enclosure models. 3 different configurations are available:

Enclosure with 1 lifting ring Enclosure with 2 lifting brackets Enclosure with 4 lifting brackets

Figure 24: Sling attachment points on a generating with a protective cover

4.2.2.3. Fitting slings to containerised generating sets

Each ISO corner of the container is marked by a pictogram

IMPORTANT

1. Attach the lifting machine's slings to the ISO corners on the container.

2. Slightly tension the slings without lifting the container.

3. Check that the sling hooks are correctly attached, and that the equipment used is solid.

RAMIRENT

35

4. Lift the container carefully and without jerking.

5. Direct the container towards its final position, keeping it stable.

6. Manoeuvre the container to its final position, while still off the ground.

7. Carefully set down the container without jerking, while continuing to position it.

8. Once the container is on the ground and correctly positioned, release the slings, check that the container is stable and correct it if necessary.

9. Detach the slings and remove them from the lifting rings.

Example of attachment by an ordinary hook on the ISO

corner

Example of attachment by a safety hook on the ISO corner

Example of attachment by a shackle on the ISO corner

Example of attachment by a manually coupled lock on an

ISO corner

Figure 25: Examples of handling equipment

Example of container lifting using a lifting beam fitted with hooks, shackles or manually coupled locks.

Example of a container lifted by the four bottom ISO corners

Figure 26: Examples of container lifting methods

RAMIRENT

36

Figure 27: Examples of prohibited lifting methods

4.2.3 Moving the equipment using a forklift truck

4.2.3.1. Handling generating sets with and without an enclosure

Each forklift pocket area of the generating set is marked by a pictogram

IMPORTANT

Use a forklift truck which has arms that are longer than the width of the frame.

IMPORTANT

1. Position the forklift arms under the frame (except with generating sets fitted with "forklift pockets", in which case position the forklift arms in these pockets), making sure that only its cross members are resting on the arms.

2. Lift the equipment, handling it gently.

3. Set down the generating set in its unloading position.

Figure 28: Examples of handling using forklift trucks

RAMIRENT

37

4.2.3.2. Handling containerised generating sets

It is prohibited to handle containers using a forklift truck

IMPORTANT

4.2.4 Moving the equipment using a mobile winch

If you are using a room equipped with a suitable rail or mobile winch, proceed as described in the paragraph "Moving the equipment by hoisting".

Figure 29: Handling a generating set using a mobile winch

RAMIRENT

38

4.2.5 Moving the equipment using rollers

Only generating sets that do not have brackets built into the frame can be moved using rollers.

The base frame support surface on the rollers must be free from deformations.

IMPORTANT

1. Lift up the edge on the engine side slightly with 2 jacks, then slide 3 rollers under the frame.

2. Leave the base frame resting on the rollers, then move the generating set manually.

3. As the generating set is moved, re-use the released rollers by sliding them in turn under the base frame.

4. When it has reached its final location, position the generating set then lift it up using jacks, and support it on chocks.

5. Withdraw the rollers and lower the generating set, checking that it is in the correct position, then remove the jacks.

Figure 30: Handling a generating set using rollers

RAMIRENT

39

4.3. Transporting the equipment 4.3.1 Warnings concerning transport

Only ISO 20 and ISO 40 containers can be stacked.

It is prohibited to stack other generating set models. IMPORTANT

It is prohibited to operate generating sets whilst they are being transported.

IMPORTANT

4.3.2 Preparing for transport

Before the equipment is transported, perform the following operations:

1. Close the tap on the oil top up tank outlet.

2. Fill up the oil top up tank with oil.

3. Fill up the crankcase with oil.

4. Fill up the on-board tank with fuel.

5. Check that the batteries are fitted and filled with electrolyte.

4.3.3 Road transport

4.3.3.1. Generating sets with and without an enclosure

Generating sets must be transported by road in accordance with the regulations of the countries concerned.

When transporting generating sets in containers by road, the following steps must be observed:

1. Put a plastic cover over non-enclosed generating sets during transportation.

2. Select transport equipment (trailer, semi-trailer, etc.) suitable for this usage and having all the safety guarantees in terms of load bearing capacity and of the securing devices.

3. Chock and fix the generating sets to the floor of the transport equipment.

4. Strap the generating sets to the transport equipment.

5. Select a transport route which makes it possible to travel on roads suitable for vehicles, and whose quality will not damage the on-board generating sets.

4.3.3.2. Containerised generating sets

Containers must be transported by road in accordance with the regulations of the countries concerned.

When transporting generating sets in containers on roads, the following steps must be observed:

1. Select transport equipment (trailer, semi-trailer, container carrier, etc.) suitable for this usage and having all the safety guarantees in terms of load bearing capacity and securing devices.

2. It is essential to plug the openings (air inlets and outlets, exhaust, etc.) during transportation.

3. Select a transport route which makes it possible to travel on roads suitable for vehicles, and whose quality will not damage the container or its contents.

RAMIRENT

40

4.3.3.3. Generating sets on trailers Hitching and unhitching the trailer

"On‐road" trailer

Before hitching up the trailer, check the hitching ring on the towing vehicle; this must be perfectly compatible with the trailer.

Any attempt to tow a trailer with a non-compliant device (bar, cables, lashing, etc.) runs the risk of serious accidents.

Also check:

- That there are no incipient ruptures or significant wear on the hitching system.

- That the locking system is working properly. IMPORTANT

Coupling a trailer fitted with a hitching ring

1. Drive the towing vehicle or move the trailer (after releasing the parking brake, if fitted) to the coupling position.

2. Put the trailer in the horizontal position using the guide wheel (jockey wheel).

3. Put the hitching ring above the towing vehicle hook, and then lower the adjustable towbar (if fitted) or lower the front of the trailer to secure the ring in the hook; the trailer must remain in the horizontal position after this adjustment. Make any necessary height adjustments using the jockey wheel to enable coupling.

4. Once this has been done, raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load.

5. Fix the release cable to the attachment point on the hitching plate (see Figure 31: Release cable ), and then connect the electrical cable plug controlling the lights, indicators, etc. to the socket on the towing vehicle.

6. Lift up the jockey wheel completely and lock it in position, making sure that it is not impeding the brake rod or the release cable.

7. Ensure that the parking brake (if fitted) is completely disengaged by pushing its handle down fully. If necessary, remove the wheel chocks and store them.

If the hitching ring is not correctly connected to the hitching hook, the trailer will become separated from the towing vehicle. The release cable engages the parking brake (acting as an emergency brake) should the trailer detach from the towing vehicle. For the braking system to fulfil its role effectively, it is essential to observe the following advice:

- The release cable MUST NOT be wound around the guide roller, as this would prevent the emergency brake from working.

- The release cable MUST run as straight as possible, without being impeded at any point.

- The release cable must be long enough to allow turning, and it must not be stressed or impeded in use, as this would trigger the parking brake while the vehicle is being towed. IMPORTANT

Figure 31: Release cable

RAMIRENT

41

Coupling a trailer fitted with a coupling head

1. Drive the towing vehicle or move the trailer (after releasing the parking brake, if fitted) to the coupling position.

2. Open the coupling head. To do so, pull the coupling handle (see Figure 32: Example of coupling head) in the direction of the arrow.

The coupling mechanism can remain open as long as the coupling head is not resting on the hitching joint.

3. Put the trailer in the horizontal position using the guide roller (jockey wheel), and then mount the open coupling head on the hitching joint by lowering the adjustable towbar, if fitted, or by lowering the front of trailer. This must remain in the horizontal position after this adjustment.

If necessary, adjust the height using the jockey wheel. The coupling head will be engaged automatically, accompanied by a clearly audible click; then lower the coupling handle. The coupling mechanism will then be engaged, and the coupling handle cannot adopt a lower position (when manoeuvred by hand).

4. Once this has been done, raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load.

5. Attach the release cable to the attachment point on the hitching plate (see Figure 31: Release cable) then connect the electrical cable plug controlling the lamps, indicators, etc. to the socket on the towing vehicle.

6. Lift up the jockey wheel completely and lock it in position, making sure that it is not impeding the brake rod or the release cable.

7. Ensure that the parking brake (if fitted) is completely disengaged by pushing its handle down fully. If necessary, remove the wheel chocks and store them.

If the coupling head is not correctly attached to the hitching joint, the trailer will separate from the towing vehicle. The release cable engages the parking brake (acting as an emergency brake) should the trailer detach from the towing vehicle. For the braking system to fulfil its role effectively, it is essential to observe the following advice:

- The release cable MUST NOT be wound around the guide roller, as this would prevent the emergency brake from working.

- The release cable MUST run as straight as possible, without being impeded at any point.

- The release cable must be long enough to allow turning, and it must not be stressed or impeded in use, as this would trigger the parking brake while the vehicle is being towed.

IMPORTANT

Figure 32: Example of coupling head

RAMIRENT

42

Uncoupling a trailer fitted with a hitching ring

1. Immobilise the trailer by placing chocks under the wheels, after engaging the parking brake (if fitted) fully.

2. Release the hitching ring using the jockey wheel. The jockey wheel retraction mechanism (if fitted) must lock automatically before the wheel touches the ground. When you are sure that the mechanism is locked and that the jockey wheel can bear the load, you can unhitch the trailer from the vehicle.

3. Disconnect the electrical cable plug controlling the lights, indicators, etc. from the socket on the towing vehicle.

4. Remove the release cable from the hitching plate.

Uncoupling a trailer fitted with a coupling head

1. Immobilise the trailer by placing chocks under the wheels, after engaging the parking brake (if fitted) fully.

2. Open the coupling handle and lift up the coupling head, using the jockey wheel, to release it from the hitching joint. The jockey wheel retraction mechanism (if fitted) must lock automatically before the jockey wheel touches the ground. When you are sure that the mechanism is locked and that the wheel is bearing the load, you can uncouple the trailer from the vehicle.

3. Disconnect the electrical cable plug controlling the lights, indicators, etc. from the socket on the towing vehicle.

4. Remove the release cable from the hitching plate.

Wear indicator (on certain models)

The coupling head has a wear indicator (see Figure 33: Wear indicator) that tells you whether the wear limit of the towing vehicle's hitching joint or of the towed vehicle's coupling has been reached.

To use this indicator, couple the trailer and drive the towing vehicle around 500 m, so that the coupling head is positioned. When you have done this, check the wear as indicated below.

Figure 33: Wear indicator

red

green

RAMIRENT

43

If the green section of the indicator can be seen on the coupling (secured), the coupling head is in good condition, or the hitching joint wear is less than the prescribed limit.

If the green section of the indicator is completely masked, and only the red section is visible, it can be assumed either that the hitching joint has reached the wear limit (diameter < 49.61 mm), or that the coupling head and hitching joint both show signs of wear, or finally that the hitching joint is in good condition (diameter 50 mm), but that the coupling head is worn.

n these conditions, the coupling head may come free from the hitching joint, and the trailer detach from the towing vehicle. Therefore, the coupling head and hitching joint must be checked before they are reused. Any defective part must be replaced.

IMPORTANT

"Site" trailer

Before hitching the trailer, check the hitching system on the towing vehicle; this must be perfectly compatible with the trailer.

Any attempt to tow a trailer with a non-compliant device (bar, cables, lashing, etc.) runs the risk of serious accidents.

Also check:

- That there are no incipient ruptures or significant wear on the hitching system.

- That the locking system is working properly. IMPORTANT

Coupling a trailer fitted with a hitching ring

1. Drive the towing vehicle or bring the trailer up to the coupling point.

2. Put the trailer in the horizontal position using the guide wheel (jockey wheel).

3. Place the hitching ring above the towing vehicle hook, and then lower the trailer to secure the ring in the hook. Make any necessary height adjustments using the jockey wheel to enable coupling.

4. Once this has been done, raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load.

5. Lift up the guide roller and lock it in position.

If the hitching ring is not correctly connected to the hitching hook, the trailer will become separated from the towing vehicle.

IMPORTANT

RAMIRENT

44

Coupling a trailer fitted with a coupling head

1. Drive the towing vehicle or bring the trailer up to the coupling point.

2. Open the coupling head. To do so, pull the coupling handle (see Figure 32: Example of coupling head) in the direction of the arrow.

The coupling mechanism can remain open as long as the coupling head is not resting on the hitching joint.

3. Put the trailer in the horizontal position using the guide roller (jockey wheel) and then mount the open coupling head on the hitching joint; the trailer must remain in the horizontal position.

If necessary, adjust the height using the jockey wheel. The coupling head will be engaged automatically, accompanied by a clearly audible click; then lower the coupling handle. The coupling mechanism will then be engaged, and the coupling handle cannot adopt a lower position (when manoeuvred by hand).

4. Once this has been done, raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load.

5. Lift up the jockey wheel fully and lock it in position.

If the coupling head is not correctly attached to the hitching joint, the trailer will separate from the towing vehicle.

IMPORTANT

Uncoupling a trailer fitted with a hitching ring

1. Immobilise the trailer by placing chocks under the wheels.

2. Release the hitching ring by lowering the jockey wheel. When you are sure that the wheel can bear the load, you can unhitch the trailer from the vehicle.

Uncoupling a trailer fitted with a coupling head

1. Immobilise the trailer by placing chocks under the wheels.

2. Open the coupling handle and lift up the coupling head while lowering the jockey wheel to release it from the hitching joint. When you are sure that the wheel can bear the load, you can unhitch the trailer from the vehicle.

Check before towing

Before towing, check the following:

- Tightness of the generating set cover bolts.

- Wheel tightness.

- Hitching hook locked.

- Tyre pressure.

- Signalling lights working, for "on-road" trailers.

- Enclosure doors closed.

- Parking brake released, for "on-road" trailers.

- Guide wheels (jockey wheels) and stands lifted (if fitted).

- Towbar arm locking levers tightened and pinned (if fitted with an adjustable towbar).

- Brake test, for "on-road" trailers.

- Safety cable fitted, for "on-road" trailers.

RAMIRENT

45

Operation

"On-site" trailer

These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. It is therefore absolutely prohibited to exceed this speed.

Nor are these trailers fitted with signalling lights. On-road use is prohibited.

"On-road" trailer

The driving speed must be suited to the condition of the road and the handling of the trailer.

Driving at high speed causes the tyres to heat; it is therefore important to stop from time to time and check them. Excessive heating may cause a puncture, and therefore a serious accident. For reversing manoeuvres, remember to lock the inertia brake.

Particular attention must be paid to the tightness of the wheels on new vehicles.

In the first few miles' driving, heating of the brake hubs and drums will actually reduce the wheel tightness. It is therefore essential to check the tightness every 6 miles (10 kilometres) until no further loosening is noted.

The tightness check must nonetheless be carried out whenever you have towed the trailer. IMPORTANT

Lights/signalling (only for "on-road" trailers)

Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use.

Figure 34: Example of French signalling

Front reflective devices (white)

Side reflective devices (orange)

Red rear lights + direction indicators + stop lights

Rear reflective devices (red triangle) RAMIR

ENT

46

4.3.4 Rail transport

4.3.4.1. Generating sets with and without an enclosure

Generating sets must be transported by rail in accordance with the specific rules governing rail transport.

When transporting generating sets in containers by rail, the following steps must be observed:

1. Put a plastic cover over non-enclosed generating sets during transportation.

2. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

4.3.4.2. Containerised generating sets

Containers must be transported by rail in accordance with the specific rules governing rail transport.

Containers must receive the necessary approvals for rail transport.

When transporting generating sets in containers on roads, the following steps must be observed:

1. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

2. It is essential to plug the openings (air inlets and outlets, exhaust, etc.) during transportation.

4.3.5 Shipping

4.3.5.1. Generating sets with and without an enclosure

Transportation must be carried out in accordance with the rules of shipping. Generating sets must be transported in a shipping container.

When shipping generating sets in containers, the following steps must be observed:

1. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

2. In the case of a grouped load container, SEI cases must be used for packing.

4.3.5.2. Containerised generating sets

It is essential to plug the openings (air inlets and outlets, exhaust, etc.).

For electrical cabinets, packing in a SEI 4 C case (solid case with waterproof cover) is obligatory.

"ISO" type container

ISO 20’ and 40’ containers are basic ISO "boxes" to which modifications have been made (doors, intake grille, exhaust outlet).

These containers, in spite of their modifications, have received CSC approval, i.e. are authorised for shipping.

CSC certified containers may be stacked in a cellular ship, and have top grips. Most of these containers are "ISO containers", which meet the standards stipulated by the International Organisation for Standardisation ISO.

RAMIRENT

47

"CIR" and "EURO" type container

The modifications made to these containers relating to the basic ISO "box" (doors, apertures for cooling, exhaust, etc.) disqualify them from CSC approval, and therefore prohibit them from being shipped as a container. In this case special transport is recommended (flat container carrier).

It is essential to transport CIR 20 and EUR 20 containers with chocks.

IMPORTANT

4.3.6 Air transport

Containers must be transported by air in accordance with the specific rules governing air transport.

The UN has classified generating sets as "dangerous goods" listed under UN code 3166 - class 9 - "Engine, internal combustion (flammable liquid powered)".

Any air shipment of generating sets must be subject to prior declaration to the air freight company, in accordance with form MOD3909.

For air transport, observe the following steps:

1. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity and securing devices.

2. For control boxes, packing in an SEI 4 C case (solid case with waterproof cover) is obligatory.

RAMIRENT

48

4.4. Installing a generating set indoors

The contents of this chapter are only general recommendations.

It is recommended that professionals are employed to ensure correct installation and start-up.

The company cannot be held responsible for breakdowns related to the conditions of installation. IMPORTANT

4.4.1 Introduction

Note: failure to respect the main principles exposes the entire installation to damage and abnormal wear. The procedure described lists the main requirements for installing a "standard" generating set composed of a heat engine, a generator and an electrical panel. These requirements must be considered to be the general principles. For any special applications and if in doubt, our technical services will advise you and assess your specific installation conditions. Moreover, the current regulations, requirements and laws relating to installation locations should be respected.

Figure 35: Example of a generating set room

AIR INLET

ELECTRICAL CABLES

EARTH TERMINAL MOUNTING OF GENERATING SET TO FLOOR PLATE

FUEL PIPE

FUEL STORAGE

AIR OUTLET

FIRE RATED DOOR

EXHAUST GASES RELEASED OUTSIDE THE ROOM

RAMIRENT

49

4.4.2 Determining the installation location

The installation location of the generating set will be determined according to the application. There are no specific rules which govern the choice of location, but the following elements are deciding factors:

- proximity to the electrical distribution panel;

- disturbances caused by noise;

- fuel supply;

- burnt gas evacuation.

The choice of location will therefore be the result of a carefully considered compromise!

Incorrect ventilation and exhaust Building or terrain too rough.

Generating set incorrectly seated Reduced access

Impossible to fill with fuel Impossible to open enclosure doors

Figure 36: Examples of problems that may be encountered

RAMIRENT

50

4.4.3 Selecting the type of premises

There are two possible scenarios:

The sound level is not important. Use a simple sheltered location which

protects against bad weather (rain, snow, storms, etc.).

The low sound level is an important criterion, e.g.: standby generating set or

noise-sensitive area).

Use a room constructed from poured concrete or complete concrete blocks with a minimum thickness of 20 cm,

coated with absorbent materials, a fire wall and insulation.

The fire resistance rating must conform to the current legislation appropriate to the type of building.

IMPORTANT

4.4.4 Determining the dimensions and layout of the premises

The size and layout of the room are determined according to two requirements:

- Fixed requirements

These are the dimensions of the equipment installed and its peripherals, namely: daily fuel feed tank, electrical cabinet, silencer, batteries, etc.

- Variable requirements

These are the dimensions which must be left around each piece of equipment to allow for any maintenance and dismantling operations.

A space of about 1 metre around the generating set is considered the minimum required for carrying out problem-free maintenance. This will leave enough space to check that the doors of the covered generating sets open fully, that equipment can be accessed for maintenance and that full removal of the generating set can be carried out.

Figure 37: Example of the size of a room for a generating set with a cover

RAMIRENT

51

4.4.5 Creating the base for the generating set

An operating generating set generates a certain amount of vibratory energy. This vibratory energy makes its way to the floor plate via the frame. Mounted on elastic mountings, our generating sets do not require a special support. However, the floor plate on which the generating sets rest must be:

- firm enough;

- detached from the rest of the construction;

- level;

- smoothed by the flow;

- unshackled.

If there is a risk of vibrations being transmitted, the generating set can be mounted on a separate floor plate insulated if necessary by a resilient material. This solution is mainly used for very powerful generating sets.

4.4.6 Opening the premises for access and ventilation

Access

Ensure that there is an access door which allows the generating set and its accessories to pass through, preferably along the axis of the floor plate of the generating set.

Ventilation

- Ensure the presence of fresh air inlets and hot air outlets which are suited to the conditions of use and the cooling system.

- Define appropriately sized openings, in accordance with the following elements:

the generating set power;

the atmospheric conditions;

the cooling system;

the soundproofing method (if necessary).

- Ensure that the air is swept in the following direction: Alternator Engine Radiator.

- Ensure that the air inlets and outlets are as direct as possible.

- Connect the cooling system to a sheath or outlet cover so that it is sealed in order to prevent any hot air from being recirculated.

- Ensure that the air inlets and outlets are never located near to each other.

It is preferable to release the vapour from the crankcase outside the generating set room in order to prevent a deposit from developing on the radiator which may cause the radiator to clog and affect its cooling ability.

Ensure that the crankcase vapours are recovered in order to preserve the environment. IMPORTANT

Note: a heat engine generates a certain amount of heat, which must be evacuated outside the room to ensure that the generating set works properly. The heat released by the generating set originates from different sources:

- cylinder cooling;

- radiation from the engine unit and exhaust duct;

- alternator cooling.

Insufficient ventilation would cause the ambient temperature to increase which, at the very least, would cause loss of engine power and potentially cause the generating set to shut down.

RAMIRENT

52

4.4.7 Preparing a lifting system

The lifting system must, in general, form an integral part of the construction. It is composed of a mobile winch which moves along an H- or I-shaped sealed steel rail in the walls and ceiling. This system is generally positioned above and in the longitudinal axis of the generating set, directed towards the exit.

Figure 38: Example of a lifting system 4.4.8 Soundproofing the premises

4.4.8.1. Reminder of applicable regulations: Acoustics

Regulations concerning sound emissions are unique to each country. Refer to the regulations in force in the country concerned.

Example of current regulations in France:

Decree of 25/07/97, section 29103 - 8.1

- Noise emissions produced by the installation must not, to begin with, have an emergence greater than the permitted values specified in the following table in the statutory emergence zones:

Ambient noise level in the statutory emergence zones (including noise from

the establishment)

Permitted emergence for the period from 7:00 am to 10:00 pm except for Sundays

and bank holidays

Permitted emergence for the period from 10:00 pm to 7:00 am as well as on

Sundays and bank holidays

Greater than 35 dB(A) and less than or equal to 45 dB(A)

6 dB (A) 4 dB (A)

Greater than 45 dB(A) 5 dB (A) 3 dB (A)

3 Decree of 25/07/97 relating to general advice applicable to installations classified for the protection of the environment subject to

the declaration under section no.2910 Combustion.

RAMIRENT

53

4.4.8.2. Description of the installation

The room will be soundproofed using two methods:

- Insulation

This method consists of preventing noise from penetrating the walls by using the mass, and therefore the thickness of the wall in particular.

- Absorption

This method consists of using material which absorbs sound energy; it will therefore be used on the ventilation inlets. Consequently, the cross-sections of the air inlets and outlets will be increased.

The interior walls of the room may also be lined with absorbent material in order to reduce the sound level in the room and, consequently, through the walls, ventilation inlets and the door.

General conditions:

building structure of poured concrete or complete concrete blocks with a minimum thickness of 20 cm;

anti-vibration floor plate under the generating set, when the set is next to sensitive rooms;

walls and ceiling possibly coated with absorbent material;

choice of adapted exhaust silencer or silencers;

soundproofed door giving access to the room and possibly an airlock in order to obtain a very low sound level;

sound traps fitted in the air inlet and outlet sheaths.

Figure 39: Example of an installation

Sound trap

Silencer

Sound trap

Soundproofed doors RAMIRENT

54

4.4.9 Fuel management

4.4.9.1. Reminder of applicable regulations Fuel

The regulations concerning fuel are unique to each country. Refer to the regulations in force in the country concerned.

Example of current regulations in France:

Decree of 10/08/984.

Decree of 19/11/01 – Article EL75.

- Daily fuel tank

The maximum capacity of the Daily Fuel Tank (DT) in the generating set room is 500 L for an Establishment Receiving the Public (ERP).

Place the DT in a separate room if the volume is greater than 500 L.

- Use a retention container with a capacity greater than the capacity of the DT.

- Fuel pipe:

If the pipe is under load and underground: double skin.

Use a safety valve between the main tank and the DT.

Use a safety valve between the DT and the engine.

It is prohibited to use hoses in the ERP. Location of an underground fuel tank

Regulations concerning the installation of an underground fuel tank are unique to each country. Refer to the regulations in force in the country concerned.

Example of an underground fuel tank installation according to the current regulations in France:

Decree of 22/06/19986 articles 9 and 11.

Figure 40: Example of a fuel tank installation in France

4 Decree of 10 August 1998 modifying the decree of 25 July 1997 relating to general advice applicable to installations classified for

the protection of the environment subject to the declaration under section no.2910 (Combustion). 5 Decree of 19 November 2001 concerning the approval of conditions complementing and modifying the safety regulations against

the risk of fire and panic in establishments receiving the public. Article EL 7 concerning the installation of generating sets. 6 Decree of 22/06/1998 relating to underground tanks storing flammable liquids and related equipment.

VENT at least 4 m high, 3m open flame - opening

10 metresEMERGENCY

EXIT

PROPERTY

PROPERTY

TRANSFER

PUBLIC ROAD

UNDERGROUND FUEL OR GASSTORAGE TANK RAMIR

ENT

55

4.4.9.2. Description of the installation

Since the fuel is classed as a "dangerous product", certain regulations for storage and distribution must be followed. It is also necessary to consult current laws when carrying out the installation.

Do not used galvanised receptacles or brass coated receptacles for storing fuel.

IMPORTANT

Manual filling tank

This solution is valid for a manual start generating set that is visually monitored.

This tank is often integrated into the frame and comprises:

- a mechanical gauge;

- a filler neck;

- a drain port.

Automatic filling tank located in the room

This type of installation is subject to regulations.

Solution for automatic start generating sets. The tank is automatically filled by an electric drawing pump in a main storage tank. The pressure limit for the supply to the daily service tank is 3 bar (risk of leaks and damage if exceeded).

There must be an overflow pipe going back to the main tank. Its cross-section should be at least twice that of the supply pipes.

To prevent unpriming, the tank is fitted slightly filled in relation to the diesel engine (except in covered parking areas).

This tank must also be fitted with a safety valve for which the control must be located outside the room.

Figure 41: Example of an installation

Use a retention container capable of collecting leaks, with a capacity which is at least equal to 110% of the total volume of fluid present in the generating set (fuel, oil and coolant).

6 7

1514

5

2

c

411131211

10

398

25

24

P

27 19

21

20

16

1822

23

26

1

17

RM

REC REM

ASM

ASM

VB

1 - Daily service tank V1 10 - Non-return valve 19 - Filler 2 - Retention tank V2>V1 11 - 3-way valve 20 - Dipstick 3 - Electro-pump 12 - Filter 21 - Tank vent 4 - Manual pump 13 - Meter 22 - Earth plate 5 - DT leak detection 14 - Shut-off valve 23 - Safety valve 6 - DT dipstick 15 - Engine isolation valve 24 - Safety valve casing 7 - DT vent 16 - Single or double wall tank 25 - Shut-off valve casing 8 - Isolation valve 17 - Filling limiter 26 - Tracking 9 - Filter 18 - Foot valve with filter 27 - Leak detection (if double wall tank)

RAMIRENT

56

4.4.9.3. Built-in fluid retention container (option)

Any outflow of the fluid contained in the generating sets (fuel, oil and coolant) will be collected in a retention container if the generating set is fitted with this option.

The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected.

Three different fittings are available:

Fitting 1: Fluid retention container integrated into the tank frame

Fitting 2: Offset fluid retention container underneath the generating set frame

Fitting 3: Offset fluid retention container integrated into the frame and tank

Figure 42: Integrated fluid retention container

Note: generating sets equipped with the option corresponding to fitting 3 (see Figure 42: Integrated fluid retention container) are also equipped with a high level indicator in the retention container.

In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or condensation). If necessary, drain the containers either via the drain port or using the drain pump (for containers fitted with this pump).

Drain the fluids from the retention container into a designated container.

It is prohibited to perform this drain procedure on the ground.

IMPORTANT

RAMIRENT

57

4.4.10 Defining the exhaust circuit

4.4.10.1. Reminder of applicable regulations: Exhaust emissions

Regulations concerning exhaust emissions are unique to each country. Refer to the regulations in force in the country concerned.

Example of current regulations in France:

Engine with a thermal power consumption greater than 2,000 kW.

Decree of 25/07/97 art. 6.2.6 - 2 modified by the decree of 15/08/00.

Units of measurement (mg/m3)

4.4.10.2. Description of the installation

Study the evacuation of burnt gases by the generating set .

Ensure that the influencing criteria for this study are taken into account:

- pressure drops caused by the exhaust;

- thermal insulation;

- suspension of the pipes;

- sound level;

- air pollution.

Check that none of the components installed on the exhaust pipe cause pressure drops greater than the engine's admissible pressure.

Ensure that the exhaust circuit pipe has a smaller diameter than that of the generating set (contact us for significant lengths) and ensure that it is positioned so that no gas can flow back into the room.

Check that an exhaust compensator is fitted at the engine outlet.

Type of fuel Sulphur dioxides Nitrogen oxides (NOx) Dust (PM)

Natural gas andliquefied petroleumgas

30350

700 if dual fuel in gas mode500 if operating < 500 hrs/year

50150 for existing installations

650 150

DFO: 160 1500 650 150

Heavy fuel: 1500 3000 if overseas department and if complying with Directive1999/30/CE on air quality

2000 if operating < 500 hrs/year1900 if dual fuel in liquid fuel mode and if rotation speed < 1200 rpm 650 150

Applicability Production Emergency

Production Production Production Production

Pollutants

Other liquid fuels 100

50 if P > 10 MW and if agglomeration> 250,000 inhabitants (art 6.2.9) 150 for existing installations

Carbon monoxide (CO)

RAMIRENT

58

Check that the pipe is fixed so that the compensator is not supporting its weight. The compensator will be perfectly straight (any alignment fault may cause a rupture).

Figure 43: Example of a burnt gas exhaust circuit

Note 1: It should be noted that the more complicated a circuit, the more it causes drops in pressure and consequently, its diameter will be large and heavy and its supports and silencers expensive.

Note 2: Exhaust circuit components marked in Figure 43: Example of a burnt gas exhaust circuit, are explained in the following paragraphs.

1 - Exhaust pipe 2 - Elbows 3 - Compensator 4 - Condensation bleed 5 - Bulkhead crossing - roof outlet 6 - Exhaust outlet 7 - Suspension line 8 - Needle frame 9 - Column base 10 - Silencer suspension 11 - Thermal insulation 12 - Silencer

RAMIRENT

59

Pipework components

No. 1: Pipes

It is recommended that you use seamless pipes. However, for weight reasons, rolled steel pipes can be used. In any event, welded "bars" inside the duct are to be avoided.

No. 2: Elbows

Elbows must have a minimum curve radius equal to 2 times the diameter of the pipe, if possible in a single part. If the elbow is made of welded steel, check that it includes at least 3 sectors for 90° elbows.

Figure 44: Examples of pipes and elbows

No. 3: Compensators and hoses

- The compensator absorbs longitudinal movements due to expansion (approx. 1 mm/metre/100°C).

- The hose allows for considerable sideways travel, but with low longitudinal amplitude.

Figure 45: Example of a compensator and hose

No. 4: Condensation and rain water bleed

To be used in the lower section of the installation or for any changes in horizontal/vertical travel to protect the silencer and engine.

Figure 46: Examples of bleeds

No. 5: Bulkhead crossing - roof outlet

For each bulkhead passage and roof outlet.

Figure 47: Examples of bulkhead crossings

No. 6: Exhaust outlet

The exhaust outlets disperse the gases in the atmosphere and protect the inner section of the pipes from bad weather.

Figure 48: Examples of exhaust outlets

RAMIRENT

60

Exhaust circuit mountings and suspensions

No. 7: Suspension line

Generally made up of a flat iron ring attached to the ceiling. The suspension line enables the pipes to expand freely.

Figure 49: Examples of suspension lines

No. 8: Needle frame

Used for vertical sections, the needle frame allows the pipes to expand while holding them laterally.

Figure 50: Examples of needle frames

No. 9 : Column base

The column base is designed to hold the weight of the vertical pipes.

Figure 51: Examples of column bases

No. 10: Silencer suspension

The silencer suspensions are designed to hold the weight of the silencers; they can be vertical or horizontal.

Figure 52: Examples of suspension lines

RAMIRENT

61

Thermal insulation

No. 11: heat insulation

Depending on the type of installation, it may be necessary to insulate the heat released in the room.

Once the insulation is complete, the surface temperature must not exceed 70°C. As the recommended material is rock wool (excluding asbestos), it may be covered with an aluminium casing in order to improve the appearance of the installation and the heat insulation capacity.

A minimum thickness of 50 mm should be considered for the rock wool.

Silencer

No. 12: Silencer

Silencers reduce noise by absorbing or dephasing the sound wave. The exhaust should be suspended correctly; under no circumstances should the supports be reused on the generating set (except for original fittings).

Absorption silencer

Gas moves through a soundproofed duct composed of a highly absorbent material protected by a perforated panel.

Figure 53: Example of an absorption silencer

Absorbent reactive silencer

The gas enters between an expansion chamber lined with an absorbent material, secured by perforated panels in a soundproofed absorbent duct.

Figure 54: Example of an absorbent reactive silencer

"Adapted" silencer

The "adapted" silencer is fitted directly onto the generating set or in the cover. It is an absorption silencer.

Figure 55: Example of an adapted silencer

RAMIRENT

62

Exhaust chimney

Reminder of applicable regulations: Chimney height

Regulations concerning the chimney height are unique to each country. Refer to the regulations in force in the country concerned.

Example of current regulations in France:

Minimum ejection speed: 25 m/s

Figure 56: Schematic diagram for calculating the chimney height

- Emergency operation of the main electrical supply with a building present within a radius of 15 metres of the installation:

Decree of 25/07/97 section 2910 - 6.2.2.E

The height of the exhaust chimney should exceed the height of the buildings located less than 15 metres around the installation by 3 metres, whilst being less than 10 metres.

For d < 15 m => Hchim = Hobst + 3

RAMIRENT

63

Description of the installation

There are various types of exhaust chimney.

Self-supporting chimney

Chimney mounted on a concrete foundation on the ground, with load support on the building.

Wall-mounted chimney

Free-standing chimney

Chimney standing solely on a concrete foundation on the ground.

The sizing of the chimney's support must factor in the constraints of the site, and in particular the forces generated by the wind.

Telescoping chimneys

In the case of a facility with several generating sets, it is possible to route the various ducts to a single chimney. Each engine duct must be fitted with a non-return valve.

Telescoping chimney

Figure 57: Examples of exhaust chimneys

RAMIRENT

64

Condensate collector

Rain entering the chimney flue results in soot loaded with burnt particles and other harmful waste and is collected in a receptacle at the base of the chimney.

Fluid collected in this way produces sludge which is deposited at the bottom of the container and discharged outside through a siphon into a designated receptacle.

Figure 58: Condensate receptacle

4.4.11 Cooling

Four types of produced heat must be dissipated:

- heat from the engine cooling circuit(s);

- heat radiation from the engine and exhaust;

- room ventilation air;

- exhaust gases.

The systems described below evacuate and channel the heat produced by the engine cooling circuit.

Ventilated radiator

The engine cooling circuit is connected to a tubular ribbed radiator at the end of the frame. This radiator is cooled by the fan controlled directly by the engine.

In all cases, the air is blown in the Fan Radiator direction.

Note: an expansion vessel can compensate for variations in the volume of coolant fluid according to the temperature.

Chimney flue

Container

Siphon

Receptacle for condensate

Drain valve

RAMIRENT

65

Air cooler

The engine cooling circuit is connected to an air cooler located inside or outside the room.

When located in the room, it operates in the same way as a ventilated radiator. The fan or fans are either coupled to the engine or driven by one or more electric motors.

If the air cooler is positioned outside, on the roof or in another room, the coolant pipes are extended, meaning that ventilation of the room is separate from the cooling.

In these installations the degassing conditions should be considered even more carefully than for a radiator.

In all cases, the air cooler is cooled by the fan(s).

Lost water exchanger

This type of cooling consumes a sizeable amount of water and hence there is an operating cost to be taken into account. This is the solution when local provisions ensure the flow of water and do not allow the ventilation provisions required for cooling by a ventilated radiator or air cooler to be enacted.

These lost water installations consist mainly of an exchanger, with one of its circuits fitted with an expansion vessel, connected to the engine cooling circuit. The latter's water pump ensures circulation. The second exchanger circuit, known as raw water, is connected between the building's water supply and the drain. A valve fitted upstream of the exchanger can enable and cut off circulation. With automatic generating sets, this valve should also come with an electric control (solenoid valve).

This system's heat exchange ensures engine cooling. The room will require a ventilation system and this type of installation requires a detailed study.

Ventilation of the room

Extractor fans and/or air blowers can evacuate heat radiated from the engine and supply fresh air to the room and equipment in the case of external air coolers or lost water exchangers.

If fans are being used, several fans will regulate the temperature better than one large one fan.

Ventilation of the premises requires a detailed study and should take into account the atmospheric air temperature and loss of pressure of components located in the air inlet and outlet (grilles, sound traps etc.) in particular.

Note: if cooling using a radiator or air cooler in the room, the increase in temperature due to heat radiation for the sizing of the installation should always be taken into account.

4.5. Installing a containerised generating set

The contents of this chapter are only general recommendations.

It is recommended that professionals are employed to ensure correct installation and start-up.

The company cannot be held responsible for breakdowns related to the conditions of installation. IMPORTANT

RAMIRENT

66

4.5.1 Determining the installation location

The position of the container should first be considered in relation to the:

- proximity to the electrical distribution panel;

- disturbances caused by noise;

- fuel supply;

- burnt gas evacuation;

- the nature of the ground.

The installation area should be flat enough for the frame to rest level on it and strong enough so that the container does not sink down.

It is prohibited to rest the container on its ISO corners.

A recess should be made in the concrete slab at the ISO corners.

IMPORTANT

CORRECT INSTALLATION

INCORRECT INSTALLATION

INCORRECT INSTALLATION

Figure 59: Installation of containers on the ground

RAMIRENT

67

4.5.2 Limiting noise pollution

Analyse any noise pollution that the equipment may cause in order not to disturb those living close by

Be aware of the regulations in force, in order not to be vulnerable to future legal action.

The sound level of the set and reverberation effects on buildings must be taken into account .

Figure 60: : Examples of an increase in sound level caused by reverberations and sound directivity

4.5.3 Fuel management

4.5.3.1. Reminder of applicable regulations Fuel

The regulations concerning fuel are unique to each country. Refer to the regulations in force in the country concerned.

Example of current regulations in France:

Decree of 10/08/987.

Decree of 19/11/01 – Article EL78.

- Daily fuel tank

The maximum capacity of the Daily Fuel Tank (DT) in the generating set room is 500 L for an Establishment Receiving the Public (ERP).

Place the DT in a separate room if the volume is greater than 500 L.

- Use a retention container with a capacity greater than the capacity of the DT.

- Fuel pipe:

If the pipe is under load and underground: double skin.

Use a safety valve between the main tank and the DT.

Use a safety valve between the DT and the engine.

It is prohibited to use hoses in the ERP.

7 Decree of 10 August 1998 modifying the decree of 25 July 1997 relating to general advice applicable to installations classified for

the protection of the environment subject to the declaration under section no.2910 (Combustion). 8 Decree of 19 November 2001 concerning the approval of conditions complementing and modifying the safety regulations against

the risk of fire and panic in establishments receiving the public. Article EL 7 concerning the installation of generating sets.

RAMIRENT

68

Location of an underground fuel tank

Regulations concerning the installation of an underground fuel tank are unique to each country. Refer to the regulations in force in the country concerned.

Example of an underground fuel tank installation according to the current regulations in France:

Decree of 22/06/19989 articles 9 and 11.

Figure 61: Example of a fuel tank installation in France

4.5.3.2. Description of the installation

Since the fuel is classed as a "dangerous product", certain regulations for storage and distribution must be followed. It is also necessary to consult current laws when carrying out the installation.

Do not used galvanised receptacles or brass coated receptacles for storing fuel.

IMPORTANT

Manual filling tank

This solution is valid for a manual start generating set that is visually monitored.

This tank is often integrated into the frame and comprises:

- a mechanical gauge;

- a filler neck;

- a drain port.

9 Decree of 22/06/1998 relating to underground tanks storing flammable liquids and related equipment.

VENT at least 4 m high, 3m open flame - opening

10 metresEMERGENCY

EXIT

PROPERTY

PROPERTY

TRANSFER

PUBLIC ROAD

UNDERGROUND FUEL OR GASSTORAGE TANK

RAMIRENT

69

Automatic filling tank located in the room

This type of installation is subject to regulations.

Solution for automatic start generating sets. The tank is automatically filled by an electric drawing pump in a main storage tank. The pressure limit for the supply to the daily service tank is 3 bar (risk of leaks and damage if exceeded).

There must be an overflow pipe going back to the main tank. Its cross-section should be at least twice that of the supply pipes.

To prevent unpriming, the tank is fitted slightly filled in relation to the diesel engine (except in covered parking areas).

This tank must also be fitted with a safety valve for which the control must be located outside the room.

Figure 62: Example of an installation

Use a retention container capable of collecting leaks, with a capacity which is at least equal to 110% of the total volume of fluid present in the generating set (fuel, oil and coolant).

6 7

1514

5

2

c

411131211

10

398

25

24

P

27 19

21

20

16

1822

23

26

1

17

RM

REC REM

ASM

ASM

VB

1 - Daily service tank V1 10 - Non-return valve 19 - Filler 2 - Retention tank V2>V1 11 - 3-way valve 20 - Dipstick 3 - Electro-pump 12 - Filter 21 - Tank vent 4 - Manual pump 13 - Meter 22 - Earth plate 5 - DT leak detection 14 - Shut-off valve 23 - Safety valve 6 - DT dipstick 15 - Engine isolation valve 24 - Safety valve casing 7 - DT vent 16 - Single or double wall tank 25 - Shut-off valve casing 8 - Isolation valve 17 - Filling limiter 26 - Tracking 9 - Filter 18 - Foot valve with filter 27 - Leak detection (if double wall tank)

RAMIRENT

70

4.5.4 Ensuring correct ventilation

Install the equipment, taking into account the prevailing winds: position the air inlets away from the wind to ensure there are no difficulties in adverse weather conditions (entry of air, snow, sand, etc.).

Respect a minimum distance of 2 metres between the container air inlets and outlets and any ventilation obstacles.

Figure 63: Positioning constraints 4.5.5 Guaranteeing a correct exhaust system

Check that the air inlets are facing away from the prevailing winds to ensure that there are no difficulties in adverse weather conditions (entry of air, snow, sand, etc.).

Check that the equipment is positioned such that the prevailing winds hit the back of the operator during operations performed on the console so that the operator is not affected by exhaust fumes.

1. Be sure to remove the blanking cover(s) from the exhaust outlet(s) (used for transport).

2. Install the extension piece(s) supplied with the generating set in place of the blanking cover(s).

IMPORTANT

Figure 64: Removing the blanking cover

Air inlet

Air inlet

Air discharge

2 m, min.

2 m, min.

RAMIRENT

71

If using a high chimney, it is preferable to use a free-standing chimney installed beside the container.

Figure 65: Example of a container installation with a free-standing chimney

4.6. Installing a mobile generating set

- Respect the instructions provided for generating sets in a room.

- Reserve an installation area which is flat and strong enough so that the generating set does not sink into it. It could be made of concrete or even large planks fitted together. Note: a generating set that does not rest correctly on its base (frame or trailer) will be subject to vibrations that could cause significant damage to all the equipment.

- It is essential to respect the neutral system of the generating set associated with the current regulations, in order to ensure personal protection.

- Earth the generating set. To do this, use a copper wire, with a minimum cross-section of 25 mm2 for a stripped cable, and 16 mm2 for an insulated cable, connected to the generating set earth socket, and a galvanised steel earthing rod embedded vertically into the ground (see section "Electrically connecting a generating set").

- Protect generating sets without covers from bad weather with a suitable construction (see section "Installing a generating set in a room").

4.6.1 Trailer-mounted generating set

Operations to be carried out for the installation:

1. Ensure that the ground is strong enough for the assembly not to sink into it.

2. Unhitch the trailer in accordance with the paragraph "Road transportation / Generating sets on trailers / Hitching and unhitching the trailer".

3. Immobilise the trailer by placing chocks under the wheels.

4. Fully engage the parking brake (if fitted).

5. Using the front wheel, position the generating set as horizontally as possible.

6. Lower the stands (if fitted), and lock them.

RAMIRENT

72

4.7. Connecting the generating set electrics 4.7.1 Wiring

Notes

Low voltage electrical installations are subject to the regulations set out in standard NFC 15.100 (France) or the standards in the countries concerned based on international standard IEC 60364.

They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country.

Power cables

- Power cables should preferably be installed in ducts or on a cable tray for this purpose.

- Determine the cable cross-section and number of cables according to the cable type and the current standards to be observed in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52. Note: the power cables may be unipolar or multipolar according to the power of the generating set.

Three phase - Calculation hypothesis

Fitting method = wiring in cable runs or non perforated trays.

Permissible voltage drop = 5%

Multiconductors or single conductor joined when precision 4X…(1)

Cable type PVC 70°C (e.g. H07RNF).

Ambient temperature = 30°C.

Circuit breaker rating

(A)

Cable sizes 0 to 50 m 51 to 100 m 101 to 150 m mm²/AWG mm²/AWG mm²/AWG

10 1.5 / 14 2.5 / 12 4 / 10 16 2.5 / 12 4 / 10 6 / 9 20 2.5 / 12 4 / 10 6 / 9 25 4 / 10 6 / 9 10 / 7 32 6 / 9 6 / 9 10 / 7 40 10 / 7 10 / 7 16 / 5 50 10 / 7 10 / 7 16 / 5 63 16 / 5 16 / 5 25 / 3 80 25 / 3 25 / 3 35 / 2 100 35 / 2 35 / 2 4X(1X50) / 0 125 (1) 4X(1X50) / 0 4X(1X50) / 0 4X(1X70) / 2/0 160 (1) 4X(1X70) / 2/0 4X(1X70) / 2/0 4X(1X95) / 4/0 250 (1) 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X150) / 2350MCM 400 (1) 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 630 (1) 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM

RAMIRENT

73

Single phase - Calculation hypothesis

Fitting method = wiring in cable runs or non-perforated trays.

Permissible voltage drop = 5%

Multiconductors.

Cable type PVC 70°C (e.g. H07RNF).

Ambient temperature = 30°C.

Circuit breaker rating (A)

Cable sizes

0 to 50 m 51 to 100 m 101 to 150 m

mm²/AWG mm²/AWG mm²/AWG 10 4 / 10 10 / 7 10 / 7 16 6 / 9 10 / 7 16 / 5

20 10 / 7 16 / 5 25 / 3 25 10 / 7 16 / 5 25 / 3 32 10 / 7 25 / 3 35 / 2 40 16 / 5 35 / 2 50 / 0 50 16 / 5 35 / 2 50 / 0 63 25 / 3 50 / 0 70 / 2/0 80 35 / 2 50 / 0 95 / 4/0 100 35 / 2 70 / 2/0 95 / 4/0 125 50 / 0 95 / 4/0 120 / 2250MCM

Battery cables

- Install the battery or batteries in close proximity to the electric starter motor. The cables will be connected directly from the battery terminals to the starter motor terminals.

- Check that the polarities of the battery and starter motor correspond. (an inversion could cause severe damage to the electrical equipment).

- The minimum cross-section of the cables is 70 mm2. This cross-section varies according to the power of the starter motor but also the distance between the batteries and the generating set (voltage drops on the line).

Safety guidelines

References: NFC 15-100:2002 (France) - IEC: 60364-4-41.

In order to ensure that staff are protected against electric shocks, generating sets are equipped with a general residual current protection device which is configured in the factory to be triggered instantly with a sensitivity of 30mA.

Any change to the setting on the general residual current device could pose a risk to personal safety. The user will be held liable - any changes must only be made by trained, qualified engineers.

IMPORTANT

Note: when the generating set is disconnected from an installation after use, the general residual current device must be restored to factory settings by a qualified engineer who can then check this.

To ensure that the device providing protection against electric shocks is effective, connect the generating set to the earth. To do this, use a copper wire with a minimum cross-section of 25 mm2 for a stripped cable and 16 mm2 for an insulated cable, connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground.

Ensure that the resistance value of this earthing rod complies with the values indicated in the table below (use the highest differential setting from the installation as a guideline).

RAMIRENT

74

The resistance value is calculated in the following way:nI

UIR

For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below

Nature of ground Length of

rod in metres

Thick arable land,

moist compact ballast 1

Lean arable land,

Gravel, coarse ballast 1

Bare stony soils, dry sand,

impermeable rock 3.6

To obtain an equivalent length, you can use several earthing rods connected in parallel and set apart by at least their length.

Example: 4 interconnected 1 metre rods separated by 1 metre.

Note: for the United States (National Electrical Code reference NFPA-70).

The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most) connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically and fully into the ground.

This earthing rod embedded fully in the ground must have a minimum length of 2.5 m.

Maximum resistance value of the earth socket R (Ω) according to the differential unit operational current (operation time should not be longer than 1 second)

I ∆n differential

Earth R (Ω)

Ul: 50 V

Earth R (Ω)

Ul: 25 V ≤ 30 mA 500 > 500 100 mA 500 250 300 mA 167 83 500 mA 100 50

1A 50 25 3A 17 8 5A 10 5

10A 5 2.5 The Ul value: 25 V is required for site installations, and livestock buildings, etc

RAMIRENT

75

4.7.2 Neutral system

The Earthing system, or SLT (formerly Neutral system) of the electrical installation defines the situation of the generating set neutral in relation to earth and the grounds of the electrical installation at the user end.

The purpose of the earthing systems is to protect personnel and equipment by managing the risks posed by insulation defects. For safety reasons, any live conducting part of a facility must be insulated from the earth. This insulation may be achieved by distance, or by using insulating materials. But with time, insulation may deteriorate (due to vibrations, mechanical impacts, dust, etc.), and therefore generate an earth with dangerous potential. This defect poses risks for personnel and property, but also continuity of service.

Earthing systems are codified by two letters that define the connections:

- The first letter defines the neutral connection:

I Insulated or earthed via an impedance device

T Connected to earth

- The second letter defines the grounding situation of the electrical facility:

T Connected to earth

N Connected to

neutral

E.g.: IT = Isolated Neutral + Ground earthed

Speed Number of conductors

Detection Note

TT 4 poles Measurement of residual current Triggering of 1st fault by RCD

TN

C 3 poles

No measurement of residual current Triggered by overcurrent protection upon 1st fault

S 4 poles

IT SN 3 poles Insulation resistance measurement Triggered upon 2nd fault by overcurrent protection

RAMIRENT

76

4.7.2.1. TT system

R

Ph 1

Ph 2

Ph 3

N

PE

R

id

id

id

Figure 66: Neutral TT system

The alternator neutral is earthed, and the grounds of the user equipment have their own earth connection.

This earthing system is the most frequent in the private sector in France.

In the TT system, automatic power cut-off via a Residual Current Device (RCD) is obligatory at the upstream part of the facility, to ensure that personnel are protected (with a maximum 30 mA device on outlet circuits).

4.7.2.2. TNS system

In the TN system, the alternator neutral is earthed and the user grounds are connected to the main protective conductor (PE), itself connected to the earth socket.

Ph 1

Ph 2

Ph 3

N

PE

id

id

id

Figure 67: Neutral TN-S system (separate earth and neutral)

In the TN-S system, the power supply is automatically cut by the opening of the overcurrent protection circuit breaker protecting the faulty circuit.

TN-S is obligatory for networks with aluminium conductors which have a cross-section ≤ 16 mm2.

Ph 1

Ph 2

Ph 3

N

PE

Neutral connected to earth

T

Ground to neutralN

SeparateSeparate Neutral conductor

protective conductor

Neutral earth

R

Ph 1

Ph 2

Ph 3

N

PE

R

RNeutral connected to earth

T

Ground connected to earth

T

Neutral earth Ground earth

RAMIRENT

77

4.7.2.3. IT system

Ph 1

Ph 2

Ph 3

N

PE

CPIZ

id

id

id

id

Ph 1

Ph 2

Ph 3

N

PE

CPIZ

id

id

id

id

1st fault 2nd fault

Figure 68: Neutral IT system

In the IT earthing system, the alternator's neutral is earthed via an impedance device (Z) greater than 1000 Ohms, or insulated (Z=∞). The installation's grounds are earthed (see Figure 68: Neutral IT system). It should be noted that an IMD (Insulation Monitoring Device) is connected in parallel to this impedance device Z to monitor the circuit's insulation at all times.

- First fault: the current flowing through the metal frame passes through the neutral impedance device Z, which means a very low current (or practically zero if neutral is insulated), so the contact voltage is not dangerous. That is why hospitals, concert halls, etc. use this system to avoid outages in the case of a first fault. The IMD (Insulation Monitoring Device) detects this leak and reports it via an indicator light and/or an alarm.

- Second fault: both conductors concerned by insulation faults are interconnected, leading to a short-circuit. The power supply is automatically cut by the opening of the over-current protection circuit breaker, as in the TN system. It should be noted that the IT neutral system must not be used if you do not have a technician on call 24/7.

For the IT neutral system, in the case of a 20 kV/400V step-down transformer, it is necessary to provide overvoltage protection for the 400V network. This protection must be mounted between earth and the neutral point, if available, or a phase if not available.

For an LV generating set with an IT system, this protection is not necessary, as the voltage cannot be over 500V.

The network's insulation voltage must be the value of the phase-phase voltage.

Ph 1

Ph 2

Ph 3

N

PE

CPI

Neutral insulated I

Ground connected to earth

T

Z

Neutral earth Ground earth

RAMIRENT

78

4.7.3 Overvoltage

Generating sets are not equipped with devices that protect against voltage surges from atmospheric discharges or due to handling operations.

The company disclaims all liability for any accidents caused by these phenomena.

However, it is possible to install surge protectors considering that this assembly does not provide complete protection.

5. Installation 5.1. Warnings concerning commissioning

The general checks referred to in this section enable the generating set to operate. They must be adapted or complemented according to the actual commissioning conditions.

Specific qualifications are required to carry out these operations.

These operations must only be entrusted to personnel with the necessary skills. IMPORTANT

For generating sets equipped with series 4000 MTU engines.

It is essential to remove the flywheel locking device (to protect the crankshaft during transportation) when the generating set is commissioned (before starting for the first time).

IMPORTANT

For generating sets fitted with Lombardini/Kohler engines.

These engines require a running-in period. For the first 50 hours of operation, do not exceed 70% of the rated power.

IMPORTANT

5.2. Checking the generating set installation

- Check the position of the generating set (stability, mounting, available space, ventilation, exhaust, etc.) See the section entitled "Installation".

- Check the electrical connections see the section entitled "Electrically connecting a generating set":

earthing;

electrical control connections;

electrical power connections;

starter battery charging system (rating and voltage) if fitted to the generating set.

- Check that the residual current devices are operating correctly.

- Check the tension of the drive belt(s).

5.3. Preparing for operation of the generating set

- Become familiar with the controls useful to operate the generating set.

- Read and understand the "user" menus of the control unit.

- Become familiar with the maintenance plans for the generating set see the paragraph entitled "Maintenance plans".

- Become familiar with the operation of the generating set at no load or under load see "Checking the generating set after starting".

- Become familiar with the fluid specifications (fuel, lubricant and coolant) see the paragraph entitled "Fuels, lubricants and coolants" and the engine's maintenance manual.

RAMIRENT

79

5.4. Checking the generating set before startup

- Check that the plugs, blanking covers and protective adhesive strips have been removed.

- Ensure that the anti-humidity bags have been removed from the electrical sections (cabinet or control console, alternator, etc.).

- Check the insulation of the alternator see the alternator's maintenance manual.

- Check the levels see the engine's maintenance manual:

coolant;

oil;

fuel.

- Open the oil filler tap (if fitted to the generating set).

- Check the starter battery or batteries (connecting and charge) see the paragraph entitled "Starter batteries".

- Check the starter battery charging system (if fitted to the generating set). 5.5. Checking the generating set after startup

Off-load tests

- Carry out the safety checks (emergency shutdown, oil pressure, coolant temperature, etc.).

- Check the mechanical parameters:

engine parameters (oil pressure, coolant temperature);

absence of abnormal vibrations;

absence of abnormal noises;

absence of leaks.

- Check the electrical parameters:

voltage, frequency, current;

rotating field.

On-load tests

- Check the mechanical parameters:

engine parameters (oil pressure, coolant temperature);

absence of abnormal vibrations;

absence of abnormal noises;

absence of leaks.

- Check the electrical parameters:

voltage, frequency, current;

rotating field.

RAMIRENT

80

Adjustments to the air coolers' variable temperature controller and regulator Some generating sets are fitted with variable temperature controllers and regulators which control the speed of rotation of the fans according to the level of cooling required for the correct operation of the generating set. To ensure this system operates correctly, certain adjustments and checks must be made before starting up the generating sets. The procedure below describes these operations and applies to Schneider systems fitted with an "ALTIVAR 21" variable controller and a "REG48PUN1JLU" regulator.

All the operations are carried out while the generating set is running

IMPORTANT

a) Checking the settings on the temperature regulator Check the values shown in the temperature regulator value settings

table

DISPLAY NAME OF SETTING FUNCTION VALUES TO CHECK

Type of PV input Defines the type of input sensor 1 (PT 100Ω)

Position of the decimal point Defines the position of the decimal point on the PV/SV display 1 (one decimal)

Operating control for the ramp and soak

function

Switches between operating states for the ramp and soak function OFF (stop/end)

Key locking Prevents operating errors being displayed 0 (no locking)

OUT2 range Defines the range of the control

output (OUT2) (also configured for the retransmission output)

4-20 (4 mA to 20 mA)

USER key assignment setting Defines the function of the USER key 5 (Launch autotuning (standard))

RAMIRENT

81

Note: the setpoint for starting the variable speed control is a water temperature of 85°C.

The temperature regulator display enables the reading to be taken directly.

To modify this setpoint, use the keys opposite.

b) Launching the auto-configuration function The auto-configuration function is launched with the generating set "On Load", with an output of approx. 75% of the rated power. The setpoint can be modified according to the generating set's environment (hot country, etc.). The auto configuration function is launched by pressing and holding the On/Off button.

6. Maintenance 6.1. Maintenance plans

The user should continuously check that the installation is constantly in good working condition. The maintenance operations outlined in the documentation supplied with the generating set must also be carried out.

In addition, regular checks and tests are recommended as these will ensure the correct operation of the installation.

The regular checks and tests may require the test report to be filled in, including the following information: interval, nature of the inspection and/or test performed, date and time carried out, report of operations, name and signature of technician.

The maintenance plans (periodic maintenance tables) are outlined in the respective documentation (maintenance manual) for the engines, alternators and for some additional accessories. As a general rule, these plans make a distinction between use under continuous operation and use under emergency operation.

They also take the consumables used into account, for example: the sulphur content of the diesel or the grade of lubricant oil.

These maintenance plans must be referred to as soon as the generating set is received so that, taking the aforementioned elements into account, the maintenance intervals to be adopted can be defined. RAMIR

ENT

82

In addition to the maintenance plans mentioned above, it is also recommended that the following checks be carried out (the checks must be carried out by specialist personnel):

- Mechanical:

Check the cooling equipment;

Check the equipment mountings (correctly tightened), retighten the bolts;

Drain the exhaust chimney condensate collection pot (if fitted);

Retighten the alternator bus bars.

- Electrical:

Check the automatic and safety functions;

Check the alternator insulation;

Check the auxiliaries' insulation and their current consumption;

Check the starter battery charge systems and remote control batteries;

Check the starter batteries and remote control batteries.

These checks must be carried out at the following recommended intervals (or in accordance with the manufacturer's instructions):

- Generating set running as back-up ( 100 hours per year): once per year;

- Generating set running as back-up ( 500 hours per year): 3 times per year;

- Continuous operation of the generating set:

Mechanical checks: during oil changes;

Note: as the drain frequency of the exhaust chimney condensate collection pot cannot be defined (because it depends on the installation conditions), this drain operation must be performed each time a maintenance operation is carried out on the generating set.

electrical checks: every 6 months.

6.2. Cleaning a generating set with an enclosure

The sealing between the cover and the frame and between the frame and the retention tank is ensured by a gasket. It is essential to replace the gasket if the cover has been removed.

IMPORTANT

Users must maintain the enclosures and base frames to ensure that the paintwork retains all its protective properties.

6.2.1 Cleaning frequency

Carry out cleaning:

- whenever necessary;

- at least every 6 months;

- after sea transportation.

Clean generating sets more frequently if they are installed in wooded areas or corrosive atmospheres, or if soiled by dust or organic matter (rotting leaves, foam, waste, etc.). Check regularly that the holes for draining rain and condensation are not blocked. If there is a blockage, stagnant water can damage the generating set's enclosure and fill the retention tank (if fitted, optional).

RAMIRENT

83

6.2.2 Cleaning procedure Clean the inside and outside of the generating set regularly:

1. Open the doors of the generating set if necessary, then remove the panels and keep the bolts.

2. Clean the inside of the generating set: remove any plant debris, leaves and waste and check that the drainage holes are not blocked.

3. Carefully screw the removable panels back on and close the generating set doors if necessary.

4. Wash the outside of the generating set using a cleaning agent (water with a mild detergent added, e.g. car shampoo).

5. Rinse liberally with clear fresh water to remove any trace of cleaning product at an operating pressure of less than 120 bar (if using a high-pressure washer, allow a distance of at least 20 to 30 cm between the washer nozzle and the surface to be cleaned).

6. Dry with a soft, absorbent cloth.

A cleaning foam may be used and wiped off using a soft, absorbent cloth. Stubborn stains may be removed using a suitable solvent (white spirit or equivalent) and wiped off using a soft, absorbent cloth.

Curative treatment will be necessary to eliminate any major scratches. This treatment should be carried out by a trained professional.

M1x

x en

clos

ures

Removable panel

M2x

x en

clos

ures

Removable panel

Drainage holes

Removable panel

Drainage holes

The use of abrasives is prohibited.

When cleaning, ensure that the drain holes are plugged.

IMPORTANT

Drainage holes

RAMIRENT

84

M3x

x en

clos

ures

Removable panel

Drainage holes

Air inlets

Removable panel

Drainage holes

Figure 69: Drainage holes for generating sets with enclosure

6.3. Cleaning a containerised generating set 6.3.1 Cleaning frequency

Carry out cleaning:

- whenever necessary;

- at least every 6 months;

- after sea transportation.

Clean containerised generating sets more frequently if they are installed in wooded areas or corrosive atmospheres, or if soiled by dust or organic matter (rotting leaves, foam, waste, etc.). 6.3.2 Cleaning procedure Clean the inside and outside of the generating set regularly:

1. Open the container doors.

2. Inspect and clean the inside of the container: remove any plant debris, leaves and waste and check that the drainage holes are not blocked.

3. Lubricate the hinges, locks and seals with silicon grease.

4. Wash the outside of the generating set using a cleaning agent (water with a mild detergent added, e.g. car shampoo).

5. Rinse liberally with clear fresh water to remove any trace of cleaning product at an operating pressure of less than 120 bar (if using a high-pressure washer, allow a distance of at least 20 to 30 cm between the washer nozzle and the surface to be cleaned).

6. Dry with a soft, absorbent cloth.

The use of abrasives is prohibited.

When cleaning, ensure that the drain holes are plugged.

IMPORTANT RAMIRENT

85

Removable panel

A cleaning foam may be used and wiped off using a soft, absorbent cloth. Stubborn stains may be removed using a suitable solvent (white spirit or equivalent) and wiped off using a soft, absorbent cloth.

Curative treatment will be necessary to eliminate any major scratches. This treatment should be carried out by a trained professional.

M427 CIR 20 EUR 40

Drainage holes

6.4. Exhaust silencer maintenance

Maintenance must only be carried out when the generating set or installation is switched off, and the engine and its components have cooled down.

IMPORTANT

The user must carry out the following checks annually (or more frequently if the installation or operating conditions require):

- check the mechanical performance of the components;

- check the tightness of the various fastenings;

- check that the drainage system operates correctly (cf. condensate collector);

- periodic cleaning of spark arresters if fitted to the silencer;

- periodic check of the catalytic converters (efficiency and condition) if fitted to the silencers.

All repairs must be carried out by qualified personnel.

Removable panel Drainage hole

Drainage holes

Removable panel

RAMIRENT

86

6.5. Testing generating sets

Notes on operation at no load and under load

When operating at no load or low load (< 30% of nominal power), the operating conditions do not allow for optimum operation of the engine. The main causes are as follows:

- The low volume of fuel burned in the combustion chamber leads to incomplete combustion; the resulting thermal energy means that the optimum engine operating temperature cannot be reached.

- Overheated engines have lower compression ratios (low compression ratio without turbocharging), which are defined for full load and not suitable for good combustion at low load.

All of these factors lead to choking of the engine, in particular the piston rings and valves, which leads to:

- accelerated wear and glazing of the cylinder liners;

- loss of sealing of seats, and sometimes sticking of valve stems.

Consequently, operating any turbocharged engine at low load (< 30%) during tests or normal use can only have adverse repercussions on an engine's operation and its service life. Maintenance intervals will have to be shortened to accompany harsh operating conditions. Shortening draining intervals, among other things, will enable you to change the oil more frequently, which will tend to be choked with unburnt particles and contaminated with fuel. A ballast resistor is generally added to limit low load phases and obtain the periodic full loads necessary to unchoke the engine.

Finally, when operating under load, we advise vigilance with regard to the oil breather circuit, and more particularly to engines which have the crankcase vent connected to the turbocharger inlet (risk of oil or oil vapour absorption and accelerated engine speed).

Under load tests

It is recommended to test the generating set under load every month, for a period of around 1 hour after the parameters have stabilised.

The load must be greater than 50% of nominal power (ideally 80%), to ensure unchoking of the engine and to obtain a decent picture of the generating set operation.

Off load test (no load)

This test is not recommended; it should not last longer than 10 minutes and should not be repeated without the monthly test under load. This test only allows you to check for correct engine start-up. It does not allow you to check that the generating set is working properly.

Tests on emergency supply generating sets (only concerns France, see NF E 37-312)

For emergency supply generating sets (GSS), the following tests must be performed:

- periodic checks on the oil, coolant and fuel levels, the engine heating device and the condition of the source used for start-up (battery or compressed air), for example every two weeks;

- automatic starting test with a minimum load of 50% of the nominal power of the generating set when used or on a ballast resistor, for example every 6 months. During this test, the fuel supply cut-off valve, reserved for emergency purposes, must never be used when the generating set is in operation.

RAMIRENT

87

7. Storage/Removal from storage

A generating set which is left unused may have a damaging effect on the engine and alternator. To reduce these effects, it is advisable to prepare and store the generating set correctly.

Storing the engine

- Clean the engine.

- Replace all fluids with protective fluids or fresh fluids.

- For details of storage or removal from storage, refer to the manufacturer's documentation

Storing the alternator

- Store the alternator in a dry place (use of independent radiators is advised to keep the coils dry).

- For details of storage or removal from storage, refer to the manufacturer's documentation

Storing batteries

- Batteries ready for use must be stored in a cool and dry place (frost-free) protected from the sun.

- Batteries must be transported and stored in a vertical position to prevent any risk of acid spillage.

- Leave the terminal cover on the positive terminal.

8. Additional equipment

This section contains general descriptions and maintenance procedures concerning additional equipment which may be fitted to our generating sets.

This equipment is as follows:

- JAPY manual pump;

- JAPY pump assembly;

- REN-RAB automatic oil top up regulator;

- air filters for dusty environments;

- GenPARTS and SEPAR additional fuel filters;

- starter batteries;

- AEES battery chargers;

- cooling towers.

RAMIRENT

88

8.1. JAPY manual pump 8.1.1 Technical specifications

Type Use Composition

EZ 254 Diesel and petrol

Cast iron casing

ZAMAK piston, seat and valves

Stainless steel shaft – counter flanges and mounting lugs

O-ring

HT 254

Hydrocarbons

Maximum viscosity of 300 cst

Cast iron casing

Brass piston, seat and valves

Stainless steel shaft – counter flanges and mounting lugs

O-ring

Figure 70: JAPY manual pump

8.1.2 Maintenance

Fault finding and resolution

- The pump no longer provides suction or is draining:

There is air ingress: check all the seals and suction pipe.

The base valve (suction valve) no longer works: it is likely that there are impurities or some sort of waste under the valve which is preventing it from resting on its seat; check it.

There are impurities inside the pump blocking the valves: remove the cover, clean the inside, check the free play of the valves.

- Leaks from the cable gland:

Tighten the two nuts of the cable gland bracket by one or two turns alternately. If necessary, remove this bracket, remove the cable gland inside its housing. Clean this housing by removing the residues on the lining. Replace the lining with a graphite strap.

In the case of a pump without a cable gland, model 254, remove the cover, replace the O-ring, ensuring that the piston axis is not oxidised. In this case, clean it thoroughly. Also refit the trim on the graphite grease neck.

RAMIRENT

89

Recommendations in the event of frost

The drain screw is ineffective, also unless a special request is made at the time of ordering, the JAPY manual pump has not been equipped with this for a long time. However, if the pump is exposed to frost, it is essential to position a small drain valve on the suction pipe, approximately 0.75 m above the pump. The pipe should be fitted with a base valve; this device is essential if the pump is to be drained correctly.

If frost is likely, do not forget to open this valve, whilst ensuring that the discharge opening is free to allow air to enter.

The draining operation should be performed normally, but for improved safety, after water has flowed out, knock the lever slowly two or three times to complete the draining operation.

If the casing or cover breaks due to frost, do not try to repair it by autogenous welding as this could damage the part.

Recommendations in the event of prolonged inactivity

If the pump remains inactive for a certain amount of time, the following is recommended:

- If there is no threat of frost, ensure that the pump casing is still full of pumped liquid.

- If there is a threat of frost:

Perform the draining operation and if possible, knock the lever several times to prevent the inside components from oxidising, otherwise:

Perform the draining operation and apply vaseline (by spraying if possible) in order to prevent oxidation and to prevent the internal components from jamming.

In the event of oxidation and jamming, never force the lever as this may damage the piston. Remove the cover, clean inside the pump thoroughly with a lubricated cloth, but never with an abrasive. Lubricate slightly before refitting.

The JAPY manual pump does not normally require any lubrication.

After a considerable number of years of service or after being used with water or fluids loaded with impurities or slightly acidic, it is necessary for a mechanic to replace the main internal components.

In general, when the pistons and seats are to be replaced, we recommend a standard pump replacement be performed.

To remove the cover, and in order to be able to check the inside, start by loosening the 6 mounting bolts from this part on the pump body. Then, to remove the cover, alternately hit the discharge pipe and suction pipe using a piece of wood, holding the piston rod and the cable gland bracket in the other hand. It is important to perform these removal operations correctly.

Before refitting, clean the entire interior thoroughly using a cloth, lubricate the parts inside the body slightly with vaseline, refit the piston by pushing it in slowly using a semicircular movement.

Ensure that the suction seat is secure and that the felt tab is correctly in place.

Refit the bolts, retighten the nuts moderately and alternately until they are secure.

RAMIRENT

90

8.2. JAPY electric pump 8.2.1 Technical specifications

Technical data

- Maximum flow rate: 37 L/min

- Maximum pressure: 2.2 bar (with water)

- Rotation speed: 2800 rpm

- Max suction head: 6 m

- Fitted with a bypass

- Operation with discharge cut off 2 to 3 mins max

- IP 55 protection

Figure 71: JAPY JEV pump assembly

Electrical data

- Output: 0.37 kW

- Engine designed for continuous work

- Single phase JEV 10/658: 50 Hz 220 V – 2.4 A – 240 V – 2.1 A

- Single phase JEV 10/658: 60 Hz 208 V – 3.7 A – 277 V – 3.3 A

- Three-phase JEV 11/661: 50 Hz 380 V – 0.8 A – 415 V – 1 A

- Three-phase JEV 11/661: 50 Hz 200 V – 1.5 A – 240 V – 1.6 A

- Three-phase JEV 11/661: 60 Hz 380 V – 0.9 A – 480 V – 1.4 A

- Three-phase JEV 11/661: 50 Hz 208 V – 1.8 A – 240 V – 2 A

Engines are not explosion proof.

Only use JAPY pump assemblies in locations where flammable vapour is not present.

DANGER

Permitted fluids

- Water, fuel, diesel & light oil

- Maximum viscosity of 10 cst at ambient temperature.

RAMIR

ENT

91

Prohibited fluids

Fluids Potential dangers

Petrol Fire, explosion

Flammable liquids with PM below 55°C Fire, explosion

Liquids for human consumption Pollution of fluids

Corrosive chemical liquids Corrosion of the pump

Solvents Damage to trims and seals

8.2.2 Maintenance

The pumps do not have any particular maintenance requirements. Check for leaks around the seals if necessary.

Fault finding and resolution

The motor does not work

Possible causes Actions

No electric current Check the connections

Rotor jammed Remove the pump from the motor.

Look for any foreign bodies

No flow or insufficient pressure

Possible causes Actions

Suction height too high Bring the pump closer to the fluid to be pumped

Foot valve jammed Clean or replace

Filter clogged Clean the filter

Significant load loss Increase the diameter of the pipes

Bypass valve blocked Clean or replace

Air in the suction pipes Check that they are sealed

Fluid leak Check the pipe connections.

Replace the seals

RAMIRENT

92

8.3. REN-RAB automatic oil auxiliary adjuster The REN regulator type RAB 101 -70 is an oil level regulator for all engine power ratings. It keeps the oil level in the crankcase correct. Set to "engine running" oil level, it regulates the level in line with consumption. 8.3.1 Technical specifications

Most models have a low level alarm or stop threshold to inform the user about insufficient oil supply, a drop in the crankcase oil level or potential overfilling.

An integrated oil level threshold triggers an alarm or stops the engine and warns the user that there is an insufficient oil supply, whilst the engine continues to consume.

Figure 72: General view of the regulator

8.3.2 Operation

When the crankcase oil level drops, the float drops and opens the valve.

The open valve allows oil to flow through from the tank to the crankcase via the regulator.

When the desired level is reached in the crankcase, the regulator float rises which causes the valve to close and stops the flow.

The valve has been designed to be self-cleaning and cannot clog.

A 3 mm hole in the regulator is large enough to allow the oil sump to be topped up.

Figure 73: Simplified diagram of valve action

TOP

BOTTOM

Float action

Oil supply

Separation of unitLR857

Low level contacts

RAMIRENT

93

8.4. Air filter for dusty atmospheres Some generating sets are fitted with GenPARTS air filters for dusty environments, for generating sets fitted with MITSUBISHI, JOHN DEERE, VOLVO and CUMMINS engines and DONALDSON air filters for generating sets fitted with other engines. These filters are maintained according to the status of the maintenance indicator present on these filters.

Note: the maintenance indicator may be a DONALDSON indicator or the original engine manufacturer's indicator (for example, MTU engines). The maintenance indicator is fitted on the engine's air inlet duct downstream of the air filter.

DONALDSON maintenance indicator

The maintenance indicator shows the correct point at which the filter cartridge should be replaced. The maintenance indicator is a static pressure measuring device. This measurement is taken at the filter outlet towards the engine. It indicates the air restriction level (resistance to air suction).

Dust particles captured by the filter cartridge gradually increase the filter's level of restriction (resistance to air suction). At a certain restriction level, defined by the manufacturer, the maintenance indicator is activated.

The maintenance indicator must be screwed onto the filter (by hand only).

Recommendations

- Do not assess the condition of a filter based on its visual appearance.

- Maintenance performed too frequently can cause:

damage to the filter cartridge;

the filter cartridge to be incorrectly installed;

dust to accidentally penetrate the engine;

If the air filter is fitted with a dust control valve (A), press the tip of the valve to evacuate any accumulated dust particles.

Check the air filter maintenance indicator (B). If the indicator is red, replace the filter cartridge.

B

A

RAMIRENT

94

The maintenance operations are described below.

These operations must only be performed when the generating set is switched off.

These operations must only be carried out by qualified personnel.

IMPORTANT

1. Remove the cartridge carefully.

2. Thoroughly clean the inside of the filter and the parts in contact with the gaskets using a clean damp cloth.

3. Check that the gaskets on the new filter cartridge

are in good condition and check the elasticity.

4. Refit the new filter cartridge and close the cover carefully.

5. Check the sealing of the entire air inlet circuit.

6. Reset the maintenance indicator by pressing the button marked C, after the filter cartridge has been replaced.

C

RAMIRENT

95

8.5. Additional fuel filters Additional fuel filters are fitted on some generating sets. In addition to the recommendations that appear in the maintenance manuals for the engines (filters fitted by the engine manufacturers), the operations described in this paragraph must be performed. 8.5.1 Diesel filters

8.5.1.1. Filter maintenance

The frequency required to inspect for water and replace the filter element depends on the quality of diesel used and level of contaminants.

In the event of frequent use, the following intervals should be respected:

- Checking for the presence of water:

in the event of power loss, or;

once a day, if necessary.

- Replacing the filter element:

during each oil change, or;

every 500 hours, or;

once per year, or;

in the event of power loss.

Note: it is easy to check for the presence of water in the filter; water has a higher density than diesel, therefore it is found at the bottom of the transparent bowl.

8.5.1.2. Bleeding

1. Stop the generating set and wait until the engine is cold to avoid any risk of fire.

2. Open the bowl's bleed screw (anti-clockwise) and drain the water into an appropriate container.

3. Close the bleed screw (clockwise).

4. Check that there are no leaks from the bleed screw.

8.5.1.3. Filter replacement

1. Stop the generating set and wait until the engine is cold to avoid any risk of fire.

2. Close the isolation valve between the tank and the filter if it is present.

3. Open the bowl's bleed screw (anti-clockwise) and drain the diesel into an appropriate container.

4. Undo the filter cartridge and the bowl by hand (it is strongly recommended not to use a spanner).

5. Undo the bowl of the used filter cartridge. The bowl can be reused.

6. Screw the bowl onto the new filter cartridge.

7. Close the bleed screw (clockwise).

8. Fill the filter cartridge with clean diesel.

9. Lubricate the seals with engine oil.

10. Screw the bowl and filter cartridge assembly onto the top of the filter then tighten the bowl and filter cartridge by hand.

11. Open the isolation valve between the tank and the filter if it is present.

12. Bleed the circuit, start the generating set and check that there are no leaks.

RAMIRENT

96

8.5.2 Separ diesel filters

8.5.2.1. Filter maintenance

The frequency required to inspect for water and replace the filter element depends on the quality of diesel used and level of contaminants.

In the event of frequent use, the following intervals should be respected:

- Checking for the presence of water:

in the event of power loss, or;

once a day, if necessary.

- Replacing the filter element:

in the event of power loss, or;

if the engine speed drops.

Note: it is easy to check for the presence of water in the filter; water has a higher density than diesel, therefore it is found at the bottom of the transparent bowl.

8.5.2.2. Bleeding Note: If two filters are fitted in parallel, deactivate the filter to be bled.

I: left-hand filter activated II: right-hand filter activated

RAMIRENT

97

1. Open the air bleed screw (no. 1) of the filter which is to be bled of water.

2. Release the bleed valve (no. 2) by pressing the button then open it.

3. Allow the water and dirt to drain out of the filter into an appropriate container until clean fuel flows through.

4. Close the bleed valve (no. 2).

5. Undo the bolts on the cover (no. 3) and remove the cover.

6. Fill the filter unit with clean fuel.

7. Fit a new seal in the cover (no. 3).

8. Fit the cover with the seal and tighten the bolts.

9. Refit the filter in the circuit.

10. Close the air bleed screw (no. 1) as soon as fuel flows out.

11. Check the sealing of the filter.

8.5.2.3. Filter replacement Note: if two filters are fitted in parallel, deactivate the filter to be replaced.

I: left-hand filter activated II: right-hand filter activated

1

2

3

RAMIRENT

98

1. Open the air bleed screw (no. 1) of the filter to be replaced

2. Release the bleed valve (no. 2) by pressing the button then open it.

3. Allow the water and dirt to drain out of the filter into an appropriate container until clean fuel flows through.

4. Close the bleed valve (no. 2).

5. Undo the bolts on the cover (no. 3) and remove the cover.

6. Remove the spring unit (no. 4) and the filter cartridge (no. 5).

7. Fit the new filter cartridge (no. 5) and the spring unit (no. 4) in position.

8. Fill the filter unit with clean fuel.

9. Fit a new seal in the cover (no. 3).

10. Fit the cover with the seal and tighten the bolts.

11. Refit the filter in the circuit.

12. Close the air bleed screw (no. 1) as soon as fuel flows out.

13. Check the sealing of the filter.

8.6. Starter batteries

DANGER

Risk of explosion or fire (oxygen and hydrogen present). The battery must never be exposed to any naked flames or sparks.

Risk of sparks forming and an explosion. When fitting the battery, never invert the polarities. Do not short the battery terminals with a tool or other metal object.

Risk of injury. Battery electrolyte is extremely corrosive. Always protect your eyes, skin and clothing when handling batteries. Always wear protective goggles and gloves. In the event of contact with the skin, wash thoroughly with water and soap. If the eyes are splashed, rinse thoroughly with water and consult a doctor immediately.

1

2

3

4

5

RAMIRENT

99

8.6.1 Checking the electrolyte level

The electrolyte level must be approximately 10 mm above the battery plates.

1. Top up with distilled water if necessary.

2. Pour the distilled water carefully to avoid any splashes.

Wear protective goggles and rubber gloves when handling the battery (adding water, charging, etc.).

Note: some batteries requiring no maintenance form the subject of specific instructions which must be respected.

After the battery has been topped up, it must be recharged for at least 30 minutes. 8.6.2 Checking the voltage/acid density

Every 2 months, the following checks must be performed:

1. Check the density of the acid contained in the cells (all the battery cells must have the same density; if this is not the case, the battery must be replaced)

2. Check the voltage when idle.

Acid density Charge status Voltage when idle Observation / action

1.27 100% Above 12.60 V

1.25 80% 12.54 V

1.20 60% 12.36 V From 60% recharge

1.19 40% 12.18 V Risk of sulphation

1.13 20% Below 11.88 V Unusable

The results of the density and voltage measurements make it possible to define the charge status of the battery. If the charge status is less than 60%, the battery must be recharged. 8.6.3 Connecting/disconnecting the battery

To connect the battery:

1. Connect the red connecting cable (+) to the positive battery terminal.

2. Then connect the black cable (-) to the negative battery terminal.

To disconnect the battery:

1. First disconnect the black cable (-)

2. Then disconnect the red cable (+).

RAMIRENT

100

8.6.4 Charging the battery Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard) can no longer regenerate or be charged in a generating set.

A discharged battery should be recharged immediately, or else it will suffer irreparable damage.

IMPORTANT

Battery charge

Example of charge:

- 12V 60 Ah battery = 6 A charging current;

- Charge status: 50% (acid density 1.19 and voltage when idle 12.30V);

- The battery is short 30 Ah, and this must be recharged.

- Charge factor: 1.2;

- 30 Ah x 1.2 = 36 Ah to be charged;

- Charging current: 6A, approximately 6 hours charging required; the charging current must always be 1/10th of the nominal capacity of the battery.

Recharging is complete when the battery voltage and the acid density stop increasing. The power of the charger must be suitable for the battery to be charged and the charging time available. Note: if several batteries connected together are being recharged, the following points must be checked:

- Are the batteries connected in series?

- Is the voltage chosen exact? 1 battery x 12 V, 3 x 36V batteries.

- Adjust the charge current to the lowest battery.

- The power difference between the batteries must be as low as possible.

8.6.5 Cleaning the battery

Keep the batteries clean and dry. The presence of impurities and rust on the battery and terminals may cause the current jumps, voltage drops and the battery to discharge, particularly in humid weather.

1. Clean any signs of oxidation on the battery terminals and the cable terminals using a brass brush.

2. Fully tighten the cable terminals and lubricate them with grease for battery terminals or vaseline. A terminal which is not secured correctly may cause sparks and therefore lead to an explosion.

RAMIRENT

101

8.6.6 Fault finding

Fault observed Probable origin Measures or observations

The acid heats up when a new battery is filled

Incorrect composition Incorrect storage Prolonged storage in a damp place

Cool

Charge the battery

Check the acid density

The acid escapes through the filler holes The battery is too full Reduce the battery fluid level

Acid level too low Battery tray not leaktight Considerable formation of gas due to a very high charging voltage

Replace the battery

Check the charger and repair if necessary

Acid level too low Incorrect operation from start-up

Insufficient charge Short circuit in the power circuit Consumption fault

Recharge the battery

Check the electrical installation

Acid density too high The battery has been filled with acid instead of water

Reduce the acid level and fill with distilled water. Repeat the operation if necessary

Starting problems Starting test incorrect

Battery empty Recharge the battery

Battery exhausted or faulty Capacity too low Battery sulphated

Replace the battery

Battery terminals melted Incorrect electrical connection Battery cabling incorrect

Tighten the ends of the battery cables or replace them if necessary and replace the battery

One or two cells release a lot of gas at high charge

Faulty cell(s) Replace the battery

The battery discharges very quickly

Charge status too low Check the load

Short circuit in the power circuit High self-discharge (for example: through electrolyte contamination) Sulphation (storage of discharged battery)

Replace the battery

Short service life

Incorrect battery part no Define the correct battery part no. for the recommended use

Repeated deep discharging Battery stored too long without charge

It is recommended to charge the battery using a regulator

High water consumption Overload Charging voltage too high

Check the charger (voltage regulator).

The battery explodes

Sparks after battery charging Short circuit Connection or disconnection during charging Internal fault (for example: interruption) and low electrolyte level

Replace the battery

RAMIRENT

102

8.7. AEES battery charger 8.7.1 Function

Battery chargers are charging modules for emergency electrical supplies, adapted to equipment and systems with inrush currents: relays, motors, solenoid valves, automata, audible warning devices, etc. and their constant monitoring, signalling, inspection and control circuits or designed to charge accumulator batteries.

These charger modules associated with batteries comprise battery charger assemblies which make each system safe in the event of mains supply faults.

They permanently supply the equipment (monitoring, signalling, inspection and control) and ensure that the batteries are maintained.

8.7.2 Locating and resolving faults

Observation Charger model (AEES) Probable cause Solution

The green LED is off.

CE-D

Mains 230 VAC absent. Fuse FS (under the charger cover) faulty.

Check for the presence of the supply voltage on terminals 0 230. Replace the fuse If the fault persists, replace the charger.

CN-D and CPN-D

Mains 230 or 400 VAC absent. FS fuse protector or circuit breaker cut-off (external to charger).

Check for the presence of the supply voltage on terminals 0 230 400. Check the FS fuse protector or circuit breaker. If the fault persists, replace the charger.

ACP2 12 ACP3 12 ACP4 24 -5

Mains 230 VAC absent. Upstream fuse or circuit breaker open. Faulty (internal) FS fuse.

Check the mains power supply and the condition of the protective devices. Check the FS internal fuse: 1A-T for ACP2 and 3 2A-T for ACP4.

The output voltage is abnormally low. The red LED is lit (options mD or mM).

CE-D CN-D and CPN-D

Battery has discharged, the charger current is limited. Same cause as above, but the battery has completely discharged.

Remove the F2 output fuse from the charger (external) and check the output voltage on the + - terminals with the battery disconnected: 13.2Vcc for CE-D 13.2Vcc, 26.4Vcc or

52.8Vcc for CN-D and CPN-D.

If the voltage is correct, refit the F2 fuse. Wait until the battery has recharged (the voltage should gradually increase), otherwise replace the charger.

The output voltage is abnormally low, charger operating.

ACP2 12 ACP3 12 ACP4 24 -5

Battery has completely discharged, the charger current is limited.

Check the charger voltage with the battery disconnected: 13.2Vcc for ACP2 and 3 26.4Vcc for ACP4. Wait until the battery has recharged (the voltage should gradually increase). Check the condition of the battery.

RAMIRENT

103

Observation Charger model (AEES) Probable cause Solution

The battery is discharged with the charger's green LED lit.

CE-D CN-D and CPN-D

Faulty F2 fuse (external).

Check the battery connections (+ / - polarities). Replace the F2 fuse. If the fault persists, replace the charger.

The battery is discharged, mains power supply present and charger operating.

ACP2 12 ACP3 12 ACP4 24 -5

Faulty F2 fuse.

Check the battery connections (+ / - polarities). Replace the F2 fuse: 5A-T for ACP2 and 3 10A-T for ACP4. If the fault persists, replace the charger.

The output voltage is abnormally high. The red LED is lit (options mD or mM).

CE-D CN-D and CPN-D

Charger regulation fault. Replace the charger.

The "preheating" function does not work (the yellow "PRE" LED does not light up).

ACP2 12 ACP3 12 ACP4 24 -5

C27 connector not connected properly

Check the potential on the central terminal of the C27 connector: +12Vcc for at least ACP2

and 3 +24Vcc for at least ACP4.

The fault signal is active. The alarm signal is active.

ACP3 12 ACP4 24 -5

The FS fuse is faulty. The F2 fuse is faulty. The charger has caused a surge. The charger is supplied with voltage. Charging fault.

The charger inlet has a short circuit; replace the charger. Check the battery connections (+ / - polarities). Replace fuse F2: 5A-T for ACP3 10A-T for ACP4. If the fault persists, replace the charger. Disconnect the mains power supply then the battery, reconnect the mains power supply then the battery; if the fault is still present, replace the charger. The battery and/or use causes a surge. Disconnect the use and the battery, if the fault is still present without any load, replace the charger. The charger is faulty, replace the charger.

RAMIRENT

104

8.8. Shut-off valve

Damper valves are safety components which close automatically and are reset manually.

All models are equipped with a resetting system comprising:

- either a hexagon shape if using a spanner.

- or a lever to be activated directly.

To reset:

1. Hold the lever or position the spanner on the hexagon shape (we recommend using a ring spanner for improved ergonomics).

2. Slowly but firmly turn in the direction indicated Figure 74: Damper valve models until it is possible to feel the point at which locking begins.

3. Gradually release the pressure: the valve should remain open.

Figure 74: Damper valve models

Genset R66 Genset R350 Genset R550

Model "B" Model "N" Model "F" Model "E"

Hexagon 19 Hexagon 17 Lever Lever or Hexagon 19 or 22

depending on model

RAMIRENT

105

8.9. Air coolers

Before starting any operation:

- Check that the installation has been switched off.

- Ensure that the power supply has been made safe.

- For an operation on the harness, reduce the temperature and the pressure.

Operations should only be carried out by qualified personnel.

IMPORTANT

Regularly check that the harness fins are not clogged and clean as often as local conditions require. Note: The cleanliness of the device is a factor which will determine its performance and length of service life.

As the engines are fitted with an oil vapour recirculation system, the harness should not get greasy. As a general rule, using compressed air directed parallel to the fins should be sufficient to clean the harness.

In all cases, cleaning should be undertaken with care to ensure the surface of the fins is not damaged.

The operating procedure described below is a theoretical operating procedure.

It will have to be adapted to the installation which is actually fitted. If in any doubt, please refer to a specialist.

IMPORTANT

RAMIRENT

106

1. Drain the high temperature (HT) and low temperature (LT) cooling circuits via tapping points in the lower section of the air cooler (drain boss and vents provided on the manifolds or pipes).

2. Remove the flexible pipes connected to the engine.

3. Disconnect the wiring on all the extractor fans (after making the power supply safe), and then remove the fans, starting at the top of the air cooler.

4. Carry out the same procedure for the other fans. 5. Remove the fan support panels.

6. Disconnect the servomotors from the motorised ventilation flap.

7. Remove the motorised ventilation flap to gain access to the harness.

8. Using an industrial vacuum cleaner, remove all foreign bodies that might obstruct the harness. Blow the harness with compressed air, if necessary.

9. If there are any traces of grease, use commercial solvents to clean the harness.

10. Refit the components in the reverse order to removal, then close the circuits and fill the harness with antifreeze coolant.

Motorised

Servomotor connection unit

Servomotors

Drain point LT circuit

Drain point HT circuit

RAMIRENT

107

9. Glossary

AIPR Name given by SDMO to designate an electrical device (cabinet or control unit) housing the master circuit breaker (downstream of the power alternator) and the auxiliary outgoing terminals. The AIPR is generally mounted on the generating set base frame. It is used for housing circuit breakers of 800 A or more.

Auxiliaries

(auxiliary electrical equipment of a generating set)

The electrical auxiliaries of a generating set comprise the electrical equipment which ensures the correct operation of the generating set, in particular that of the heat engine: battery charger, heat engine preheating, electric fuel supply pump, etc.

Bulk tank This is a vessel for collecting generating set leaks, to prevent them from polluting the environment.

Welding seam This is a welding bead.

Box This is the common name given to an ISO container.

Earth terminal

(of a generating set)

Generating set connection terminal identified by a PE marking or by a standardised "Earth" symbol and provided to enable the generating set to be earthed. This terminal is internally connected to the earths of the generating set and, according to the earthing system (SLT), to the alternator neutral.

LV Low Voltage Low voltage A: 50 V <LVA < 500 V alternating current

Low voltage B: 500 V <LVB < 1000 V alternating current

Multipolar cable Cable comprising more than one insulated conductor.

Tripolar cable Multipolar cable comprising three insulated conductors.

Single pole cable Cable comprising a single insulated conductor.

Rotating field

(rotating field check)

Checking the rotating field on a three-phase installation involves checking the rotation direction of the phases using a device (phase rotation tester or rotophaser): when the device pins marked phase 1, phase 2, phase 3 are connected to the corresponding phases of the network being checked, the display on the device makes it possible to check whether the order 1-2-3 indicated by the markings on the tested conductors (terminals, cables) is correct or not.

Classes of application

(or performance)

Classes of application (or performance): G1, G2, G3 and G4.

Standardised performance classes for generating sets defined by standard ISO 8528-1:

They define the particular requirements concerning precision and stability for the voltage and frequency of a generating set during load variations in the installation to be supplied.

- Class G1: for an application requiring minor voltage and frequency constraints;

- Class G2: for an application whose constraints are approximately the same as those of the public network;

- Class G3: for an application imposing severe requirements for stable voltages, frequencies and waveforms (for example: telecommunications and loads regulated by thyristors);

- Class G4: for an application imposing particularly severe stability requirements for voltages, frequencies and waveforms (for example: data processing).

RAMIRENT

108

Output class Output class: COP, PRP, LTP and ESP.

Standardised output class of a generating set defined by standard ISO 8528-1.

ISO corner Standardised fitting on all 8 corners of ISO containers enabling containers to be handled and transported.

IMD Insulation monitoring device.

CSC Container Safety Convention.

International convention governing container safety (or CSC convention), which was rendered in France by Decree no. 80-837 of 20 October 1980 and the orders issued for its application.

These orders define the process for obtaining CSC approval, and list the bodies authorised to issue this approval. This approval, which comes in the form of a standardised plate permanently fixed on each approved container, is obligatory for authorisation of sea transportation. The stacked load that the container can bear is indicated on this plate.

This approval is obtained by the manufacturer, for each container model, by submitting a technical file, subject to validation of standard tests by the approved body.

RCD Residual current device.

Fuel tank filler This is the filling pipe for a fuel tank.

RAMIRENT

109

Differential Residual current device RCD.

Device protecting against the risks of an electric shock based on detecting an abnormal leakage current to earth resulting from an insulation fault in an electrical installation.

This device is provided in order to cut off the power supply to the faulty electric circuit when the leakage current to earth becomes greater than the maximum allocated residual current (sensitivity) of the device. The sensitivity and the activation time may be fixed or adjustable depending on the differential device model.

They can be distinguished according to their sensitivity:

- high sensitivity (≤ 30 mA);

- average sensitivity (100 mA to 1 A);

- low sensitivity (3 A to 20 A).

There are three types of differential device:

- differential circuit breaker;

- differential switch;

- differential relay.

Differential circuit breaker Differential device cutting off the supply to an electrical circuit when a fault current to earth has been detected or in the event of an overload or short circuit.

Emergence

(acoustic)

Difference between the sound pressure level ("sound level") measured at a given location near an operating generating set and the level measured when this generating set is switched off.

ERP Establishment receiving the public.

Power factor:

cos φ *

Parameter specific to an electrical installation at a given moment obtained by dividing the active power P (kW) by the apparent power S (kVA) at this moment. The power factor varies according to the nature of the devices being supplied at a given moment (for example: when powerful electric motors are switched on, the power factor reduces).

In an installation, the active power P (kW) and the apparent power S (KVA) are related to the power factor PF by the relationship: PF = P / S. In an installation comprising various devices in operation (lights, computers, electric heating, lifts, etc.) the power factor is between 0.8 and 1 on average.

* the power factor of an installation is sometimes referred to as the cos PHI (cos φ) of this installation.

Stacking This is the action of placing containers on top of each other

NG Natural gas

GNR Off road diesel

LPG Liquefied petroleum gas

HV High Voltage High voltage A: 1000 V < HVA < 50,000 V alternating current

High voltage B: 50,000 V < HVB alternating current

RAMIRENT

110

Impedance Electrical impedance measures the opposition of an electrical circuit to passage of a sinusoidal alternating current.

The concept of impedance is a generalisation of Ohm's law in the study of alternating current circuits

Differential switch Differential device cutting off the supply to an electrical circuit when a fault current to earth has been detected. Unlike the differential circuit breaker, the differential switch does not provide protection against overloads or short circuits.

LpA Sound pressure level (of a generating set).

The sound pressure level LpA (commonly called "sound level") of a generating set is expressed in dBA and is measured using a standardised method at a given distance from the generating set. It represents the sound intensity emitted by the generating set and detected by the human ear at this point. The sound pressure level depends on the sound power level LWA of the generating set and the distance from the measuring point to the generating set; this distance should therefore always be specified when a sound level is indicated.

- The sound pressure level indicated in the instruction manual for the generating set is measured in a free field 1m away from the generating set, in accordance with the applicable European Directives.

LWA Guaranteed sound power level (of a generating set).

Sound emission level in dBA characterising the acoustic energy radiated by a generating set. The sound power level is a characteristic of the generating set which does not change; it must not be confused with the sound pressure level LpA (sound level).

The marking of the guaranteed sound power level LWA on the identification plate of the generating set designed to be used outside buildings in countries within the European Union meets the requirement of European Directive 2000/14/CE.

Weight Metal part of electrical equipment likely to be touched and which is not normally supplied with voltage but could be in the event of an insulation fault. All the earths of the generating set are connected to an earth busbar equipped with a generating set earth terminal.

Earthing

(of a generating set)

The generating set earthing consists of establishing an electrical connection between the generating set earth terminal and an earth connection or a local earth terminal of an installation using a cable (green and yellow earth conductor which has a cross-section appropriate to the generating set output).

Single phase

(generating set or alternator)

A single phase generating set (or an alternator), supplies the electrical current with a single phase and a neutral (2 poles).

Forklift pockets These are the rectangular apertures in the lower part of a base frame where the forks are inserted to move the generating set.

Exhaust head loss When fluid is flowing in a pipe and energy is lost due to friction, we talk about head loss. RAMIR

ENT

111

MEP Mean effective pressure.

The MEP*, or mean effective pressure, is the pressure which, if it was applied constantly to the piston of a spark ignition engine throughout its power stroke, would make it possible to obtain the same level of work to that which is actually created. This is therefore a false measurement which is used to compare various engines and to determine the application class of the generating set according to standard ISO 8528 (class G1, G2 or G3). The MEP is indicated in Bar or KPa in the technical specifications of fuel engine manufacturers.

* in English: BMEP (Brake Mean Effective Pressure).

Earth connection Conductive current element embedded in the ground to establish an electrical contact with the local earth (for example: earthing rod, earthing electrodes).

Active power (kW) The active power P of a generating set is the real power, measured in kW, supplied by this generating set to an installation. It is the mechanical power of the fuel engine converted into electrical power by the alternator. It is related to the apparent power S (kVA) and the power factor (PF) through the relationship: P (kW) = S (kVA) x PF.

- The nominal active power (kW) which appears on the identification plate of the generating set is the maximum power that the generating set is capable of providing under the operating conditions defined by the output class (COP, PRP, LTP or ESP) assigned by the manufacturer to the generating set and indicated on the identification plate.

Apparent power (kVA) The apparent power S provided by a generating set to an installation is the power calculated in kVA from the current (I) per phase and the voltage (U) between phases independently of the power factor (PF) of the installation. The apparent power is calculated using the following formulas:

- Single phase generating set: S (kVA) = U (V) x I (kA) I (kA) = I (A) / 1000

- Three-phase generating set: S (kVA) = U (V) x I (kA) x √3

Example: a three-phase generating set supplies 400 V between phases and 100 A per phase to an installation. The apparent power S (kVA) = 400 x 0.100 x 1.732 = 69.28 kVA.

- A three-phase generating set is designed and protected (circuit breaker setting) to be able to provide its nominal active power (kW) to an installation whose power factor (PF) can vary from 1 to 0.8.

- The nominal apparent power (kVA) indicated on the identification plate of a three-phase generating set is determined for a nominal power factor (PF) of 0.8 and is therefore equal to the nominal active power (kW) divided by 0.8.

Example: If the nominal active power of a three-phase generating set is 80 kW, the nominal apparent power in kVA is: 80 / 0.8 = 100 kVA.

- When the nominal power factor (PF) indicated on the identification plate of a single phase generating set is 1, the nominal apparent power (kVA) is equal to the nominal active power kW). RAMIR

ENT

112

Continuous power: COP Maximum power in kW that a generating set is capable of supplying continuously under a constant load for an unlimited number of hours per year, under the agreed operating conditions, provided that the maintenance intervals and operating modes are performed according to the manufacturer's requirements.

Legend

t time

P power

a continuous power (100%)

Main power: PRP Maximum power in kW that a generating set is capable of supplying continuously under a variable load for an unlimited number of hours per year, under the agreed operating conditions, provided that the maintenance intervals and operating modes are performed according to the manufacturer's requirements.

The mean admissible power (Ppp) over a 24-hour period must not exceed 70% of the main power, unless otherwise agreed by the manufacturer of the heat engine.

Emergency standby power: ESP

Maximum power available in kW, for a variable power sequence, under the operating conditions specified, that a generating set is capable of supplying up to 200 hours per year if the network energy is interrupted or under test conditions, provided that the maintenance intervals and operating modes are performed according to the manufacturer's requirements.

The mean admissible power (Ppp) over a 24-hour period must not exceed 70% of the emergency standby power, unless otherwise agreed by the manufacturer of the heat engine.

Legend

t time

P power

a emergency standby power (100%)

b mean admissible power for 24 hours

c mean real power over a period of 24 hours

d stop

NOTE: t1 + t2 + t3 + …………….+ tn = 24 hrs

RAMIRENT

113

Limited running time power: LTP

Maximum power in kW that a generating set is capable of supplying up to 500 hours per year, under the agreed operating conditions, provided that the maintenance intervals and operating modes are performed according to the manufacturer's requirements.

NOTE: The limited running time power (100%) is limited to a maximum value of 500 hours per year.

Legend

t time

P power

a limited running time power (100%)

Neutral speed Term sometimes used to designate the earthing system (SLT) of an installation (see paragraph "Neutral system").

Differential relay Differential device which only detects the fault current to earth in an electrical circuit. It is designed to be connected to the control of a circuit breaker which it opens in order to cut off the electrical supply when a fault current is detected.

DT Daily service tank.

Jockey wheel This is the wheel on the boom of a trailer. It may be swivelling and height adjustable.

SLT Earthing system.

(see paragraph "Neutral system").

VLV Very low voltage. VLV < 50 V alternating current

VLV < 120 V alternating current

Phase-to-phase voltage Voltage between any two phases of a three-phase system.

Phase-to-neutral voltage Voltage between neutral and any one phase of a three-phase system with neutral.

LVCCP Low voltage central control panel.

This is a low voltage electric panel for large electrical facilities.

This panel forms the link between the supplier's incoming line and the customer network.

Tracking

(fuel circuit)

Electrical system (for example: heating tape) installed on pipes or fuel tanks to prevent them from freezing.

Three-phase

(generating set or alternator)

A three-phase generating set (or an alternator), supplies the electrical current with three phases (3 poles) or with three phases and a neutral (4 poles).

RAMIRENT

114

Expansion bottle This is used for compensating for volume variations to which the mass of a fluid in the facility is subjected due to temperature fluctuations.

RAMIRENT