Operation & Maintenance Manual for WP6CD Series Marine ... Manual... · II. METHODS ... 10 Speed regulating mode Electric speed regulation/mechanical speed regulation 11 Exciting

Operation & Maintenance Manual for WP6CD

Series Marine Diesel Gen-set

Weichai Heavy Machinery Co., Ltd.

Operation & Maintenance Manual for WP6CD Series Marine Diesel Gen-set

Foreword

Weichai Heavy Machinery Co., Ltd. is China’s appointed manufacturer of various types

of stationary gen-set and marine gen-set.

The manual provides instructions on the installation, operation, maintenance and trouble

shooting of marine gen-set according to the characteristics of WP6CD Series marine diesel

gen-set for user’s safe and reliable operation. Please refer to the Operation Manuals for diesel

engine, power alternator and various special parts in instrument boxes when using this manual,

and operate, service and maintain it in accordance with corresponding requirements.

Along with technical development and product improvement, changes will be made on

this manual accordingly. This manual is subject to revisions and changes from time to time.


Contents

CHAPTER I CODE REPRESENTING METHOD .............................................................. - 1 -

CHAPTER II WORKING CONDITIONS ........................................................................... - 1 -

I. RELIABLE WORKING CONDITIONS........................................................................... - 1 -

II. WORKING CONDITIONS FOR GEN-SET TO OUTPUT RATED POWER ............... - 2 -

CHAPTER III TECHNICAL SPECIFICATIONS AND MAIN PARAMETERS ................ - 2 -

I. MAIN TECHNICAL SPECIFICATIONS ......................................................................... - 2 -

II. MAIN ELECTRICAL PERFORMANCE INDICATORS ............................................... - 2 -

III. GEN-SET PROTECTION PARAMETERS ................................................................... - 3 -

IV．OVERALL DIMENSIONS OF GEN-SET ................................................................... - 4 -

V. GEN-SET OUTLINE DRAWING .................................................................................... - 4 -

CHAPTER IV OVERVIEW OF MAIN STRUCTURES ..................................................... - 6 -

I． DIESEL ENGINE .......................................................................................................... - 6 -

II. AC ALTERNATOR .......................................................................................................... - 7 -

III. INSTRUMENT BOX ...................................................................................................... - 8 -

IV. SOLID BASE FRAME ................................................................................................... - 8 -

CHAPTER V STORAGE AND INSTALLATION ............................................................... - 8 -

I. STORAGE ......................................................................................................................... - 8 -

II. UNPACKING ACCEPTANCE ........................................................................................ - 8 -

III. LIFTING & HANDLING ....................................................................................... - 9 -

IV. INSTALLATION ............................................................................................................. - 9 -

1. Installation of gen-set external pipes ................................................................................. - 9 -

2. Installation of vent-pipe .................................................................................................. - 10 -

3. Installation of fuel pipes ................................................................................................... - 11 -

4. Installation of cooling pipes ............................................................................................ - 12 -

5．Installation of starting system ....................................................................................... - 13 -

6. Other requirements .......................................................................................................... - 13 -

CHAPTER VI GEN-SET ELECTRICAL SYSTEM .......................................................... - 14 -

I. INSTRUMENT BOX ...................................................................................................... - 14 -

1. Local ordinary instrument box ........................................................................................ - 14 -

2. Local self-starting instrument box ................................................................................... - 18 -


3. New style local ordinary instrument box ........................................................................ - 22 -

4. New style local self-starting instrument box ................................................................... - 26 -

5. Onboard instrument ......................................................................................................... - 30 -

6. Accelerator servo mechanism .......................................................................................... - 33 -

II. ALTERNATOR ............................................................................................................... - 35 -

CHAPTER VII OPERATION ............................................................................................. - 36 -

I. PREPARATION ............................................................................................................... - 36 -

II. COMMISSIONING ........................................................................................................ - 36 -

CHAPTER VIII PARALLEL OPERATION ....................................................................... - 38 -

I. CONDITIONS FOR PARALLEL OPERATION ............................................................ - 38 -

II. METHODS ..................................................................................................................... - 38 -

III. LOAD TRANSFER IN PARALLEL ............................................................................ - 39 -

IV． DISCONNECTION OF PARALLEL GEN-SET ..................................................... - 39 -

CHAPTER IX PRECAUTIONS ......................................................................................... - 40 -

CHAPTER X ANALYSIS OF COMMON FAULTS AND TROUBLESHOOTING ........ - 41 -

CHAPTER XI RULES FOR SAFE OPERATION ............................................................. - 42 -

CHAPTER XII SERVICING AND MAINTENANCE ...................................................... - 42 -

ANNEX I: LIST OF TOOLS DELIVERED WITH GEN-SET (EX-FACTORY STANDARD

CONFIGURATION) ........................................................................................................... - 45 -

ANNEX II: LIST OF SPARE PARTS DELIVERED WITH GEN-SET (EX-FACTORY

STANDARD CONFIGURATION) ..................................................................................... - 46 -

Operation and Maintenance Manual for WP6CD Series Marine Diesel Gen-set

- 1 -

Chapter I Code Representing Method

Chapter II Working Conditions

I. Reliable working conditions

Gen-set can operate reliably under following conditions:

Table 2-1 Working Conditions

1 Ambient temperature 45C

2 Outboard water

temperature

32C (Outboard water temperature of gen-set in limited navigating zone

and under corresponding conditions shall be 25C.)

3 Relative air humidity 60%

4 Absolute atmosphere 100kPa

5 Transverse inclination 15°(22.5° for emergency gen-set and inland vessel)

6 Longitudinal

inclination 7.5° (10° for emergency gen-set and inland vessel)

7 Rolling 22.5°

8 Pitching 10°

9 Able to bear the vibration and shock generated during normal sailing.

10 Having salt fog, mould, oil mist, condensing fog, damp air.

CCF × ×

Code of navigation zone applicable to gen-set , W for unlimited navigation zone and Y for limited navigation zone

Gen-set classification code, J for basic type, Z for automatic type and Z for emergency type

Gen-set rated power code representing in kW

Current classification code, J for AC and Z for DC

Marine diesel gen-set code

Factory design code, represented in capital lettersranging from A to Z


- 2 -

II. Working conditions for gen-set to output rated power

Gen-set should be able to continuously output rated power under following working

conditions:

a For gen-set in unlimited navigating zone: ambient temperature 45C, primary cooling

water temperature 32C, relative humidity 60%;

b For gen-set in limited navigating zone and under corresponding conditions: ambient

temperature 40C, primary cooling water temperature 25 , re℃ lative humidity 60%.

Chapter III Technical Specifications and Main Parameters

I. Main technical specifications

Table 3-1 Main technical specifications

II. Main electrical performance indicators

Table 3-2 Main electrical performance indicators

Serial Items Electrical indicators

Serial No. Items Contents

1 Mode of gen-set CCFJ90J-W* CCFJ100J-W* CCFJ120J-W*

2 Diesel engine mode WP6CD132E200 WP6CD152E200

3 Rated power(kW) 90 100 120

4 Rated voltage (V) 400/230

5 Rated frequency (Hz) 50Hz

6 Rated current (A) 163 181 217

7 Rated power factor 0.8 (lagging)

8 Rated speed (r/min) 1500r/min

9 Starting mode Electric motor

10 Speed regulating mode Electric speed regulation/mechanical speed regulation

11 Exciting mode Brushless self-excitation

12 Voltage regulating mode Automatic

13 Wiring mode Three-phase four-wire Y-connection

14 Cooling method Opening type bi-circulating water cooling

15 Remarks 60 Hz diesel gen-set can be used as required by the customer


- 3 -

No.

1 Steady-state voltage regulation

factor ±2.5% (for emergency gen-set ±3.5%)

2 Transient voltage regulation factor -15% transient voltage regulation factor +20%

3 Voltage stabilization time 1.5s

4 Voltage fluctuation ratio ±1%

5 No-load voltage setting range ≥±5% rated voltage

6 Steady-state speed regulation factorElectronic speed regulation 3%/(mechanical speed

regulation 5%)

7 Transient speed regulation factor ±10%

8 Stabilization time 5S

9 Speed fluctuation ratio ±0.5%

10 110% rated load operating for 1 hour is allowed by gen-set continuously running for each 12

hours

11

Two gen-sets can maintain long-term stable parallel operation. It can maintain stable operation

and steadily transfer active power and reactive power when the load varies within 20%-100% of

total rated power against rated power factors; the active power sharing unbalance is not greater

than 15% of alternator’s rated power and reactive power sharing unbalance is greater than 10% of

alternator’s rated reactive power.

III. Gen-set protection parameters

Table 3-3 Gen-set protection parameters

Serial

No. Alarm description Alarm value Remarks

1 Speed is high 110% rated speed Alarming

2 Oil pressure is low 0.15±0.02Mpa Alarming

3 Water temperature is high 95+3C Alarming

4 Oil temperature is high 120+3C Alarming

5 Speed is too high 115% rated speed Alarming and shutdown

6 Oil pressure is too low 0.12±0.02Mpa Alarming and shutdown

7 Storage battery voltage is low <19V Alarming

8 Fuel leakage alarm (optional) Alarming, and fuel leakage

alarm apparatus required


- 4 -

IV．Overall dimensions of gen-set

Table 3-4 Overall dimensions of gen-set

Gen-set Model L*W*H (mm) Weight (kg)

CCFJ90J-W*

CCFJ90J-WF 2150×1020×1400 1500

CCFJ90J-WJ 2150×1020×1400 1375

CCFJ90J-WV 2150×1020×1400 1385

CCFJ90J-WR 2150×1020×1400 1387

CCFJ90J-WZ 2150×1020×1400 1480

CCFJ100J-W*

CCFJ100J-WF 2150×1020×1400 1550

CCFJ100J-WJ 2150×1020×1400 1375

CCFJ100J-WV 2150×1020×1400 1385

CCFJ100J-WR 2150×1020×1400 1425

CCFJ100J-WZ 2150×1020×1400 1480

CCFJ120J-W*

CCFJ120J-WF 2250×1100×1400 1595

CCFJ120J-WJ 2250×1100×1400 1405

CCFJ120J-WV 2250×1100×1400 1485

CCFJ120J-WR 2250×1100×1400 1483

CCFJ120J-WZ 2250×1100×1400 1485

Note: “*”in “W*” represents the alternator to be used for the diesel gen-set. “*” can be

replaced by E, I, U, Q, Y, among which, F represents LD alternator, J represents Marathon

alternator, V represents Stanford alternator, R represents Kangfu alternator (formerly known

as Sanbo alternator) and Z represents Wuxi Siemens alternator.

V. Gen-set outline drawing

Outline drawing examples of CCFJ90J-W*/CCFJ100J- W*/CCFJ120J- W* marine diesel

gen-set (standard configuration: equipped with ordinary instrument box) are as shown in

Figure 3-1, Figure 3-2, Figure 3-3, Figure3-4 and Figure 3-5 (relevant drawings of other

configurations can also be provided according to customer’s requirements):


- 5 -

Figure 3-1 Front view Figure 3-2 Left view

Figure 3-3 Rear view Figure 3-4 Right view

①Belt

Fuel oil return opening

E engine oil filler

Intercooler cooling water inlet

Intercooler cooling water outlet


- 6 -

Figure 3-5 Top view

Chapter IV Overview of main structures

I． Diesel engine

Diesel engine is the power source of gen-set and this unit adopts Weichai WP6CD series

alternator (please refer to Operation and Maintenance Manual for WP6CD Series Gas

Alternator for detailed structure principles). Main technical specifications of the diesel engine

are shown in Table 4-1:

Table 4-1 Main technical specifications of diesel engine

Serial

No.

Model

Items WP6CD132E200 WP6CD152E200

1 Model In-line, four-stroke, water cooling, direct

injection, pressurization, intercooling

2 Number of cylinders 6

3 Cylinder diameter/stroke mm/mm 105/130

4 Rotation of crankshaft (towards the end of

flywheel) Anticlockwise

5 Declared speed r/min 1500

6 Declared power kW 120 132

7 Piston total displacement L 6.75

8 Compression ratio 17:1


- 7 -

9 Start-up mode Electrical starting/pneumatic starting

10 Electric motor starting power kW 6

11 Starting battery capacity Ah 100*2

12 Starting cable mm2 70(mm2)

13 Fuel consumption under rated conditions

g/kW.h 200±5%

14 Fuel type Domestic 0# or -10# light diesel oil (GB252)

15 Fuel system Mechanical/electrical pump

16 Engine oil grade CF or above

17 Maximum oil volume of oil pan L 18

18 Inlet air flow under rated condition kg/h 572

19 Exhaust back pressure kPa ≤6

20 Exhaust flow under rated conditions 595

21 Exhaust temperature before turbine C ≤700

22 Exhaust temperature after turbine C ≤580

23 (standard configuration) sea water pump flow

L/min 316

24 (standard configuration) sea water pump lift 15

Note: this table mainly describes relevant parameters of WP6CD Series 1500r/min

marine diesel engine. For this series, 1800r/min diesel engine can be used for 90-120kW/

60Hz and below gen-set if required by the customer.

II. AC alternator

Alternator is a kind of equipment which is able to convert mechanical energy into

electric energy. Please refer to alternator manual for detailed structure principles. Main

technical specifications are shown in Table 4-2:

Table 4-2 Main technical specifications

Serial No. Item Value Remarks

1 Rated voltage V 400

2 Rated frequency 50

3 Rated power factor cosφ 0.8 (legging)

4 Rated current A I=1.804P

5 Insulation grade F/H

6 Protection level IP23

7 Exciting mode Brushless self-excitation


- 8 -

8 Outgoing line Three-phase Y-connection

9 Bearing type Rolling bearing

10 Radio interference level Level N

11 Anti-condensation heater 220V

12 Stuffing box outlet direction In the left (seeing from diesel engine to

alternator)

13 Steady-state short circuit

current 3-5times rated current, duration 5s

14 Over-current features 1.5 times rated current, last for 2 min

15 Cooling method Self-ventilation

Note: alternators operating at other voltage levels and with 1800r/min speed

(corresponding rated frequency 60 Hz) may be selected as required by the customer.

III. Instrument box

Please refer to “Instrument box” in “Chapter VI Electric System of Gen-set” for detailed

structure functions.

IV. Solid base frame

The common chassisshall be made from bent steel plate.

Chapter V Storage and Installation

I. Storage

Storage yard shall be well ventilated with no acid gas, alkaline gas and other corrosive

gases and protected from the sun and rain. The factory guarantees that gen-set can be stored

for half a year after delivery, in case of more than half a year, proper treatment measures shall

be taken, such as alternator winding insulation measurement, moisture removal as the case

may be.

II. Unpacking acceptance

Unpacking method: remove connections between packing case housing and the bottom

of packing case and use lifting tools to open the case. Note: a person shall be assigned to

support the packing case housing with hand during lifting to protect exposed parts of gen-set

from being damaged by packing case housing. Generally, gen-set shall undergo unpacking

acceptance after arriving in delivery destination. Acceptance method and personnel shall be in

accordance with contract specifications. As the basis of acceptance, “packing list” shall be put

in same document pocket with other documents to be provided with the unit.


- 9 -

Basic acceptance items are:

Appearance inspection: check whether exposed parts are damaged by visual inspection

or whether there is collision, deformation and other abnormal phenomena and make records;

Check accompanying documents according to the list of accompanying documents

and make records;

Check the spare parts according to the “list of accompanying spare parts” and make

records;

Check accompanying tools according to the “list of accompanying tools” and make

records.

In case that gen-set has any damages in appearance and accompanying spare parts,

attachment, documents and tools are inconsistent with the list. The consigner and

carrier shall be informed within 24 hours by fax or telephone after acceptance for

claims.

III. Lifting & handling

Steel wire rope shall have enough strength, and carrying capacity of lifting tools shall

meet safety specifications. Each steel wire rope shall be in the same length to avoid tilting

during lifting.

Steel wire rope shall be attached onto the lifting position of gen-set packing case base.

When bare machine is lifted, steel wire rope shall be attached onto the lifting position of

the common chassis of the generating unit. Contact between steel wire rope and other gen-set

components shall be prohibited, if not, separate them with a board. Cover lifting shall be

stopped if contact parts are small or non-bearing parts, and try again after changing the length

of rope or adding support to change force bearing point. Please contact us for any questions.

IV. Installation

1. Installation of gen-set external pipes

Installation of various gen-set pipes shall abide by following rules:

External pipes and gen-set shall be connected by flexible hose.

Sharp turn shall be avoided on the pipe line, and bend & tee shall be avoided in most

cases.

For the convenience of maintenance, valves shall be installed in proper position.


- 10 -

Pipes shall be reliably secured on the support. Measures should be taken to relieve

stress generated by expansion and contraction of pipelines.

After the completion of gen-set installation, oil supply and water supply can only be

allowed after pipes are totally cleaned. Test run shall be carried out for checking

whether various pipes meet relevant requirements, pipeline pressure drop is too large,

pump drive capability is enough and cooling water flow meets operating

requirements. Otherwise, pipes in larger size shall be used.

2. Installation of vent-pipe

(1) Installation of vent-pipe shall abide by following rules:

a. Vent-pipe dead-weight shall be reliably supported, and it is strictly prohibited to use

supercharger to bear vent-pipe weight. Generally, fixed support shall be located 1m away

from expansion joint to prevent stress generated by vent-pipe gravity, thermal expansion or

transversal displacement from being transferred to supercharger. Diesel supercharger shall be

provided with precise bearing and impeller and has high speed. In case that supercharger

exhaust flange bears too much bending moment, supercharger shaft will be deformed and

normal operation of supercharger is disturbed with noise which finally leads to the damage of

supercharger.

b. External vent-pipe shall be made from steel tube without too many turns and shall be

fixed tightly on ship body with no vibrations. Its weight shall not be applied on diesel

expansion pipe. Exhaust back pressure of diesel engine shall be not greater than 6kPa after the

completion of exhaust system installation. Otherwise, diesel engine performance will be

affected. As diesel vent-pipe surface temperature is high during operation, vent-pipe shall be

kept away from flammable objects to avoid worker scald. Thermal insulation apparatus shall

be mounted on the surface of external exhaust pipes.

c. Exhaust silencer shall be installed on the end of vent-pipe to reduce influence of

exhaust noise.

d. There is vapor generated in the process of diesel oil burning, therefore, condensate

water drain valve shall be installed on vent-pipe to discharge condensate water in vent-pipe.

Condensate water drain valve shall be located as low as possible on the pipe close to diesel

engine.

(2) Diffuser pipe and vent-pipe diameter

The size of the bellow expansion joint provided by the manufacturer is not exactly the

same as the diameter of vent-pipe. Sometimes, a 500-800mm long diffuser pipe with


- 11 -

increasing diameter is needed, which is also used as a connector to reduce airflow resistance.

Diffuser pipe can be made from 3-5mm sheet steel.

(3) Exhaust silencer

Exhaust noise is generated when diesel combustion emission is discharged from exhaust

valve to vent-pipe, which always causes exhaust gas vibration and pressure wave. Pressure

wave is the mixture of many waves of different lengths and amplitudes. These wave lengths

(frequency) and amplitudes (loudness) are all within the recognizable range of human ear.

Exhaust silencer can consume and absorb the energy of pressure wave to reduce pressure

wave amplitude of exhaust gas discharged from exhaust silencer. Most diesel exhaust silencer

reduces acoustics energy by reflecting the pressure wave. Generally, increase of silencer

dimension will improve noise reduction effect. If there is limitation on silencer dimension,

increase of silencer decay degree will result in increase of exhaust resistance. Therefore,

proper silencer shall be selected according to the resistance of exhaust system.

Exhaust silencer is not covered in standard supply scope. The user can purchase in the

market or order from us.

3. Installation of fuel pipes

Installation of fuel pipes shall abide by following rules:

a. Volume of fuel tank for everyday use can keep gen-set continuously running for at

least 8h.

b. Oil tank shall be made aluminum sheet, phosphatization steel plate, and reinforced

plastic plate instead of galvanized steel plate.

c. Contact between oil return pipe and high temperature components (such as vent-pipe,

turbocharger, exhaust gas return pipe) of diesel engine shall be avoided during installation.

Throttling area is not allowed in oil return pipe. Return pipe shall not contact with sharp edges,

be bended with sharp corners or distorted. Improper installation of return pipe will lead to fuel

leakage on alternator. Fuel return pipe shall be connected to fuel tank with returned oil

flowing along with the tank wall to reduce eddying flow. The return oil of WP6CD series

diesel engine is internal return oil passed through cylinder head (Figure 5-1). Oil injector

mounting hole in cylinder head can ensure that return oil can be fully sealed.


- 12 -

Figure 5-1 Oil return method

d. Diesel engine inlet and outlet fuel pipe shall be equipped with stop valve for the

convenience of maintenance.

4. Installation of cooling pipes

Proper installation of cooling system plays an important part in diesel engine service life

and performance. Please read the operating principles and installation precautions of cooling

system to ensure the design and installation of gen-set external pipes meet following

requirements:

(1) Diameter of inlet and outlet pipes shall meet relevant requirements of gen-set.

Large diameter pipes shall be used when too many lengthy pipelines are required. Excessive

resistance of pipeline system will lead to insufficient flow of cooling water; therefore, the

diesel engine is lack of sufficient cooling water which causes abnormal operation of the diesel

engine. Elbows and tees shall be minimized.

(2) Pump suction pipe shall be as short as possible to guarantee that pump water inlet

pressure is greater than atmospheric pressure (i.e. positive pressure). Negative pressure will

cause pump gas etching and insufficient cooling water flow which cause abnormal operation

of pump.

(3) Pipeline system must be equipped with exhaust apparatus to discharge air in pipeline.

(4) Purchase a new pump when the lift of the pump supplied with the unit can not satisfy

pipeline lift requirement.

(5) Preservative must be added to cooling water in closed cooling system. Filter screen

shall be mounted on water suction pipe mouth in open type cooling system to protect

intercooler and oil/water cooler from being blocked by dirts.

Injector oil

return hole

O-ring sealing

oil return

Seal ring

Internal oil return through cylinder head


- 13 -

Figure 5-2 Circulating cooling system diagram

5．Installation of starting system

Sectional area of cables (multi-core copper flexible cable) between starting engine and the

battery shall be not less than 70mm² and the length shall not exceed 1.5m. Our standard

marine diesel gen-sets are all equipped with starting battery cable.

6. Other requirements

a. A 1m maintenance space shall be reserved around gen-set.

b. Foundation of gen-set shall be firm and has no deformation during installation and

operation of gen-set. During installation, level gauge shall be used to measure the levelness of

foundation installation surface which should be leveled up with flat gasket to ensure that the

gen-set can be placed horizontally. Gen-set shall be fixed with foundation bolt and its classis

undersurface shall be in good contact with the ground during installation, in case of gaps, use

thin iron sheet to level them up to guarantee the concentricity of diesel engine and alternator

axial lead.

c. Diesel vent-pipe shall extend outboard to facilitate ventilation, and vent-pipe bending

Sea water inlet

Diesel engine intake

Sea water outlet

Intercooler Fresh water

pump

Diesel engine

Small circulation

Diesel engine effluent

Box-type fresh water heat exchanger

Fresh water filler

Thermostat


- 14 -

angle shall be not less than 90° without too many bends. Inner diameter of external vent-pipe

shall not be less that the inner diameter stipulated in Diesel Engine Operation and

Maintenance Manual. Vent-pipe shall not be too long and satisfy fire protection requirements.

Vent-pipe and the diesel engine shall be in flexible connection instead of rigid coupling. Water

drain valve shall be installed at the lowest position of vent-pipe in order to guarantee the

smooth discharge of condensate water in vent-pipe. For other requirements, follow the Diesel

Engine Operation and Maintenance Manual.

d. The cabin shall be equipped with intake channel and exhaust channel. There shall be no

obstacles obviously hindering the airflow.

e. If ambient environment of gen-set in the winter is lower than 0C, anti-freezing solution

shall be added into gen-set cooling system.

f. Fuel tank separate from gen-set shall be 0.5m above the ground.

g. Sectional area of gen-set major loop connecting cable shall meet relevant current

requirements.

h. Gen-set must be equipped with ground lead and reliably grounded.

Chapter VI Gen-set electrical system

I. Instrument box

Please refer to Operation Manual for Diesel Engine Monitoring and Control Instrument

delivered with gen-set for main operation and maintenance instructions for instrument box.

Brief introduction to several common instrument boxes is hereunder provided. We can also

produce special instrument boxes according to customer’s special requirements.

1. Local ordinary instrument box

Local ordinary instrument box of WP6CD Series marine diesel gen-set is a

microcomputer-controlled full-automatic electronic measurement and control system for the

diesel engine and alternator which precisely detects and displays diesel engine speed, oil

pressure, water temperature, oil temperature, pressure and other parameters, and monitors all

detected parameters to send out audible alarm, visual alarm, remote alarm and other signals in

real time. In addition, it is provided with starting and stopping functions. So it will send out

shutdown signal when the parameter exceeds shutdown limit. Meanwhile, remote displayer or

diesel engine remote display instrument can also be used to realize remote monitoring and


- 15 -

control of diesel operating parameters. There are several indicators on instrument box which

can display the operating status and functional status of gen-set in real time. Instrument box is

characterized by advanced design, high measurement precision, reliable operation, small size,

digital display, precise and clear display, and easy installation.

Figure 6-1 Standard ordinary local instrument panel

6-1 Local ordinary instrument panel

(1) Operating function

Table 6-1 Local ordinary instrument function

Serial

No. Name Function description

1 Power switch Turn on this switch to power on the instrument box.

2 Local/remote

control Selection of diesel control position.

3 Starting Instrument box will send out signals to start the diesel engine by pressing this

button.

4 Idling/rated When the switch is in “rated” position, diesel engine runs in high speed;

When the switch is in “idling” position, diesel engine runs in low speed.

5 Shutdown Instrument box will send out shutdown signal to shutdown the diesel engine

forcefully by pressing this button.


- 16 -

6 Emergency

shutdown

When diesel engine shutdown and emergency shutdown functions are used,

this button has self-locking function. Press this button to close fuel magnetic

valve and shut down the diesel engine forcefully. Press this button again after

the diesel engine is completely stopped to open fuel magnetic valve for next

starting.

7 Speed fine

adjustment Diesel speed fine adjustment

8 Self-inspection

Press this button when there is no rotation, various channels of instrument box

will simulate external changing conditions to carry out self-inspection items

one by one. Instrument box will send out audible and visual alarm signal when

alarm setting value is reached, and instrument box will send out automatic

stopping signal when stopping setting value is reached.

9 Silencer Press this button when there is alarm signal, and the audible alarm will be

turned off and alarm light keeps shining and stop blinking.

10 Timekeeping Press this button, and speed display window shows the accumulative running

time of diesel engine. Speed will be displayed after 5 sec.

11 Reset Press this button to reset instrument box

Please refer to accompanying document Operation Manual for Diesel Engine

Monitoring and Control Instrument for more function descriptions and usage information.

(2) Local ordinary instrument box alarm protection function

Table 6-2 Local ordinary instrument box alarm protection function

Serial


1 Speed is high 110% rated

speed Audible and visual alarm

2 Oil pressure is low 0.15±0.02Mpa Audible and visual alarm

3 Water temperature is

high 95+3C Audible and visual alarm

4 Oil temperature is high 120+3C Audible and visual alarm

5 Speed is too high 115% rated

speed Audible and visual alarm and shutdown

6 Oil pressure is too low 0.120.02Mpa Audible and visual alarm and shutdown

7 Battery voltage is low <19V Audible and visual alarm

8 Fuel leakage alarm

(optional)

Audible and visual alarm; fuel leakage alarm

apparatus is required


- 17 -

(3) Local ordinary instrument wiring diagram

Figure 6-2 a) Local ordinary instrument wiring diagram

Figure 6-2 b) Local ordinary instrument wiring diagram

Wiring diagram

Excitation voltage

Onboard alternator

Pow

er supply-

Pow

er supply+

Starting motor

Rem

ote high/low speed control

Control position signal output

Diesel operation signal output

Com

prehensive alarm output

Fuel leakage alarm

input

Outage m

agnetic valve

Double output during

pneumatic starting

Rem

ote starting

Rem

ote emergency

Rem

ote shutdown

Shunt passive alarm contact, contact to central control room

Microcomputer self-starting controller

Alarm when speed

is high

Relay board

Stop when water

temperature is high

Battery undervolta

ge Alarm

when oil temperature is high

Alarm when water

temperature is high

Alarm when oil

pressure is low

Fuel leakage

Rated speed

Successfulstarting

Stop indication

Stop when oil pressure is low

Stop when speed is

high

Alarm when speed

is high

Stop when water

temperature is high

Battery undervolta

ge

Alarm when oil

temperature is high

Alarm when water

temperature is high

Alarm when oil

pressure is low

Fuel leakage

Rated speed

Successfulstarting

Stop indication

Stop when oil pressure is low

Stop when speed is

high


- 18 -

2. Local self-starting instrument box

Local self-starting instrument box (hereinafter referred to as instrument box) of WP6CD

Series marine diesel gen-set is a microcomputer-controlled full-automatic electronic

measurement and control system. The whole system has functions of distribution panel loss of

power status monitoring, automatic starting of diesel engine, automatic monitoring and

measurement of working conditions, output of diesel alternator automatic switching on and

tripping signals, automatic stop, limit protection and other basic monitoring and control

functions. Control of speed-up and speed-down, preheating of cooling water and lubricating

oil and electronic speed regulating control can also be configured for the diesel engine on the

basis of basic functional configuration. Meanwhile, remote display or diesel remote display

instrument can also be configured to perform remote monitoring and control of diesel

operating parameters. There are various indicators on instrument box which displays gen-set

operating status and functional status in real time. In addition, many ways are available for the

communication between instrument box and cabin distribution panel to realize remote control

of the operation, remote monitoring and measurement, remote RS485 communication so as to

form a highly automatic marine diesel generating station.

Figure 6-3 shows standard local self-starting instrument box operation panel

Figure 6-3 Self-starting instrument panel

(1) Operation function


- 19 -

Table 6-3 lists the operation functions of local self-starting instrument

Table 6-3 Operation functions of local self-starting instrument

Serial


1 Power switch Turn on this switch to power on the instrument box.

2

Manual/

automatic

switching

Local operation can be performed when the switch is in “manual”

position.

Gen-set is in standby status when the switch is in “automatic” position

to automatically supply power for startup or stop power supply for

shutdown according to instructions from switch panel.

3 Starting Self-starting instrument box will send out signals to start the diesel

engine by pressing this button.

4 Idling/rated

When the switch is in “rated” position, diesel engine runs in high

speed;

When the switch is on “idling” position, diesel engine runs in low

speed.

5 Shutdown Press this button to stop the diesel engine forcefully.

6 Emergency

shutdown

Operator can manually shut down the diesel engine in emergency

cases by pressing this button. Actuator can be controlled manually to

cut down the fuel pipe by this button so as to shut down the diesel

engine and open the main switch of gen-set forcefully.

7 Speed up/speed

down Diesel engine speed fine adjustment

8 Voltage fine

adjustment Alternator voltage fine adjustment

9 Heating switch

When gen-set is in standby status, open this switch and the heater

works after being charged. When diesel engine is started or in

operation, the heater will be automatically switched off and stop work.

10 Self-inspection

Press this button when there is no rotation, self-starting instrument

box will simulate external changing conditions to carry out

self-inspection items one by one. Audible and visual alarm signal will

be sent out when alarm setting value is reached and automatic

stopping signal will be sent out when stopping setting value is

reached.

11 Silencer Instrument box can send out audile and visual alarm signals when

diesel engine working condition is out of limit or the diesel engine


- 20 -

fails to start for three times, and relevant alarm indicators on the panel

twinkles; meanwhile digital display window corresponding to digital

displayer twinkles. Press “Silencer” button, and audible alarm will be

turned off and alarm light keeps shining and stop blinking until the

operation returns to normal conditions.

12 Timekeeping Press this button, and speed display window shows the accumulative

running time of diesel engine. Speed will be displayed after 5 sec.

13 Reset

In case that diesel engine fails to start for three times and stops

because limit protection is triggered, it represents that the diesel

engine is faulty and needs to be repaired. In case that gen-set is to be

started after troubleshooting, press “reset” button to notify the

instrument box that the fault is eliminated. At this time, controller will

cancel alarm signal and put gen-set into operation again.



(2) Alarm protection function

Table 6-4 Self-starting instrument alarm function

Serial

No.

Alarm description Alarm value Remarks


speed

Audible and visual alarm

2 Oil pressure is low 0.15 ±

0.02Mpa



high

95+3C Audible and visual alarm

4 Oil temperature is high 120+3C Audible and visual alarm


speed

Audible and visual alarm and shutdown

6 Oil pressure is low 0.12 ±

0.02Mpa

Audible and visual alarm and shutdown

7 Battery voltage is low ＜19V Audible and visual alarm

8 Starting fails three

times



(optional)

Audible and visual alarm, and fuel leakage alarm



- 21 -

(3) Local self-starting instrument box wiring diagram

Figure 6-4 a) local self-starting instrument box wiring diagram

Figure 6-4 b) local self-starting instrument box wiring diagram

Alarm when speed is high

Alarm when oil pressure is

low

Alarm when water

temperature is high

Alarm when oil

temperature is high

Battery

undervoltage

Fuel

leakage

Failure

starting

Microcomputer self-starting controller

Speed Oil pressure

Oil temperature

Water temperature

Oil

temperature

sensor

Speed sensor

Oil

pressure

sensor

Water temperature

sensor

Remote control 10-core aviation plug

Remote control 5-core aviation plug

Alarm

when speed

is high

Battery

undervoltage

Alarm when oil

temperature is high

Alarm when

water

temperature is

high

Alarm when oil

pressure is low

Fuel

leakage

Failure

starting

Alarm when oil

pressure is low

Relay board


- 22 -

Figure 6-4 c) local self-starting instrument box wiring diagram

3. New style local ordinary instrument box

On the basis of original WP6CD marine diesel gen-set local ordinary instrument panel,

our company has launched new style local ordinary instrument box by optimizing instrument

box components and parts, its functions and redesigning appearance. New instrument box has

more beautiful appearance, firm installation, reasonable functional design, beautiful wiring

layout and convenient plug connectors. Instrument box is a microcomputer-controlled

full-automatic electronic measurement and control system of diesel engine and gen-set which

precisely detects and displays diesel engine speed, oil pressure, water temperature, oil

temperature, water pressure and other parameters and monitors all detected parameters

according to user’s settings and sends out audible alarm, visual alarm, remote alarm and other

signals. If there is a stop setting, it will send out shutdown signal when the parameter exceeds

shutdown value. Meanwhile, remote displayer or diesel engine remote control display

instrument can also be provided to realize remote monitoring and control of diesel engine

operating parameters. There are several indicators on instrument box which can display the

operating status and functional status of gen-set in real time. Diesel engine instrument box

also has diesel engine running time accumulation function. It can also provide extended

alarms, diesel engine operating parameter and computer data communication functions

according to user’s special requirements.

Figure 6-5 standard new style ordinary local instrument panel


- 23 -

Figure 6-5 New style local ordinary instrument panel


Table 6-5 New style local ordinary instrument function

Serial


1 Power switch Turn on this switch to power on instrument box.

2 Local/ remote

control Selection of diesel engine control position.

3 Starting Instrument box will send out signals to start the diesel engine by pressing this

button.

4 Idling/rated When the switch is in “rated” position, diesel engine runs in high speed;

When the switch is in “idling” position, diesel engine runs in low speed.

5 Shutdown Instrument box will send out shutdown signal to shutdown the diesel engine

forcefully by pressing this button.


- 24 -

6 Emergency

shutdown

When diesel shutdown and emergency shutdown functions are used, this button

has self-locking function. Press this button to close fuel magnetic valve and

close the diesel engine forcefully. Press this button again after the diesel is

completely stopped to open fuel magnetic valve for next starting.

7 Speed fine

adjustment Diesel speed fine adjustment

8 Self-inspection

Press this button when there is no rotation, various channels of instrument box

will simulate external changing conditions to carry out self-inspection items

one by one. Instrument box will send out audible and visual alarm signal when

alarm setting value is reached and instrument box will send out automatic

stopping signal when stopping setting value is reached.



10 Timekeeping Press this button, and speed display window displays the diesel accumulative

running time. Speed will be displayed after 5 sec.

11 reset Press this button to reset the instrument box.

Please refer to accompanying document Operation Manual for Diesel Engine Monitoring

and Control Instrument for more function descriptions and usage information.

(2)New style local ordinary instrument box alarm protection function

Table 6-6 new style local ordinary instrument alarm protection function

Serial

No. Alarm descriptions Alarm value Remarks

1 Speed is high 110% rated speed Audible and visual alarming

2 Oil pressure is low 0.15±0.02Mpa Audible and visual alarming


high 95+3℃ Audible and visual alarming

4 Oil temperature is high 120+3℃ Audible and visual alarming

5 Speed is too high 115% rated speed Audible and visual alarming and shutdown

6 Oil pressure is too

low 0.12±0.02Mpa Audible and visual alarming and shutdown

7 Storage battery voltage

is low <19V Audible and visual alarming

8 Water pressure is low 0.01MPa Audible and visual alarming


(optional)

Audible and visual alarm, and fuel leakage alarm



- 25 -

10 Main power source fails Audible and visual alarming

11 Auxiliary power source

fails Audible and visual alarming

(3) New style local ordinary instrument wiring diagram

Figure 6-6 a) New style local ordinary instrument wiring diagram

Figure 6-6 b) New style local ordinary instrument wiring diagram


- 26 -

4. New style local self-starting instrument box

On the basis of original WP6CD marine diesel gen-set local ordinary instrument panel,

our company has launched new style local ordinary instrument box by optimizing instrument

box components and parts, its functions and redesigning appearance. New instrument box has

more beautiful appearance, firm installation, reasonable functional design, beautiful wiring

layout and convenient plug connectors. Marine diesel alternator new style local self-starting

instrument box (hereinafter referred to as instrument box) is a full-automatic alternator

working condition electronic monitoring and control system, which is controlled by a control

system consisting of GEC16W monitoring display module and GEC8000-K1 safety

protection module. GEC16W monitoring display module has a large LCD which has CAN

communication interface and displays alternator speed, oil pressure, water temperature, oil

temperature and other parameters. Meanwhile, it can also detect battery voltage, alternator

accumulative operating time and other parameters; monitor and display all detected

parameters in real time. When there is alarm signal detected in control box, it will send out

audible and visual alarm signals; when fault shutdown signal is detected (for example

over-speed shutdown), control box will output shutdown control signal automatically to stop

the alternator. Control box system can be used to perform automatic starting and automatic

shutdown operations. Meanwhile, remote displayer or diesel engine remote control display

instrument can be used to perform remote monitoring and control of diesel engine remote

display instrument.

Figure 6-7 shows the new style local self-starting instrument box operation panel


- 27 -

Figure 6-7 new style local self-starting instrument panel


Table 6-7 shows the operation functions of new style local self-starting instrument

Table 6-7 Operation functions of new style local self-starting instrument

Serial


1 Power switch Open this switch to power on the instrument.

2 Local/remote/automatic

control Selection of “remote”, “local” and “automatic” control mode

3 Heating switch

Alternator oil/water heater control switch. Such change-over

switch shall be in “off” position during normal condition;

change-over switch shall be in “on” position when oil water


- 28 -

heater indicator light is on.

4 Idling/rated

When the switch is in “rated” position, diesel engine runs in

high speed;

When the switch is in “idling” position, diesel engine runs in

low speed.

5 Starting of standby device

This button can be used for emergency start when GEC 16W

module fails.

6 Emergency shutdown

This button shall be used by operator for the emergency

stopping of diesel engine. Actuator is manually controlled by

using of this button for disconnecting fuel pipe, stopping

diesel engine and open the main switch of gen-set forcefully.

7 Starting Used to control the starting of alternator under local mode.

8 Shutdown Used to control the stop of alternator under local mode.

9 Scrolling up/down

To change displayed content (parameters of alternator) on the

main page, select parameter number on the parameter

selection page, and set the digitals on the parameter editing

page.

10 Page switching

To switch to parameter selection setting page from the main

page, return to the main page from parameter selection setting

page, and return to parameter selection setting page under

parameter modification status.

11 Confirmation

To enter into corresponding submenu from parameter

selection setting page, and write the modified parameter

under parameter modification status.

12 Self-check in double

MODE combination

Press the two buttons when alternator stops running, and the

system will enter self-check procedure and displays user’s

predefined alternator parameters successively, such as

number of flywheel tooth, rated speed, over-speed alarm

value, etc. The system will return to initial state automatically

after completion of self-check procedure.

13 Silencer

Instrument box can send out audile and visual alarm signals

when diesel engine working condition is out of limit or the

diesel engine fails to start for three times, and relevant alarm

indicators on the panel twinkles; meanwhile digital display

window corresponding to digital displayer twinkles. Press

“Silencer” button, and audible alarm will be turned off and

alarm light keeps shining and stop blinking until the

operation returns to normal conditions.

14 Reset

In case that diesel engine fails to start for three times and

stops because limit protection is triggered, it represents that

the diesel engine is faulty and needs to be repaired. In case

that gen-set is to be started after troubleshooting, press


- 29 -

“reset” button to notify the instrument box that the fault is

eliminated. At this time, controller will cancel alarm signal

and put gen-set into operation again.

Please refer to accompanying document Operation Manual for Diesel Engine Monitoring

and Control Instrument for more function descriptions and usage information.

(2) Alarm protection function

Table 6-8 New style self-starting instrument alarm function

Serial



speed Audible and visual alarming

2 Oil pressure is low 0.15±

0.02Mpa Audible and visual alarming

3 Water temperature is high 95+3℃ Audible and visual alarming

4 Oil temperature is high 120+3℃ Audible and visual alarming

5 Speed is too high 115% rated

speed Audible and visual alarm and shutdown

6 Oil pressure is too low 0.12±

0.02Mpa Audible and visual alarming and shutdown

7 Storage battery voltage is

low <19V Audible and visual alarming

8 Starting fails for three

times Audible and visual alarming


(optional)

Audible and visual alarming, and fuel leakage

alarm apparatus is required

10 Water level/oil level is low

(optional)

Audible and visual alarm, and level switch is

required

(3) New style local self-starting instrument box wiring diagram


- 30 -

Figure 6-8 a）new style local self-starting instrument box wiring diagram

Figure 6-8 b) new style local self-starting instrument box wiring diagram

5. Onboard instrument

Diesel engine monitoring and control instrument (hereinafter referred to as monitoring

and control instrument) shall be mounted on diesel engine body, so it is called onboard

instrument and is a microcomputer-controlled full-automatic electronic measurement and

control system of diesel engine and alternator which precisely detects and displays diesel

engine speed, oil pressure, water temperature, oil temperature, pressure and other parameters,

monitors all detected parameters and sends out audible alarm, visual alarm, remote control

alarm and other signals in real time according to user’s settings. If there is a stop setting, it

will send out shutdown signal when the parameter exceeds shutdown value. Meanwhile,

remote displayer or remote control display instrument can also be used to realize remote

monitoring and control of diesel engine operating parameters. Compared with local

instrument, onboard instrument is simpler in structures and functions.


- 31 -

Figure 6-9 onboard instrument panels

6-9 onboard instrument panel

(1) Operating function

Table 6-9 onboard instrument function

Serial


1 Power switch Turn on this switch to power on the onboard instrument.

2 Local/ remote

control

When “local/remote” control change-over switch is in “remote” position, the

monitoring and control instrument shall be in remote control state; therefore,

remote control instrument can be used to start the diesel engine remotely. When

“local/remote” change-over switch is in “local” position, monitoring and

control instrument shall be in local status; therefore, the diesel engine can be

controlled locally.

3 Starting Onboard instrument will send out signals to start the diesel engine by pressing

this button.

4 Shutdown Onboard instrument will send out shutdown signal to shut down the diesel

engine forcefully by pressing this button.

5 Self-inspection

Press this button when there is no rotation, various channels of onboard

instrument will simulate external changing conditions to carry out

self-inspection items one by one. Onboard instrument will send out audible and


- 32 -

visual alarm signal when alarm setting value is reached and instrument will

send out automatic stopping signal when stopping setting value is reached.



7 Timekeeping Press this button, speed display window displays the diesel accumulative

running time. Speed will be displayed after 5 sec.

8 Reset Press this button to reset onboard instrument.



(2) Onboard instrument alarm protection function

Table 6-10 Onboard instrument alarm protection function

Serial


1 Speed is high 110% Rated speed Alarming

2 Oil pressure is low 0.15±0.02Mpa Alarming

3 Water temperature is high 95+3℃ Alarming

4 Oil temperature is high 120+3℃ Alarming

5 Speed is too high 115% rated speed Alarming and shutdown

6 Oil pressure is too low 0.12±0.02Mpa Alarming and shutdown

7 Storage battery voltage is low <19V Alarming

8 Fuel leakage alarm (optional) Audible and visual alarming, and fuel

leakage alarm apparatus is required

(3) Onboard instrument wiring diagram


- 33 -

Figure 6-10 Onboard instrument wiring diagram

6. Accelerator servo mechanism

A set of accelerator servo mechanism shall be equipped for mechanically regulated marine

diesel gen-set to control diesel engine speed. Generally, WP6CD Series marine diesel gen-set

adopts A-300B6 type servo mechanism. Hereinafter provide a simple introduction of such

servo mechanism.

(1) Main technical data

Voltage: DC 24V Power: 40W Current: 3A

Boundary dimension: 235×220×95mm weight: 5kg

(1) Motor wiring diagram

Power

supply-

Power

supply+

Battery

charging+

Alarm+

Shutdown+

Starting+

Excitation+

Shutdown-

Com

prehensive alarm

Fuel leakage

(input)

Fuel leakage

(input)


- 34 -

a)Reducer 0.75WHJ type worm speed reducer

b)Torque regulating scope 1-100KG-CM

c)Speed ratio: 1：42135

d)Input speed: 3000 r/min

(3) Typical application wiring diagram (reference)

(4) Precautions (the product shall be in power-driven status during delivery)

High speed limit

switch

Low speed limit

switch

Notes: KMA1, KMA2, KMA3 adopts SchneiderCJX2-Z/25A auxiliary equipment Contact 2-open, 1-close A-300B3 type servomechanism Buttons SA1, SA2, SA3 adopts LA18. Indicator AD11


- 35 -

1）Hand wheel shall rotate in clockwise direction from left to right during electric or

manual operation.

2）Hand wheel shall be pulled back during manual operation and make spindle nose turn

right by 60.

3）Hand wheel shall be pulled back during electric operation and make spindle nose turn

left by 60.

Please refer to Operation Manual for Servo Mechanism for more information about the

operation of servo mechanism.

II. Alternator

1. WP6CD Series marine diesel gen-set adopts five kinds of alternators: Marathon

alternator, Stanford alternator, Siemens alternator, Kangfu alternator (formerly known as

Sanbo alternator) and Landian alternator. WP6CD Series marine diesel gen-set is mainly

configured with above-mentioned five alternators. Please refer to relevant alternator

operation manual supplied with the unit for relevant alternator descriptions and wiring

principles.

2.Special configuration for marine alternator

Working environment of marine gen-set is very bad. Moisture on water surface, salt fog

on the sea, oil mist in the cabin and large day and night temperature difference has a bad

influence on alternator insulating material. Therefore, following special configurations are

added to marine alternator.

(1) Air filter

Some dust, oil mist can be removed by installing air filter on alternator air inlet to

prevent moist air during shutdown.

(2) Anti-condensation heater

220V electric heater shall be mounted on the end of alternator stator winding. Electric

heater shall heat alternator winding to remove moist air and prevent water condensation on

the winding.

(3) Winding temperature sensor, alarm and protection


- 36 -

Alternator’s external circuit or improper operation will lead to the sharp rise of winding

temperature which will exceed the alternator’s temperature rise limit. In order to prevent

motor winding damage, temperature sensor shall be embedded on motor winding.

Temperature sensors are divided into two kinds: one is PTC thermistor, the other is PT100,

which together with detection, alarm and trip circuit, can provide protection for the alternator.

Chapter VII Operation

I. Preparation

1.Clean the dust and other dirt on gen-set surface.

2.Check whether various fasteners and connectors are loose and various revolving

components are flexible.

3.Check whether all electrical connection parts are in good contact and correct wiring.

4.Add corresponding fuel into fuel tank to remove the air left in fuel system according to

fuel specifications stipulated in Diesel Engine Operation and Maintenance Manual.

5.Check whether diesel lubricating oil meets requirements according to lubricating oil

specifications stipulated in Diesel Engine Operation and Maintenance Manual. In case

of replenishment, lubricating oil in corresponding grade shall be added.

6.Check whether the stored cooling water meets requirements.

7.Check whether battery voltage is within specified ranges (generally it is 23-28V)

8.Check the status of following switches:

(1) Gen-set power distribution system air isolation switch shall be in normal tripping

position;

(2) Starting switch shall be in off position;

(3) Electron speed regulator “rated/idling” switch shall be in idling position.

II. Commissioning

1.Gen-set starting

1）Press “start” button to start the gen-set (pay attention to readings of various


- 37 -

instruments)

2）Observe whether various parts are in normal operation (engine oil pressure shall

be greater than 0.15Mpa)

3) Gen-set shall be in idling status (generally 600-750 r/min), idling engine heating

shall last for 5-10 min;

2.Engine heating

The diesel engine shall operate for 5-10min in idling status after the starting of gen-set

meanwhile observing diesel oil pressure, oil temperature, cooling water temperature and

diesel operating conditions, in case of abnormalities, shut down the unit for inspection.

3.Acceleration and voltage buildup

High/low speed switch of electronic speed regulator mounted on gen-set shall be

switched to high speed position when diesel engine speed reaches rated speed, the diesel

engine will accelerate the speed automatically. Regulate speed fine adjustment potentiometer

to make diesel engine speed reach rated speed; at this time, alternator voltage shall be built

up.

Regulate voltage setting resistor to make it reach rated value; then turn the voltage

change-over switch mounted on onboard detection device to check whether three-phase

voltage is in balance, no current value is shown, and alternator indicator light turns on.

4.Test run

1)During normal operation of the unit, connect the load and observe whether

various parts are in reliable operation and indicating device is in normal operation;

2)About 25% rated load shall be connected during test run, and check whether

various parameter indicators and whether any abnormal noise arising from

alternators or diesel engine;

3)Load shall be added gradually under normal operation and the load for first test

run shall be not greater than 80% rated load.

4)Observe the water temperature, oil temperature, oil pressure and other diesel

engine parameters and voltage, current and other electrical parameters.


- 38 -

5)Record various parameters during operation.

Notes: sharp increase and decrease of load shall be prohibited during initial operation.

5.Shutdown

Reduce the load gradually, turn off main switch and open load disconnector. The diesel

engine will operate at the speed reduced to idling value for 2~5 min; then the alternator will

be stopped and various switches shall be turned off to separate these units. Then the

commissioning is finished.

Chapter VIII Parallel operation

Parallel operation of gen-set can increase power supply reliability and stability, in

addition, number of parallel gen-sets shall be determined according to load level in places

subject to large load fluctuation for economic operation.

I. Conditions for parallel operation

Gen-set shall meet following conditions during parallel operation:

(1) Voltage of gen-set to be connected shall be the same as that of operating unit;

(2) Frequency of gen-set to be connected shall be the same as that of operating unit;

(3) Phase position of gen-set to be connected shall be the same as that of operating unit;

(4) Phase sequence of gen-set to be connected shall be the same as that of operating unit;

II. Methods

Common parallel connection methods include light extinction method, light rotation

method and synchronizing device method. Currently, the most commonly used method is

synchronizing device method. And synchronizing device method can be divided into

quasi-synchronizing parallel method and automatic self synchronizing parallel method.

Hereinafter provide the introduction of quasi-synchronizing parallel method.

On implementation model, quasi-synchronizing parallel operation is divided into manual

quasi-synchronizing parallel method and automatic quasi-synchronizing parallel method.

Hereinafter provide the introduction of manual quasi-synchronizing parallel method.


- 39 -

Gen-set to be connected in parallel shall be involved in synchronizing operation after

meeting the four parallel conditions stipulated in this Chapter. Operating steps are as follows:

(1) Check whether phase sequences of two parallel gen-sets are consistent with each

other before parallel operation and use phase sequence indicating device to check

alternator stator winding leading-out terminal marks.

(2) Start the gen-set and adjust the speed and voltage of two gen-sets into rated value,

meanwhile, their phase sequences shall be consistent (the adjustment of gen-set

steady-state speed regulation factor and steady-state voltage regulation factor shall be

completed before delivery). One gen-set shall be switched on firstly (it can operate

without load or be used to supply power);

(3) Regulate regulating resistor of gen-set to be connectedconnected to make the voltage

be consistent with that of the already connected unit;

(4) Manual quasi-synchronizing operation: observe the rotation of synchronizing

indicating finger, then make corresponding regulation upon frequency of gen-set to be

connected until synchronizing indicating finger reaches synchronizing balance line in

clockwise rotation and send out switch-on order immediately to make put gen-set into

parallel operation. After parallel operation, regulate the speed of one gen-set to achieve

power sharing balance. All input signals of combined type synchronoscope shall be

turned off after parallel operation to take the synchronoscope out of service.

III. Load transfer in parallel

Load transfer shall be done after units are put into parallel operation. There are load

transfer method, one is active load transfer between two gen-sets which is achieved by

regulating accelerator to change diesel engine oil supply. Active load increases along with oil

supply; the other is transfer of reactive load,which can be accomplished by using regulating

differential resistor and voltage regulation resistor on regulation panel to regulate reactive

power between two gen-sets.

IV． Disconnection of parallel gen-set

When load of two gen-sets in parallel operation is less than the 50% of rated load and

one unit needs to be disconnected, all the load (or most part) of the unit to be disconnected

shall be transferred to the other unit by adjusting speed before turning off load switch to

disconnect the unit.


- 40 -

Chapter IX Precautions

1.Personnel who are unfamiliar with gen-set operating specification are prohibited to

operate on the unit.

2.Gen-set output current shall not exceed the rated current stipulated on alternator

nameplate. Please refer to power correction method stipulated in diesel engine Operation

Manual to correct gen-set output power when gen-set working condition does not

conform to working conditions stipulated in this manual.

3.During initial operation, maximum power of the unit shall not exceed 90% of rated

power which help extend service life. When gen-set is started in emergency status, initial

load shall not exceed 50% of rated power.

4.Check water temperature, engine oil pressure changes regularly to meet specifications

stipulated in diesel engine operation and maintenance manual.

5.Check battery voltage regularly to ensure it is in good condition.

6.During operation of gen-set, pay attention to cooling water level in box cooler and

replenish if necessary.

7.Repair it in a timely manner in case that there is oil leakage, water leakage and air

leakage in various pipes.

8.Do not use silicon rectifier to replace battery

9.Water in cooling system shall be discharged or anti-freezing agent shall be added when

gen-set ambient temperature is low with possibility of freezing to prevent frost crack of

unit body and water drainage shall be done after the unit has stopped for half an hour.

10.During operation of gen-set, loading process shall be stable to avoid gen-set from

being damaged by impact load.

11.Gen-set shall be in horizontal position during lifting.

12.As gen-set can be exposed in moisture air, salt mist, oil mist and mould environment,

the user shall start it up regularly to guarantee that gen-set is in good working condition

to prevent gen-set from being corroded or damaged.


- 41 -

13.Pay attention to keep gen-set clean and make it in good working conditions.

14.Gen-set is heavy equipment. For the sake of human body and equipment safety, it shall

be operated with care. Operation against rules and drunk operation are prohibited.

15.In case that there are any failures and factory assistance is required, the user should

provide the detailed information for quick solution.

Chapter X Analysis of common faults and troubleshooting

1.Analysis of common faults

Table 10-1 Analysis of common faults

Fault phenomena Analysis of causes Troubleshooting methods

Cannot be started

Battery fault Check battery wiring, capacity and voltage.

Fuel circuit is blocked. Check whether fuel oil circuit is blocked and

discharge air in fuel oil circuit.

Electronic speed regulator Check electronic speed regulator.

No voltage

Excitation circuit is open. Check the wiring of excitation circuit.

AC, DC transformation system is

damaged. Refer to alternator Operation Manual.

Fuse is damaged. Replace fuse.

Alternator voltage is

unstable.

Excitation circuit is in bad contact. Check the wiring of excitation circuit.

Rectifier diode has poor

performance. Replace diode.

Alternator speed is

unstable.

Electron speed regulator does not

work in optimum status

Refer to electronic speed regulator Operation

Manual.

2.See Operation Manual for Three-phase Synchronous Alternator for synchronous

alternator fault and troubleshooting methods.

3.See Operation Manual for Diesel Engine Monitoring and Control Instrument for

gen-set instrument box fault troubleshooting methods.

4.See Operation Manual for Electronic Speed Regulator for electronic speed regulator


- 42 -

fault and troubleshooting methods.

Chapter XI Rules for Safe Operation

1.Operator shall be familiar with gen-set operations, operation method and positions of

all control mechanisms, manual valves and stop mechanism.

2.Open flame is forbidden in cabin with fuel oil and lubricating oil to avoid fire.

3.Proper fire fighting equipments shall be equipped in cabin or in nearby places.

4.Whole gen-set must be earthed reliably and meet applicable neutral earthing

requirements.

5.The equipment, barriers and dangerous goods not to be used for the unit shall not be

placed on the unit and the ground shall be dry and clean without oil contamination.

6.As there are noises generated during gen-set operation, it is recommended that worker

in noise environment shall wear proper safety devices, such as ear protector.

7.All power supply lines must be disconnected before any maintenance, especially DC

power supply circuit. Set a “during maintenance” warning plate and assign another

person to ensure the safety, especially for maintenance performed in narrow area.

Chapter XII Servicing and Maintenance

1.Please read relevant chapters of this Operation Manual carefully before maintenance and

servicing.

2.Generally, gen-set shall be inspected once a week. Operate for a short time with load

(best of all) to confirm that gen-set is in good status; meanwhile make records on relevant

conditions and parameters.

3.Basic maintenance specifications are as follows:

（1）Check the conditions of air filter, fuel filter elements, clean them in time and replace

them if necessary.

（2）Check cooling water or anti-freezing solution and replenish it in time.

（3） Check whether there is lubricating oil, fuel and cooling water leakage.


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（4） Check whether oil in pump body is within specified limit and replenish it in time.

（5） Check the battery voltage and specific gravity of electrolyte.

（6） Check the conditions of various indicating devices and various switches on instrument

box.

（7） Check whether electric connection and mechanical joint is loose and fasten it if

necessary.

4.Routine inspection items

（1）Diesel maintenance

The purpose of correct maintenance is to guarantee the normal and reliable operation of

diesel engine and is an important step to extend diesel engine service life. The user shall

maintain the diesel engine regularly according to technical maintenance items stipulated in

this Chapter.

1）Maintenance frequency of WP6CD Series diesel engine

First inspection (P) after diesel engine runs for 30-50 hours

Level I maintenance (WD1) after diesel engine runs for each 250 hours

Level II maintenance (WD2) after diesel engine runs for each 500 hours

Level III (WD3) after diesel engine runs for each 1000hours

Level IV (WD4) after diesel engine runs for each 4000 hours

Note: Above-mentioned frequency shall be calculated assuming that the unit operate for

1500 hours annually, in case that diesel engine working time annually does not exceed 500

hours, diesel engine maintenance frequency shall be 0.5 times above-mentioned

maintenance frequency; in case that diesel working time annually exceeds 1500 hours, the

maintenance frequency shall be 1.5 times above-mentioned frequency.

Note: Lubricating oil of CE grade or lower is not allowed for WP6CD Series diesel engine.

Replace oil filter element during oil replacement.

3）Operations to be done during diesel engine inspection and maintenance


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Table 12-1 Operations during diesel engine maintenance

Item First

inspection

Routine

inspection WD1 WD2 WD3 WD4

Replace diesel engine oil ▲ ▲ ▲ ▲ ▲ ▲

Check whether water pump leaks. ▲ ▲ ▲ ▲ ▲

Replace oil filter ▲ When replacing alternator oil

Check and regulate air valve gap. ▲ ▲ ▲ ▲ ▲

Replace fuel oil filter. ▲ ▲ ▲ ▲

Clean fuel oil pump coarse strainer. ▲ ▲ ▲ ▲

Check the capacity of cooling liquid

and replenish if necessary. ▲ ▲ ▲ ▲ ▲ ▲

Fasten cooling pipe clamp. ▲

Fasten air inlet pipe and flexible pipe. ▲ ▲ ▲ ▲ ▲

Clean air filter element. ▲ ▲ ▲

Check and fasten triangle belt. ▲ ▲ ▲ ▲ ▲ ▲

Check fuel oil injection pump in

special workshop. ▲

Regulate idling speed. ▲

(2) Gen-set routine inspection items

Note: “1” in Table 12-2 represents inspection after operation for each 12 h or once a

week; “2” represents inspection after operation for each 100h or once a month; “3” represents

inspection after operation for each 200h or once a year.

Table 12-12 Inspection items during diesel engine-gen-set maintenance

Parts Inspection item Frequency

Starting

part

Check battery electrolyte level. 1

Use hydrometer to check the charging status. 2

Clean battery terminals and oil it again. 3

Alternator

Use dry compressed air to purge the porthole and internals. 2

Replace bearing lubricating grease (if necessary). 3

Check whether inner coupling bolt is loose. 2

Check whether there is barrier in ventilation area. 1


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Check the conditions of alternator outgoing line insulation. 1

Check the working condition of air isolation switch. 3

Check whether alternator terminals are loose. 1

Gen-set

Check and fasten all bolts and nuts. 3

Check the status of damper. 3

Clean whole gen-set. 3

Operate gen-set for 1h at 50% load (optimal condition) and record the starting

time of gen-set. 1

Annex I: List of Tools Delivered with Gen-set (Ex-factory Standard Configuration)

Serial No. Parts name Specification Quantity

1 TOOL LIT 1

2 WRENCH DOUBLE 10×12 1





7 SOCKET 1/2SQ TWELVE 1/2×13 1








15 HANDLESS LICING 1

16 EXETENSION BAR 1/2SQ 1/2×250 1

17 EXETENSION BAR 1/2SQ 1/2×125 1

18 HANDLE-BALL PEEN 1

19 MAGNETIC PROBING PEN 1

20 WRENCH-ADI 200mm 1


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21 PLIER SHORT/JOINT 150mm 1

22 DRIVER（+-） 5×125 2

23 FEELER 1

24 L-WRENCH 5-12 1

25 U-JOINT1/2SQ DR2 1/2 1

26 RACHET HANDLE 1/2 1

27 FILTER WRENCH 1

28 JOINT-WRENCH 1/2×7mm 1



Annex II: List of Spare Parts Delivered with Gen-set (Ex-factory Standard

Configuration)

Serial No. Name Quantity Remarks

1 Narrow triangle belt 2

2 Screw filter 2

3 Fuel filter element 2

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