HIPOWER Yanmar Generators Manual

8/19/2019 HIPOWER Yanmar Generators Manual

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HIPOWER builds a

wide range of Power

Plants available for

standby or primer

power applications

providing a safe, relia-

ble and dependable

source of energy

where ever is needed.

Industrial Range Industrial Generator Sets

feature a robust construc-

tion with strict adherence

to quality, while maintai-

ning a minimal impact to

the environment.

Rental RangeHIPOWER Rental Gene-

rators Sets have been

developed from the user

and service point of view

thanks to the input of

the premium class rental

companies.

Generating SetsManualYanmar


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www.hipowersystems.com HIMOINSA POWER SYSTEMS1

Contents

Forward .......................................................................................................2

1. Safety .....................................................................................................5

1.1 General Safety Information ........................................................................ 5

1.2 Installation And Transporting .................................................................... 6

Hazards ................................................................................................................. 6

2. Identication .........................................................................................8

2.1 Generator Identication View ..................................................................... 8

3. Installation..........................................................................................10

3.1 General Information ................................................................................... 10

3.2 Control Of Material ..................................................................................... 10

3.3 Outdoor Installations ................................................................................. 103.4 Indoor Installations .................................................................................... 10

3.4.2 Exhaust Installation ............................................................................................ 12

3.4.3 Ventilation ............................................................................................................ 1

3.4.4 Remote Fuel Tank ............................................................................................... 1

3.4.5 Heating ................................................................................................................. 1

3.4.6 Electrical Connections ....................................................................................... 1

3.3.7 Three Phase Generator Sets .............................................................................. 1

3.3.8 Single Phase Generator Sets ............................................................................. 1

4. Prestart Checks ..................................................................................19

4.1 Prestart Checks.......................................................................................... 19

5. CEM7 Control Panel ...........................................................................20

5.1 Introduction ................................................................................................ 20

5.1.1 Display Module (Control Panel) ......................................................................... 2

5.1.2 Measurements Module ....................................................................................... 2

5.2 Control Panel .............................................................................................. 215.3 Control Panel Push Buttons ..................................................................... 22

5.3.1 Operating Mode Buttons .................................................................................... 22

5.3.2 Command Buttons .............................................................................................. 22

5.3.3 Display Buttons ................................................................................................... 22

5.4 Data LED’s .................................................................................................. 23

5.4.1 Contactor Status LEDs ....................................................................................... 2

5.4.2 Engine Status LEDs ............................................................................................ 2


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Forward

5.4.3 Alarm LEDs .......................................................................................................... 23

5.5 Starting And Stopping Genset .................................................................. 24

5.5.1 Starting - Manual Mode ....................................................................................... 24

5.5.2 Stopping - Manual Mode ..................................................................................... 24

5.5.3 Starting And Stopping - Automatic Mode ......................................................... 24

5.6 Interruption Of Function Mode ................................................................. 24

5.7 Working Mode ............................................................................................ 24

5.8 Transfer Fuel Pump.................................................................................... 25

5.9 Alarms ......................................................................................................... 25

5.9.1 Reseting Alarms .................................................................................................. 26

5.10 Engine Alarms .......................................................................................... 27

5.11 Genset Alarms .......................................................................................... 28

5.12 Programmable Alarms And Inputs ......................................................... 28

6. M6 Control Panel ................................................................................30

6.1 Control Panel - M6...................................................................................... 30

6.2 Starting And Stopping Genset - M6 Control Panel ................................. 31

6.2.1 Starting - Manual Mode ....................................................................................... 31

6.2.2 Stopping - Manual Mode ..................................................................................... 32

6.2.3 Starting And Stopping - Automatic Mode ......................................................... 32

6.3 Engine Alarms ............................................................................................ 33

7. DSE3000 Series Control Panel ........................................................ 34

7.1 Description Of Controls............................................................................... 34

7.2 Quickstart Guide .......................................................................................... 34

7.1.1 Starting The Engine .............................................................................................. 34

7.1.2 Stopping The Engine ............................................................................................ 34

7.3 Graphical Display......................................................................................... 34

7.4 Controls ........................................................................................................ 35

7.5 Automatic Mode Of Operation .................................................................... 357.5.1 Waiting In Auto Mode ............................................................................................ 35

7.5.2 Starting Sequence ................................................................................................. 35

7.5.3 Stopping Sequence ............................................................................................... 36

7.6 Manual Operation ......................................................................................... 36

7.6.1 Waiting In Manual Mode ....................................................................................... 36

7.6.2 Starting Sequence ................................................................................................. 36

7.6.3 Stopping Sequence ............................................................................................... 36


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7.7 Warnings ....................................................................................................... 36

7.8 Shutdowns .................................................................................................... 37

7.9 Module Display ............................................................................................. 37

7.9.1 Timer Icon .............................................................................................................. 3

7.9.2 Stopped Icon ......................................................................................................... 3

7.9.3 Running Icon ......................................................................................................... 3

7.9.4 USB Icon ................................................................................................................ 3

7.9.5 Memory Corruption ............................................................................................... 3

7.9.6 Backlight ................................................................................................................ 3

7.10 Fault Icons .................................................................................................. 38

8. DSE5310 Series Control Panel .......................................................... 39

8.1 Description Of Controls............................................................................... 39

8.5 Typical LCD Display Screens ...................................................................... 488.5.1 Typical Status Display .......................................................................................... 4

8.5.2 Typical Instrument Display ................................................................................... 4

8.5.3 Typical Alarm Display ........................................................................................... 4

8.5.4 Typical Event Display ........................................................................................... 49

8.6 Viewing The Instruments ............................................................................. 49

8.6.1 Instrument Page Content ..................................................................................... 5

8.6.2 Manually Selecting An Instrument....................................................................... 5

8.7 User Congurable Indicators ...................................................................... 518.8 Controls ........................................................................................................ 51

8.7 User Congurable Indicators ...................................................................... 52

8.8 Controls ........................................................................................................ 52

8.9 Fault Finding................................................................................................. 53

8.10 Icons And LED Identication .................................................................... 54

7.10.1 Push Buttons ....................................................................................................... 54

8.10.2 Status / Measurement Units ............................................................................... 54

8.10.3 LED Indication ..................................................................................................... 5

9. Routine Maintenance ........................................................................55

9.1 Maintenance ............................................................................................... 55

9.2 Periodic Maintenance .................................................................................. 56

10. Alternator ......................................................................................... 57

10.1 Generator Designation ............................................................................ 57


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10.2 Serial Number Location ........................................................................... 57

10.3 Rating Plate .............................................................................................. 57

10.4 Lifting ........................................................................................................ 57

10.5 Automatic Voltage Regulators ................................................................ 58

10.5.1 Type AS440 ........................................................................................................ 5810.5.2 Type MX341 ........................................................................................................ 59

10.5.4 Type MX321 ........................................................................................................ 60

10.6 Electrical Protection ................................................................................ 60

10.7 Fault Finding............................................................................................. 61

10.7.1 SX460 AVR ......................................................................................................... 61

10.7.2 SX440 AVR ......................................................................................................... 61

10.7.3 SX421 AVR ......................................................................................................... 61

10.8 Alternator Maintenance ........................................................................... 6210.8.1 Winding Condition ............................................................................................ 62

10.8.2 Guidance Of Typical Insulation Resistance [IR] Values ................................ 62

10.8.3 Winding Condition Assessment ...................................................................... 62

10.9 Replacement Parts ................................................................................... 62

11. Specications ...................................................................................63

11.1 Generator Set Models .............................................................................. 63

11.2 Engine Models .......................................................................................... 64

11.2.1 3TNV76 ............................................................................................................... 64

1.2.2 3TNV88 ................................................................................................................. 64

11.2.3 4TNV84T ............................................................................................................. 65

11.2.4 4TNV88 ............................................................................................................... 65

11.2.5 4TNV98 ............................................................................................................... 66

11.2.6 4TNV98T ............................................................................................................. 66

Illustrations and technical detail provided courtesy of Cummins Generator Technologies.

Copyright 2010, Cummins Generator Technologies, All Rights Reserved.


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1. Safety

1.1 General Safety InformationThis manual provides information and procedures to safely

operate and maintain your Hipower Generator Set. Read,

understand and observe the safety instructions described

in this manual before installing, operating and servicing the

generator.

If you have questions about operation or service, pleasecontact Hipower Systems. The information contained in this

manual was based on machines in production at the time of

publication. Himoinsa Power Systems reserves the right to

change any portion of this information without notice.

All rights, especially copying and distribution rights are

reserved. Copyright© 2010 by Himoinsa Power Systems.

No part of this publication may be reproduced in any form

or by any means, electronic or mechanical, including

photocopying, without express written permission from

Himoinsa Power Systems.

This manual is provided to assist in the maintenance and

operation of the generator and is not to be used in any manner

detrimental to the interests of Himoinsa Power systems.

Information in this manual represents components installed

when product was manufactured based upon the best

available information. Modications made subsequent

to initial delivery are not included. Always verify the parts

required with Himoinsa Power Systems.

If you have any questions, please contact our Parts and

Service Department.

Do not operate generator without an Operators Manual.

Treat the Operators Manual as part of the generator. Replace

the Operators Manual if it is lost, damaged or becomes

unreadable.

All personnel that will be operating, maintaining and working

around the generator must review these documents before

interacting with the generator.

If you have any safety concerns or questions that are not

covered by this manual, please contact Himoinsa Power

Systems at 1-913-495-5557.

^ California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects and other reproductive harm.

Battery posts, terminals and related accessories contain

lead and leads compounds, chemicals known to the

State of California to cause cancer, birth defects and

other reproductive harm. Wash hands after handling.

The safety information in this manual is denoted by th

safety alert symbol: ^

The level of risk is indicated by the following signal words

^ DANGER

Indicates a hazardous situation, which, if not

avoided, will result in death or serious injury.

^ WARNING


avoided, could result in death or serious injury.

^ CAUTION


avoided, could result in minor or moderate injury

NOTICE

Indicates a situation that could result in damage

to the equipment or other property.

Never go under raise equipment unless properly supporte

Use properly rated lifting equipment to lift heavy objects.

Extinguish all smoking material when adding fuel or workin

around generator. Engine must be stopped before addin

fuel.

Clean up spilt uids and dispose of uids, contaminate

material etc. in accordance with local regulations.

Disconnect negative (-) battery cable before performi

maintenance on generator set.

Allow components to cool before attempting a

maintenance.

Do not operate generator set with safety guard(s) remove

Seek medical attention immediately if your skin contacts

high pressure fuel.


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1.2 Installation And Transporting

Hazards

^ WARNING

Crushing hazard.

Generator set is heavy.

Use properly rated lifting devices to move

generator set.

Never enter the area under a raised generator set.

^ WARNING

The generator lifting points are designed to lift thegenerator only.

Do not lift the complete generating set by the

generator lifting points.

^ WARNING

Incorrect installation and/or protective systems

can result in injury and/or equipment damage.

Installers must be qualied to perform electrical

installation work.

1.3 Operational Hazards

^ WARNING

Risk of death or serious injury.

Do not operate, work on or around this machinewhile under the inuence of alcohol, drugs or if

feeling ill.

^ WARNING

Entanglement hazard.

Loose tting clothing and long hair can be

come entangled in moving or rotating parts.

Do not wear loose tting clothing.

Long hair must be tied back or netted.

Remove neck ties.

Do not operate generator with a guard removed

or access panel removed.

^ WARNING

Carbon monoxide hazard.

Do not operate the generator in an enclosed

building or conned area.

Avoid actions or areas that expose you and

others to carbon monoxide.

^ WARNING

Risk of death or serious injury.

Do not operate, work on or around this machine

while under the inuence of alcohol, drugs or if

feeling ill.

^You must adhere to local codes and regulations whereyour generator is being used.

1. Safety


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1. Safety

^ Do not smoke while refueling. Do not refuel near sparksor an open ame.

^ Clean up uid spills and contaminated material inaccordance with local regulations.

^ WARNING

Ensure that all personnel operating, servicing,

maintaining or working near this equipment

are wearing appropriate Personal Protective

Equipment (PPE) including eye and ear protection

and are fully aware of the emergency procedures

in case of any accidents.

^ WARNING

Generators emit noise.

Ensure appropriate ear protection is worn at all

times. Maximum A-weighted emissions levels may

reach 104 db.

1.4 Maintenance Hazards

^ Service and maintenance procedures must be carried

out by experienced, qualied engineers, familiar withthe procedures and the equipment. Before any intrusive

procedures are carried out, ensure that the engine is inhibited

and the generator is electrically isolated.

^ All electrical equipment can be dangerous if notoperated correctly. Always service and maintain the

generator in accordance with this manual. Always use

genuine replacement parts.

^ WARNING

Hot engine and exhaust system can cause severe

injury.

Do not touch hot engine parts.

Do not perform service or maintenance on

generator until cool to the touch.

^ WARNING

Risk of severed digits or limbs.

Generator can be started from a remote switch.

Disconnect the negative (-) battery cable from

generator battery before performing service or

maintenance on generator set.

^ WARNING

Electrical shock can cause injury or death.

Ensure that all personnel operating, servicing,

maintaining or working near this equipment are

fully aware of the emergency procedures in caseof accidents.

^ WARNING

Do not handle Permanent Magnet Generators

(PMGs) if you have mechanically implanted

devices; ie pacemakers.

^ WARNING

Service and fault nding procedures present

hazards which can result in injury or death.

Only personnel qualied to perform electrical

and mechanical service should carry out these

procedures. Ensure engine starting circuits

are disabled before commencing service or

maintenance procedures. Isolate any anti-

condensation heater supply.

^California Proposition 65 Warning

Diesel engine exhaust and some of its constituents a

known to the State of California to cause cancer, bir

defects and other reproductive harm.

Battery posts, terminals and related accessories conta

lead and leads compounds, chemicals known to th

State of California to cause cancer, birth defects an

other reproductive harm. Wash hands after handling.


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2. Identication

1 - Alternator 2 - Control Box 3 - Engine Turbocharger 4 - Radiator 5 - Fuel Fill

2.1 Generator Identication View

Open Skid Model HYW 45 T6

1

2

3

4

5


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2. Identication

2.2 Data Plate The genset data plate contains the following information:

Manufacturer

Model

Serial Number

Frequency

R.P.M.

Rated Power (KW)Rated Voltage (V)

Phase

Rated Current

Rated Power Factor

Insulation Class

Dimensions

Weight


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3. Installation

3.1 General Information

^ WARNING

Crushing hazard.

Generator set is heavy.

Use properly rated lifting devices to lift generator

set.

Lift only by the generator devices designed

for lifting.

Never enter the area under a raised generator.

Use an adequate lifting device to unload and set the

generator in place. Lift only by the lifting devices on thegenerator designed for lifting.

The generator set must be placed on level site designed to

carry the weight of the generator set.

Electrical wiring to and from the generator set must be

performed by a qualied electrician and conform to all

national and local code requirements.

Fuel supply to the generator set must be installed by a

qualied technician. If a remote fuel tank is used, tank must

be properly located and correct size fuel lines are installed.

Contact the generator engine manufacturer for proper fueltank location and fuel line size specications.

3.2 Control Of MaterialWhen the genset is delivered, check that the received material

matches the order, and to compare it with the delivery note

that is enclosed with the set. Also, check that the material is

not damaged. Proceed to open the packaging.

If any damage detected, contact the shipping company

immediately in order to report the incident to the insurance

company.

Himoinsa species that all deliveries are made at the

customer’s complete risk.

Operations prior to the installation of the automatic

genset.

During the operations prior to the installation of the

automatically-driven gensets, or when connecting the

electrical connections, or in order to avoid unfortunate

startups, etc. the battery/batteries must be disconnected and

the control panel switch must be set to the OFF position.

Safety rules for diesel gensets

The engine room and installation of the set (foundations, air

intake, gas exhaust) must match the “Safety rules” that exist

in the country where the genset will be installed.

Installation

For stationary gensets, two types of installation can be

considered:Outdoor assembly

Indoor assembly

3.3 Outdoor InstallationsThe generator set can be temporarily placed on a rm level

surface. If possible, avoid direct exposure to the sun, rain

and dirty conditions. It is recommended that the area around

generator set be fenced to prevent unauthorized access.

For long-term installations, a concrete foundation designed

by an engineer for the generator set is required. Foundation

must be constructed to prevent generator set noise and

vibration from surround areas and buildings.

Airow is critical for the proper operation of the generator.

Outdoor installation must allow adequate clearance to

maintain the proper ventilation for generator cooling.

Minimum clearance around generator set is 5 ft (1.5m).

^ WARNING


Engine exhaust pipe(s) must be installed tocarry exhaust gases to an area where they pose

no danger.



Engine exhaust pipe(s) must be installed to carry exhaust

gases to an area where they pose no danger.

3.4 Indoor InstallationsFor the correct installation of a genset in closed premises,

the size of the room must allow:• The regular operation of the genset.

• An easy access to its components for maintenance and

possible repairs.

• The possibility of installing the genset using the available

means of transport. The door through which the genset

will be installed must be centered, so that the set remains

centered once it is inside, and there is no need of moving

it.

• The existence of holes that allow oil replacement.

• The installation of the exhaust pipe with the minimum

possible number of pipe elbows.

• The genset to be placed in the middle of the premises,


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3. Installation

with respect to perimeter walls, in order

to facilitate access.

• The layout of the command panel (in case it is an automatic

set) to be in a position that allows the operator to have

complete visibility over the instruments when operating it.

The recommended room dimensions are displayed in the

following pictures:

Sound Attenuated Generator

1. Generating set.

2. Control panel.

3. Air intake gap.

4. Air outlet tunnel.

5. Cable wireway.6. Access door.

7. Reinforced concrete base.

8. Exhaust pipe.

9. Flexible pipe.

10. Exhaust silencer.

* May vary depending on the function of the outlet section of

the model (see plans of the specic model to be installed).

Open Skid Set

1. Generator set.

2. Control panel.

3. Air intake gap.

4. Air outlet tunnel.

5. Tray for cable-running.

6. Access door.

7. Concrete base.

8. Exhaust pipe.

9. Flexible sleeve.

10. Exhaust silencer.

* May vary depending on the function of the outlet section

the model (see plans of the specic model to be installed)

The basic elements to be considered are:

• Foundations

• Exhaust installations• Ventilation

• Fuel installation.

• Electrical connections

• Grounding.

• Heating

3.4.1 FoundationThe foundation must be designed by an engineer experience

in generator foundation design. The foundation must suppo

the weight of the generator set and all uids, and preve

the transmission of vibration and noise to other parts of th


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building.

The surface on which the set will be placed must be levelled

in order to allow its correct operation.

For cleaning reasons, it is recommended that the foundations

are approximately 10cm above the oor level, and covered

with gres industrial sandstone tiles.

3.4.2 Exhaust Installation

^ DANGER


Generator exhaust gases must be routed to an

outdoor area where they pose no danger.

Exhaust installation must be performed by

a qualied technician, experienced in indoor

generator installation.



Exhaust pipe(s) must be routed to an outdoor area where

exhaust gases pose no danger.

Exhaust pipe that passes through walls, must prevent the

transmission of heat to the walls. Exhaust pipe connections

must be sealed tight to prevent exhaust gas leaks and must

end with a protection cap to protect them from water entry, or

with a similar system (1) and (2).

In the part where they run through the walls, it is recommended

2

1

6 0 °

DX2

D

D x 0 . 3

5

4 5 °

R = D

x 2 , 5

to perform a thermal insulation of the pipes, in order to

prevent heat expansion to the walls. (3)

The joints between the different pipes must be perfectly

sealed so that there are no gas leaks. The connection

between ange and gasket is the most critical one. It is also

recommended to place a condensation collector, with drain

valve, on the bottoms point of the pipes.

The connection between the engine’s collector outlet (or the

turbocharger) and the pipe must be made by means of a

exible tube, so that the engine movement and the thermal

expansions of the pipe are absorbed by the engine without

damaging any elements.

The use of exible pipe also requires the placement of

anges in the exhaust pipe, independent of the genset.

Therefore, the pipelines must be xed to the walls or ceiling

of the engine room, with supports that can bear the weight

of the pipe to the engine outlet, so that it does not rest on

the parts of the engine (collector, turbocharger), and allow

its expansion.

When dealing with very long pipes, it is necessary to insert

expansion joints made of sealed exible pipes.

3

D

D

+ 4 m m .

D x 1 . 5

NO NO NO YES


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When establishing the trajectory of the exhaust pipe, it is

necessary that the pipe is not near the engine air lters,

in order to prevent the machine from drawing in hot air.

Otherwise, it will be necessary to insulate it.

Whenever there are several gensets, it is advisable that

all exhausts do not converge on a common pipe, as therecan be problems when some gensets are in operation and

others are not. The produced exhaust gases can penetrate

in the conduits of the sets that are not in operation and may

cause damage.

A. Exhaust pipes measurement for Standard Static Gensets

The engine’s exhaust backpressure has a remarkable

inuence on the produced power and on the thermal

charge.

Excessive backpressure values (measured at the exhaust

collector outlet for non-turbocharged engines, and at theturbine outlet on turbocharged engines) cause reductions in

power, rise in temperature of exhaust gases, fumes, high fuel

consumption, cooling water overheat, lubricant degradation,

and the ensuing consequences on the engine parts.

The limits that must not be exceeded (referred to the delivery

conditions of maximum power at full throttle) in HIMOINSA

genets must be consulted with the factory.

Such limits can be observed considering the dimensions that

are suitable for the exhaust installation, that is, the diameter

of the pipe and type of silencer.

The pipes must be as short as possible, and with as few pipe

elbows as possible. Whenever pipe elbows are necessary,

they must be used with a very wide angle of curvature (from

2.5 to 3 times the diameter of the pipe).

Pipes with bends of angles lower than 2.5 times the diameter

pose difculties so they must be avoided.

In order to calculate the total length of the pipe (which is

crucial for the exhaust’s backpressure), the following

considerations must be taken into account:

The rectied length of the pipe elbows must be determined

according to the chart and pictures:

6.7

300Pipe I.D. (mm)

Pipe Length 5.4

250

4.0

200

2.8

150

2.2

125

1.7

100

1.2

80

0.9

65

0.7

50

0.5

40

010xId

d

05xIC

d

04xIb

r = 2 , 5

x d

d

01xIa

r = 2 , 5

x d

d

The backpressure values due to the exhaust silencers ma

vary within a wide range, depending on the type of buildin

dimensions and noise abatement characteristics:

- If it is the one supplied by HIMOINSA, the length must b

multiplied by a coefcient of safety, so that the total length

be considered due to backpressure will be: L=2 X l.

- If it has been provided by another supplier, it is recommende

to check the value of backpressure derived from the silenc

with the supplier.

Example: The exhaust pipe consists of the following parts

- 5 metres of straight pipe stretches.

- Two pipe elbows type a)

- Three pipe elbows type c)

- A 1m long silencer.

If the inner diameter of the engine exhaust is 80mm, the to

length of the exhaust pipe is calculated as follows:

a) for the inner diameter 80mm, according to the chart,

l=1.2m.

b) total length of the pipe elbows type (a) is, 1l=1X1.2=1.2m. as there are two pipe elbows, 2 x 1.2=2.4m

c) the total length of the pipe elbows type c) is 5 X l=5 x 1.2

6m. as there are three pipe elbows, 3 x 6 = 18m.

d) the total length of the exhaust silencer is L=2X l = 2X1

2m.

e) the total length of the exhaust pipe is: 5+2.4+18+2

27.4metres


16/69


• In order to calculate the diameter of the exhaust pipe it is

possible to use the normogram below:

• For calculation purposes, in this normogram we will use the

following backpressure values:

- 800 mm H2O, for aspirated engines.

- 400 mm H2O, for supercharged engines.

• Exhaust gases airow in kg/h. In order to convert into m3/h,

the data must be divided by the exhaust gases density.

Request these data to the manufacturer.

Example: If we take the exhaust pipe from the previousexample, with a total length of 27.4 metres (taking into

account the rectied length of the pipe elbows and the length

equivalent to the exhaust silencer). From the following data

of the installation:

- 5 pipe elbows at 90º (2x type A and 3x type C).

- Set model: HIW-210

- Working rate: 50 Hz

- Motor: 8361 SRi 26 (supercharged).

- Insulated pipe.

a) Start from the lower part, with a total pipe length of 27.4m

Longitud de la tubería en m

Contrapresión en la tubería en mm H2O(sin silenciador)

200

300

400

500

600

700

800

Diámetro tubo en mm

100 130 160

Aislado

No Aislado

3600

3200

2800

2400

2000

1600

1200

800

400

C a u d a

l d e g a s e s d e e s c a p e m

3 / h

15

10

5

0

15

10

5

0

Números de codos a 90º - r=2,5xd

5 6 7 8 9 1 0

1 5

2 0

2 5

3 0

4 0

5 0

6 0

7 0

8 0

9 0

1 0 0

1 5 0

2 0 0

Números de codos a 90º - r=2,5xd

(straight stretches + rectied elbow length), until crossing

the straight line relative to the total number of pipe elbows in

the installation (5 elbows).

b) Continue and follow a horizontal direction to the right until

crossing again the straight line relative to the number of pipe

elbows (5 elbows).

c) Continue upwards until crossing the straight line relativeto the ow of the exhaust gases, which according to the

chart is 1120 kg/h. To convert kg/h into m3/h divide the ow

expressed in kg/h by the density of the exhaust gases. As a

rst approximation we can take the density of the exhaust

gases with a value of 0.42 kg/ m3 1120x0.42=2667 m 3/h.

d) Continue horizontally to the left. After crossing the straight

line, continue upwards until crossing the straight line relative

to the overpressure of the pipe, 400 mmH2O.

e) Continue upwards until crossing the straight line.

f) Continue to the right until the straight line relative to theinsulated pipe. After crossing this last straight line, the

pipe diameter, 122 mm, is determined on the right top

part. The commercial diameter right above is the one to be

considered.

The exhaust pipe cannot have a lower diameter than the

collector pipe of the engine exhaust, and also, the straight

stretches must have a slight inclination in order to prevent

the return of condensates, as shown on the location plan of

the genset in the room.

When the diameter of the pipe is higher, the engine joint

must have a conic connection element with a conicity below30º in order to avoid excessive load losses.

B. Exhaust pipes measuring for Sound Attenuated Static

Gensets.

Check with the HIMOINSA engineering department. There is

backpressure in the outlet of the genset which is caused by

the internal pipes. It is necessary to know this value so as not

to exceed the recommended backpressure when designing

the rest of the installation.

• Exhaust silencer

The exhaust silencer is usually attached to the stretch of pipe

that remains inside the room where the genset is located.

Whenever possible, it can be separated from the genset.

The silencer used in industrial applications performs a 15 to

20 decibels noise reduction.

In order to reduce the noise, the position of the silencer can

be altered, by reducing the length of the tube that goes into

the engine. For example, for a 10m long pipe, the optimal

position would be half-way through the distance in relation

to the outlet. In the cases of private installations, such as

hospitals or residential areas, where a higher noise reduction


17/69


is required, special silencers can be used, with a reduction

of 25 to 30 decibels, and whenever possible, using special

quiet chambers.

3.4.3 Ventilation Adequate ventilation is essential for proper operation and

durability of the generator set.

The generator set room must:

1. Allow the dissipation of the heat produced when the genset

is in operation by irradiation and convection.

2. Provide sufcient air ow for combustion and engine

cooling.

3. Allow the engine cooling by means of the radiator, keeping

the operating room temperature within the safety limits in

order to guarantee a good aspiration of the supply air.

A good ventilation solution applicable to most cases is theone indicated in the charts of the sections of the installation,

in which the engine fan draws in the cooling air from the

engine room, whereas the hot air is expelled through the

expulsion tunnel placed between the radiator and the room

window.

The expulsion window must be bigger or same size as the

radiator in case of standard static gensets, and bigger or

same as the expulsion grid in case of sound attenuated

sets.

Prevent the radiator exhaust hot air from coming back to the

engine room, making sure the expulsion conducts are leak-proof. Therefore, the air in the engine room is constantly

renovated, and the dimensions of intake grilles must be big

enough for the cooling and combustion.

In order to achieve a correct air ow, the cool air must be

introduced through the grilles that are located on the lower

part of the engine room wall. This wall should be the one

located opposite the radiator, so that the air ows all over the

set before being expelled through the fan.

Make sure there are no areas in the engine room where the

air is deposited. This usually happens in rooms with several

engines. In those cases, and whenever possible, each groupshould have its own air intake grille.

In case you need more details about the air ow required for

the different types of HIMOINSA gensets, please contact to

the manufacturer.

For safety reasons, in those premises where there are

sets in continuous operation, or in those areas where the

room temperature is high, it is advisable to use an auxiliary

extractor fan that has enough power to achieve a suitable

ventilation. Such extractor fan must be located on top of the

room, as close to the radiator as possible.

3.4.4 Remote Fuel TankThe generator set is supplied with an integrated fuel tank.

In some situations, a remote fuel tank may be required. Th

remote fuel tank must be properly connected to the engin

so the fuel transfer pump can draw fuel properly.

The remote tank must be located no more than 65.5 ft (2

m) from the engine and no more than 16.5 ft (5 m) below th

engine.

Generator sets supplied by HIMOINSA include a comple

fuel installation, since the fuel tank is located on the bedpla

of the genset.

The fuel tank is connected through exible tubes in ord

to guarantee their operating durability, depending on thmodel.

For longer run times, and in order to satisfy special demand

it may necessary to use a special tank that is tted separate

It will be necessary to connect the engine to the new tan

and install exible connections and new suitable pipes th

must be rmly connected. The new fuel tank must be locate

according to the following criteria, so that the engine injectio

pump is able to draw in fuel from the new tank:

• Closer than 20m from the engine, in case they are both

the same level.

• Less than 5m deep.

The usual connections are:

• For fuel injections to the engine injection pump.

• For fuel excess returns from the injection pump.

• For drain return of the injectors.

The pipes must not have any welds. They can be madof steel, iron or cast iron. Galvanized steel pipelines mu

not be used. Flexible connections must be tted in order

isolate the static parts of the plant from the new fuel tank,

order to avoid the possible vibrations caused by the engin

Depending on the type of engine, these can be made usinthe following:

Stretches with a suitable length made of reinforced rubb

pipes with exible insertions that are resistant to gas oil. F

the connections with the terminal rubber holders with edge

and screw clamps.

Flexible low-pressure type tubes, suitable for gas o

protected with metal mesh and with screwed terminals f

tightly-sealing. Synthetic resins must be avoided.

In complementary areas of the plant, maximum attentio


18/69


must be paid to the following issues:

- Fix pipes by means of holders, at regular intervals in a

way that vibrations and inexions caused by pipes weight

are avoided, especially those made of copper tube.

- Couplings must be avoided. In case of using them they

must be tightly-sealed, especially in depression conditions

parts (fuel aspiration intake), in order to avoid air ltrationsthat make the startup more difcult.

- Aspiration pipes below the fuel level must be placed at

a distance of 20-30mm from the bottom, in order to avoid

a possible deactivation of the circuit due to insufcient air.

Also, these must be conveniently separated from each other,

in a way that the fuel return ow does not block the supply

due to the gas oil impurities from the bottom of the tank or

mixed air.

- Thorough cleaning of the used pipes.

- Avoid abrupt variations in the tube section and the use ofelbows with a wide angles in pipes.

3.4.5 HeatingIn cold climates, automatic starting generator sets may need

an engine room heater to keep the engine room above 50° F

(10° C) to ensure the generator starts when needed.

Electric heaters with thermostatic controls ranging from 500

to 1500W, depending on the genset, have also been supplied

with those sets. They maintain the water temperature within

acceptable values in case a sudden start or power input may

damage the engine.

3.4.6 Electrical Connections

^ WARNING

Electrical shock hazard.

Electrical connections must be performed by

a qualied electrician and conform to local

electrical codes.

Refer to the following electrical schematics for your generator

for the proper electrical connection. The generator frame

must be grounded.

The gensets are ready for user connections. When making

the connections, you must comply with the conditions

specied in the diagrams enclosed with the genset.

Manual Genset

The user cables must be connected to the line terminals

which, for standard static gensets, are located inside the

electrical panel, on the rail terminals or at the bottom of the

magnetothermal switch, either inside the panel or in the

moldeada box (check the electrical diagrams included in

the manual of the panel). For sound attenuated sets, the

connection to the grounding terminals is easily accessible

and protected with a methacrylate sheet.

Automatic GensetThe cables that come from the genset, the external power

supply and user shall be connected to their respective

terminals, located in the command panel. The power cables

of the genset shall be connected directly to alternator

terminals of the genset.

The connection to auxiliary services between the set and

the command panel shall be made with a multiple cable and

using the multiple connectors plugs provided with the set.

Cable dimensions

The choice and dimensions of the cables is responsibility of

the person who carries out the installation.

Cable positioning

Power cables, for both manual and automatic sets, must be

placed in suitable channelling, tunnels or protective conduct-

holder. Do not include 400V and 12V (or 24V) cables in the

same channelling.

Grounding

Metal parts of installations which are exposed to human

contact, and due to an insulation aw or other reasons,

may get in contact with voltage, must be connected to land-

dispersion device.

The gensets and panels have been equipped with their

respective grounding terminals. The connection of these

to the land-dispersion must be made with bare copper

wires conductors with a minimum section of 16mm2, or

if not available, galvanized iron with a 50 mm2 section.

The resistance of such conductor, including the contact

resistance, must not exceed 0.15 Ohm.


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3.3.7 Three Phase Generator Sets

3. Installation


20/69


3.3.8 Single Phase Generator Sets

3. Installation


21/69


4. Prestart Checks

4.1 Prestart ChecksBefore starting the generator set engine, perform the

following prestart checks:

Verify all guards and covers are in place and fasten tight.

Check entire machine for loose hardware. Tighten all loose

hardware.

Fill fuel tank with fuel.

Check engine coolant hoses for damage and loose clamps.

Check level of engine oil on dipstick (1). Oil must be between

the min and max levels on dipstick. Add the recommended

oil if necessary.

Check coolant level in radiator (2). Add coolant to proper

level if low.

Check the engine and alternator for any signs of damage,

water, oil or fuel leaks.

Verify intake and outlet air vents and grills are not obstructedor blocked.

Verify that there are no obstructions in engine intake air lter

tube.

Check fuel lter/water separator (3) (if equipped) for water or

contaminants. Drain if necessary.

Verify battery cables are properly connected and tight.

Once engine is started, warm engine with a reduced load

before applying full load. This does not apply to emergency

power generators.


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5. CEM7 Control Panel

5.1 IntroductionThe CEM7 digital control panel is a monitoring system for

the genset electrical signal and also manages the genset

engine.

The control panel consists of 2 different modules:

5.1.1 Display Module (Control Panel)The display module provides information about the status of

the device and, at the same time, allows the user to interact

with it. The user is able to control, program and congure the

functions of the unit. This module allows checking of the last

10 failures registered in the control unit (fault history).

5.1.2 Measurements ModuleThe measurements module controls and monitors the control

board. Every signal, sensor and actuator is connected to this

module.

NOTE: An optional programming timer module can be addedto the display module, which would allow it to carry out start-

up, locking, and programmed maintenance functions.

The control panel provides the following readings of the

electric mains supply:

• Phase to neutral voltage.

• Phase to phase voltage.

• Phase amperage.

• Frequency.

• Real, apparent and reactive powers.

• Power factor and cos phi.

• Instant power (Kwh) and historical power (day, month,year) of the genset (with option programming timer).

The control panel provides the following engine information:

•Engine alarm inputs:

- Fuel reserve.

- Oil pressure.

- Coolant temperature.

- Coolant level.

- Emergency stop (stop button).

• Analogic engine inputs:

- Fuel level. - Pressure.

- Temperature.

- Congurable input (i.e. Oil temperature).

- Battery charger alternator voltage

• Congurable inputs:

The measurements device has 5 inputs that can be

programmed to carry on the following functions:

Default conguration applied in the factory:

- Start disabling.

- External start.

Consult conguration with your distributor or authorized

technical service:

- Mains contactor conrmation - Genset contactor conrmation.

- Rate change notice.

- Rate change.

- Start disabling.

- External start.

- Test.

- Manual override.

- 5 programmable alarms.

- Self-programming (S1-S2)

• Engine statistics:

- Number of working hours.

- Number of starts.

• Functions of the engine:

- Pre-heating or glow plug.

- Stop.

- Start.

- Coolant heater.

- Fuel Transfer pump.

- Alternator excitation.

The measurements module has outputs which allow

monitoring of the operative conditions of the generating set:

• Engine running (on).

• General alarm.

• 3 programmable outputs which monitor the control board

alarm conditions or the inputs about the engine data.

The measurements module commands ouputs to relays

for the activation of the genset contactor and the electronic

overload and short-circuit protection that trip the genset´s

general circuit breaker.

The connection between the measurements and visualization

modules is made by the CAN bus communication, which

allows the interconnection of additional modules, allowingthe expansion of the CEM7 device.

With the bus CAN, additional modules can be added. If

interested, please contact your distributor.


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5.2 Control PanelThe control panel has a backlit display and different LED’s to control the device status. Different push buttons allow the

user to command and program the control panel.

1

2 3 4 5 6

7

8 9 10

NOTE: The display turns off the backlighting (low consumption mode) after 10 minutes without any detectable pulse on th

keyboard.

1 - Backlit Display

2 - Start Button

3 - Stop Button

4 - Reset Button

5 - Diesel Transfer Button

6 - Auto Button

7 - Display Buttons

8 - Contactor Status LEDs

9 - Engine Status LEDs

10 - Engine Alarm LEDs



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5.3 Control Panel Push Buttons

5.3.1 Operating Mode Buttons Automatic mode.

The CEM7 device monitors the status of the generating set and controls its working process and the

programmable inputs.

LED On: Automatic mode running.

LED Flashing: Automatic mode blocked.

LED Off: Manual mode running.

5.3.2 Command Buttons Start engine push button (manual mode only).

Control Starts with only one push down.

LED on: Engine running.

Stop engine push button (manual mode only).

Press once, a cooling phase begins and then the engine stops.

Press twice, the engine stops immediately.

LED on: The engine is in stopping phase (with or without cooling down).

Reset push button.

Allows the user to acknowledge and clear the alarm condition.

LED ashing: There are alarms to check up.

LED on: Active alarms.

Transfer fuel pump push buttons.

In manual mode, this button activates the transfer pump if the fuel level is under the programmed levels.

LED on: Fuel transfer pumps working.

5.3.3 Display Buttons

Conrmation button (V). Allows access to menu and validates and store the entered data.

Cancellation button (X). Go back in the menu and cancels the entered data.

Up button (+). Moves along the selection displays and maintenance menus, also

increases the programmed values.

Down button (-). Moves back in the selection display and maintenance menus, it also

reduces the programmed values.


DIESEL

TRANSF

RESET

START

STOP


25/69



5.4 Data LED’s

5.4.1 Contactor Status LEDs

Mains contactor status.

On: Contactor activated.

Flashing: Alarm, conrming the contactor is activated. Off: Contactor deactivated.

Generating set contactor status.

5.4.2 Engine Status LEDs Engine started

On: Engine running detected.

Off: Engine stopped.

Engine starting

On: Engine starting activated.

Off: Engine starting not activated.

Pre-heatingOn: Pre-heating function activated.

Off: Pre-heating function not activated.

Battery charger and alternator status

On: The voltage supplied by the battery charger alternator is detected when the engine is running.

Off: Engine stopped or started without voltage signals in the battery charger alternator.

5.4.3 Alarm LEDs Fuel level

Battery levels

High temperature

Overspeed

Low oil pressure

Starting failure

Aux1 (Free to program)

Aux2 (Free to program)

On: Alarm caused by analogic sensors.

Flashing: Alarm caused by digital inputs.

Off: No alarms. NOTE: See alarms section for more details.

M

G

M

G

-B

W

+D +B

M

Aux. 1

Aux. 2

M


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5.5 Starting And Stopping Genset

Perform pre-start checks. See Section 4 in this manual.

NOTICE

Avoid electrical system damage.

Turn genset main circuit breaker off before

starting generator engine.

5.5.1 Starting - Manual Mode Push START button to activate the engine

starting process. The start button LED

will be illuminated. If the engine is

equipped with a starting aid, the appropriate

LED will be illuminated and there may be a delay before the

engine starts.

If the engine fails to start at the rst crank, the control panel

will wait for 5 seconds before attempting another start cycle.

It is not necessary to press start button again. The generator

will attempt to start 4 times. If the engine is still not running,

the control panel will trigger the start failure alarm.

To stop the start cycle, press the stop button.

Readings about the engine condition are shown on the

display panel and the start sequence details can be seen.

The sequence is as follows:

– Genset: Stop

– Genset: Starting

– Genset: Started

– Genset: Stabilized

– Genset: Loading

The starting process in an automatic system by means

of timer, ATS signal, etc. and works in the same way as a

starting cycle in manual mode.

5.5.2 Stopping - Manual Mode

NOTICE

Avoid electrical system damage.

Turn genset main circuit breaker off before

stopping generator engine.

The generator engine can be stopped

using one of two methods. Pressing the

stop button once will stop the engine

after a 20 second cool down cycle. This is

START

STOP

the recommended procedure. Pressing the stop button twice

will stop the engine immediately. This is not recommended.

Use this procedure only in an emergency situation.

Push the STOP button once to stop the engine after a 20

second cool down cycle.

Push the STOP button twice to stop the engine immediately,

without cooling down cycle.

5.5.3 Starting And Stopping - Automatic

Mode In automatic mode, the control panel

constantly controls the Gen-set operation.

In some situations, the gen-set can be

programmed to supply power, the controller

starts the generator set activating the gen-set contactor.

Programmable operational modes to start the Gen-Set:

• External start.

• Start controlled by timer.

• Forced start.

• Rate change notice.

• Engine test.

• Controlled by the transfer switch control board

The gen-set will stop after a 20 second cooling down cycle

after the deactivation of the command which automatically

started the genset.

5.6 Interruption Of Function Mode When the control panel is in manual mode,

the automatic mode can be initiated bypressing the AUTO button for 5 seconds.

This blocking function does not allow the

change of modes and the button of the mode running at that

moment will ash. To deactivate the automatic interruption

mode and allow the change of operational modes, press the

AUTO button for 5 seconds.

5.7 Working ModeThe generator engine works in the following way, once the

control panel detects an activation condition:

1. Delay in the starting: Once an activation conditionis detected, and before going on with the engine

starting process, a delay in the engine starting can be

programmed.

2. Engine pre-heating phase: The control board activates

the pre-heating output for a programmed time.

3. Engine Start Enabling (run signal): The engine run

signal is made by means of the PC (B+) output from the

measurements module. The output allows a no-excitation

stop (energized to-run) or an excitation stop (energized



27/69


to-stop). This output is congurable.

4. Engine starting: For a programmed period of time, the

starting output of the measurements module is activated,

waiting to detect, at least, one of the programmed starting

conditions. The possible engine starting conditions could

be:

• Generator voltage: The engine would be considered

started (running) when its voltage exceeds a given value.

• Alternator voltage: The engine would be considered

started (running) when the battery charger alternator

voltage exceeds a given value.

• Pick up frequency: The engine would be considered

started (running) when the pick up frequency exceeds a

given value. To activate the pick up calculation through the

engine ring gear, the number of teeth of the gear must be

introduced. In case the number of teeth is “0”, the frequency

of the pick up will be calculated through the generatorfrequency as per the equivalence-ratio 50Hz/1500 rpm or

50Hz/3000 rpm and 60 Hz/1800 rpm.

• Low oil pressure: It is not advisable to use the low oil

pressure signal as a way to detect if the engine is working,

but it is useful as a protection, in order to avoid engaging

the starter while the engine is running.

If in the programmed time the starting of the engine is not

detected, the control board waits for a short time before

attempting a new start. The start failure alarm will be raised

after a specied number of attempts without detecting any

starting condition.

In the starting cycle, the excitation of the battery charger

alternator is activated temporarily through the D+ output. Once

the excitation of the alternator is nished, the measurements

module checks if the battery charge alternator is working

properly. The battery charge alternator failure alarm is raised

in case of an output failure.

• Genset stabilization: Once any of the starting conditions

is detected, the controller waits for a programmed

stabilization-time of the generator output, before monitoring

output parameters.

• Nominal condition: Once the stabilization of the engine

is reached, the next step is the checking of the signal

produced by the generator. In this way, the quality of the

signal produced by the generator set is monitored (voltage

levels, frequency).

5.8 Transfer Fuel PumpThe fuel transfer pump function can be activated in the

control panel by linking its working service to the BT relay in

the measurements module.

Once the transfer pump option is activate

its operation modes are as follows:

Inhibited mode: The transfer pump is blocked fro

operation.

Manual mode: The transfer pump is operated by pressingthe diesel transfer button, provided that the fuel level is und

the maximum threshold parameters.

Automatic mode: The transfer pump becomes operative

• According to the minimum activation parameters, und

which the relay BT is activated.

• According to the maximum deactivation parameters, ov

which the relay BT is deactivated.

Control board mode: The transfer pump operation is carrie

out as follows:

• When the controller is in automatic or test-mode, th

transfer pump is operated automatically.

• When the controller is manual-mode, the transfer pum

operation is carried out in manual mode.

• When the controller is in a blocked-mode, the transf

pump operation is inhibited (CEM7+CEC7).

5.9 AlarmsThe CEM7 distinguishes between anomalies which caus

the stop of the engine (alarms) and errors, which do not sto

the engine (warnings).

When an alarm or warning is detected, the controller produc

an acoustic alarm, at the same time the digital alarm outp

(AL) activates and the LED of the reset button ashes; th

status will remain the same as long as the failure conditio

continues for a programmable period of time.

The LED of the reset button lights when alarms or warning

are active or in need of acknowledgement. Pressing res

button once allows the user to see a record of alarms an

warnings that are active and needing to be acknowledge

The up and down buttons of the display are used to go ba

and forward in the failure record. A second press of res

silences the alarm.

The record of warnings that are active or

need of acknowledgement has the

following format:

*A L A R M* E N 1 / 3

M I N F R E Q U E N C Y G E N S E T

E: Alarm or A: Warning

N: To be checked

DIESEL

TRANSF

RESET



28/69


1: Number of position in the total record of errors

3: Number of errors in the record

The LEDs on the control panel indicate alarms detected by

the sensors.

The alarms which cause the engine to stop are not auto-

resetting. They must be acknowledged and re-set by theuser in order for the engine to start again, but only if the

alarm does not remain active.

The warning alarms do not stop the engine. They need to be

reset to erase them from the display, but only if the warning

does not remain active. The fuel level alarm is an exception,

as it is automatically reset.

5.9.1 Reseting AlarmsEN - Alarm with engine stop.

AN - Warning that needs to be reset, engine does not stop.

A - Warning that automatically resets.

EN Alarm with engine stop.

When an alarm is detected, the controller produces an

acoustic signal, the LED of the RESET button ashes, the

display blinks and the appropriate digital alarm output (AL)

is activated. In this case the engine stops.

The acoustic alarm is silenced by pressing the reset button

once. The reset LED turns into xed light and the display

(which stops ashing) shows the kind of alarm.

Determine the cause of the alarm. Once the alarm is no

longer active “N”, press reset button and the engine can berestarted.

AN Warning.


acoustic signal, the LED of the reset button ashes, the


is activated.

The acoustic alarm is silenced by pressing once the RESET

button. Once the RESET LED turns into xed light and

the display (which stops ashing) shows the kind of Active

warning “AN”.

Determine the cause of the alarm. Once the alarm is no

longer active “N”, press reset button to reset alarm.

A Warning.


acoustic signal, the LED of the reset button ashes, the


is activated.

The acoustic alarm is silenced by pressing the RESET

button once. The RESET LED turns into xed light and the

display (which stops ashing) shows the kind of warning.

Warning “A”.

This kind of warning is automatically reset as long as nominal

working conditions are restored. It is focused on the type of

alarms related to fuel level and the alarms related with the

mains threshold.



29/69


DESCRIPTIONLED ON CONTROL

PANELTYPE

High water temperature (ATA) (HCT)

Immediate engine stop with no cooling.LED ashes Alarm

Low oil pressure (BPA) (LOP)Immediate engine stop with no cooling.

LED ashes Alarm

Emergency stop (PEM) (EMS)

Immediate engine stop with no cooling. Alarm

Battery charge alternator failure (engine running)

Engine does not stop.LED off Warning

Start failure LED ashes

Low coolant level (CL)

Immediate engine stop with no cooling.LED ashes Alarm

Fuel level

Engine does not stop. LED ashes Warning

Overspeed

Immediate engine stop with no cooling.LED on Alarm

Loss of speed

Engine stops with cooling. Alarm

Low battery voltage

Engine does not stop.Warning

High water temperature by sensor

Engine does not stop.LED on Warning

Low oil pressure by sensor


Low fuel level by sensor Engine does not stop.

LED on Warning

Unexpected shutdown

Stop failure

Low engine temperature

Engine does not stop.Warning

Genset voltage drops

Engine stops with cooling. Alarm

M

G

-BW

+D +B

5.10 Engine Alarms



30/69


DESCRIPTION TYPE

Overload.

Engine stop with cooling. Alarm

Genset voltage asymmetry.

Engine stop with cooling. Alarm

Maximum voltage of the genset.


Maximum genset frequency.


Erroneous phase sequence of the genset.


Inverse power


Short circuit.


Minimum genset voltage.Immediate engine stop with no cooling.

Alarm

Minimum genset frequency.


5.12 Programmable Alarms And Inputs

DESCRIPTION TYPE

Related with programmable inputs.

According to conguration. Alarm

5.11 Genset Alarms



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6.1 Control Panel - M6

1 2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

6. M6 Control Panel


33/69


1. On/Off Switch: Used to connect and disconnect the

controller.

2. Mode Selection Key: (MAN/STOP/AUTO). In “MAN”

position, the control panel will initiate a start engine

sequence (1 attempt to start ). In “STOP” position, the

controller will stop the genset. In “AUT” position, controller

will remain in automatic mode and will do as follows: if freevoltage contact closes, the controller will start the genset.

If the contact opens, the genset will stop.

3. Emergency Stop: Press to stop engine immediately. The

LED will be illuminated until the emergency stop button

has been reset.

4. Overspeed Indicator (Red). The LED will illuminate if

one of the following conditions occur: During the over

speed programming, to indicate that the programming

was successful, and also when the internal overspeed

protection device trips. When the overspeed protection

device trips, the controller initiates a stop cycle and thewarning indicator will be illuminated until reset.

5. Low Oil Pressure Indicator (red). Indicates that the

engine oil pressure switch has detected an anomaly. This

protection activates an engine stop cycle. The LED will

remain illuminated until the alarm condition is reset.

6. High Water Temperature Indicator (red). Indicates that

the engine coolant temperature sensor has detected an

anomaly. This signal activates an engine stop cycle. The

LED will remain illuminated until the alarm condition is

reset.

7. Engine Failure Indicator (red). Indicates that the engine

has stopped without a stop signal from the controller.

8. Fail To Start Indicator (red). Indicates that the controller

completed 5 attempts to start the engine, but the engine

did not start.

9. Power Supply On Indicator (green). Indicates that the

controller is on when illuminated.

10. Reset Button. Push to restart the operation cycle of the

controller.

11. Engine Running Indicator (green). Indicates that the

engine is running when illuminated.

12. Activated “LT” Contactor (green). This LED is illuminated

when the free-voltage contact is closed. The LED goes

out when the contact is opened.

13. Cooling Stop Indicator (yellow). This led starts blinking

in 1 second intervals when the controller initiates a stop

engine cycle. The LED will stop blinking when the engine

has stopped.

14. Pre-Heating Indicator (yellow). The LED starts blinking

1 second intervals during the engine pre-heating cycle

15. Auxiliary Alarm Indicator (yellow). Indicates that th

alarm condition established in the auxiliary input

the controller has been detected. The LED will rema

illuminated while the alarm condition is active.

16. Battery Charger Failure Indicator (D+) (yellow). Indicat

that the generator battery charger is not charging th

battery. The LED will remain illuminated while the alar

condition is active.

17. Fuel Reserve Indicator (yellow). Indicates low fuel lev

in the tank. The LED will remain illuminated while th

alarm condition is active.

6.2 Starting And Stopping Genset - M

Control Panel

6.2.1 Starting - Manual ModeMove on/off switch to the on position (1). The controller will ru

an internal diagnosis and lamp checking program, lighting

LEDs on the control panel. The controller remains on hol

as long as the mode operation key is in the stop position.

Move mode section key (2) to the man position. The controll

initiates an immediate start of the engine. After a programme

warm up cycle, the genset contactors automatically close.

1

2

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6.2.2 Stopping - Manual ModeMove mode selection key (2) to the stop position. The

controller initiates the stop of the genset and holds for a

mode change. Move on/off switch to the off position (1)

Note: Under no circumstances can the generator be stopped

by switching the controller off or by pushing the reset button.

The only way to stop the engine is by turning the key to thestop position.

6.2.3 Starting And Stopping - Automatic

ModeMove on/off switch to the on position (1). The controller will run

an internal diagnosis and lamp checking program, lighting all

LEDs on the control panel. The controller remains on hold,

as long as the mode operation key is in the stop position.

Move mode section key (2) to the auto position. In this mode,the engine start is co-ordinated with the closing of the free-

voltage contact. When this contact is closed, the controller

initiates up to 5 attempts to start in sequence as long as there

is no engine running detection. Every attempt is 5 seconds

long and the time in between attempts is 10 seconds.

When the free-voltage contacts opens, the controller initiates

to stop, and holds before the contact closes again or waiting

for a change of operation mode.

1

2

1

2

NOTE: If the controller disconnects, resets, or fails power

supply, once it is restored, if set to manual or automatic mode

with the free-voltage contact closed, the genset will start.

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DESCRIPTIONLED ON CONTROL

PANELTYPE

High water temperature

Engine stops.LED ashes Alarm

Low oil pressureEngine stops

LED on Alarm

Emergency stop

Engine stops. Alarm

Battery charge alternator failure (engine running)


Start failure LED ashes

Fuel level

Engine does not stop.LED ashes Warning

Overspeed

Immediate engine stop with no cooling.LED on Alarm

Unexpected shutdown LED ashes

High coolant temperature

Engine stops.LED ashes Warning

6.3 Engine Alarms

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7. DSE3000 Series Control Panel

7.1 Description Of Controls

The following section details the function and meaning of the

various controls on the module.

1 - Navigation Buttons 2 - Main Status Display

3 - Common Alarm Indicator 4 - Start engine.

5 - Select Auto Mode 6 - Select Stop Mode

7.2 Quickstart GuideThis section provides a quick start guide to the module’s

operation.

7.1.1 Starting The Engine1. First press Stop/Reset (1).

2. Then, press the Start button to crank the engine. Depending

upon module conguration, two presses may be required.

7.1.2 Stopping The Engine1. Select Stop/Reset mode (1). The generator is stopped.

7.3 Graphical Display A 32x132 pixel LCD (35mm / 1.4”) is available for the display

of generator instrumentation and alarm conditions. The

display is segmented into areas for instrumentation, unit,

alarm icons and for Front Panel Editor (FPE) use.

When not in the Front Panel Editor (FPE) mode the FPE

area of the display is used to display the currently active

conguration. The letter ‘M’ is displayed for main conguration

active, the letter ‘A’ for alternative conguration active.

VIEWING THE INSTRUMENTSIt is possible to scroll to display the different pages of

information by repeatedly operating the scroll button.

Once selected the page will remain on the LCD display until

the user selects a different page or after an extended period

of inactivity, the module will revert to the status display.

When scrolling manually, the display will automatically return

to the Status page if no buttons are pressed for the duration

of the congurable LCD Page Timer.

If an alarm becomes active while viewing the status page,

the display shows the Alarms page to draw the operator’sattention to the alarm condition.

Page order:

Engine Speed

Generator Volts

Generator Frequency

Engine Run Time

Battery Volts


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7.4 ControlsStop / Reset

This button places the module into its Stop/Reset mode.

This will clear any alarm conditions for which the triggering

criteria have been removed. If the engine is running and

the module is in Stop mode, the module will automatically

instruct the changeover device to unload the generator

(‘Close Generator’ becomes inactive (if used)). The fuelsupply de-energizes and the engine comes to a standstill.

Should a remote start signal be present while operating in

this mode, a remote start will not occur.

Auto

This button places the module into its

‘Automatic’ mode. This mode allows the

module to control the function of the generator

automatically. The module will monitor the

remote start input and once a start request

is made, the set will be automatically started

and laced on load. Upon removal of the starting signal,

the module will automatically transfer the load from thegenerator and shut the set down observing the stop delay

timer and cooling timer as necessary. The module will then

await the next start event.

Start

Pressing this button in auto mode will start the

engine and run off load. Pressing this button

in STOP/RESET mode will turn on the CAN

engine ECU (when correctly congured and

tted to a compatible engine ECU)

PagePressing this button scrolls the display to show

the various instruments.

7.5 Automatic Mode Of Operation

NOTE:- If a digital input congured to panel lock is active,

changing module modes will not be possible. Viewing the

instruments and event logs is NOT affected by panel lock.

Activate auto mode by pressing the AUTOpushbutton. The line/arrow icon around AUTO

is displayed to indicate Auto Mode operation if

no alarms are present.

Auto mode will allow the generator to operate fully

automatically, starting and stopping as required with no user

interv

Documents

HIPOWER Yanmar Generators Manual