The Mase Generators Silent 12 is a generator set designed for various applications, offering a balance of power, reliability, and ease of maintenance. This manual provides comprehensive information for its operation, maintenance, and troubleshooting.
Function Description
The Silent 12 generator set is an electromechanical device that converts mechanical energy into electrical energy. It is equipped with an electronic voltage regulator (AVR) to ensure stable output voltage. The generator is designed to provide a continuous power supply for various needs, from industrial applications to emergency backup. The unit is enclosed in a soundproof casing, making it suitable for environments where noise reduction is critical.
Important Technical Specifications
Alternator:
- Type: Synchronous, 4-pole, brush-less self-excited
- Voltage Regulation: Electronic voltage regulation (AVR)
- Cooling: Air
- Voltage (V): 115 - 230
- Frequency (Hz): 50
- Amps: 97.4 - 48.7
- Max. power (kW): 11.2
- Continuous power (kW): 10.2
- Power factor (Cos φ): 1
- Insulating class: H
- Voltage stability: ±2%
- Frequency stability: ±5%
The alternator generates a three-phase rotor winding that induces a voltage in the auxiliary excitation windings. This voltage is rectified and applied to the stator windings, which generate a magnetic field that induces an alternate current in the three-phase rotor windings. The voltage is rectified by the rotating diode bridge and applied to the rotor excitation windings, which induce in the primary winding the rated voltage to the generators terminals. The electronic voltage regulator monitors the excitation current and controls the output voltage at the genset terminals to ensure it is near the nominal value.
Engine:
- Model: 3 TNE 88
- Application: 4-stroke, vertical, water-cooled diesel engine
- Combustion system: Direct injection
- No. of cylinders - Bore x Stroke: 3 - 88 x 90 mm
- Cylinder block material: Cast iron
- Displacement: 1642 c.c.
- Rotation speed (Rpm): 1500 (continuous power), 1800 (maximum power)
- Power (PS): 16.7 (continuous power), 18.4 (maximum power)
- Direction of rotation: Anticlockwise (flywheel view)
- Power takeoff: Flywheel
- Compression ratio: 18:1
- Injection timing (FID, b.T.D.C.): 10±1 degrees
- Recommended diesel fuel: ISO 8217 DMA, BS 2869 A1 or A2 (Cetane number: min. 45)
- Lubrication system: Forced lubrication with trochoid pump
- Engine oil tank capacity: 4.7 liters (min.), 5.8 liters (max.)
- Recommended engine oil: API quality, Class CC or higher
- Cooling system: Coolant/Radiator
- Coolant tank capacity: 2 liters (for engine only), 2.7 liters (total)
- Regulator: Mechanical centrifugal regulator (all speeds)
- Ignition system: Electric
- Engine stopping system: Solenoid / 12V
- Fuel pump: Mechanical
- Max. head fuel pump: 80 cm
- Fuel consumption at full power (l/h): 4 (1500 rpm), 5.6 (1800 rpm), 6.7 (max.)
- Combustion air volume (l/min): 1100
- Max. operating inclination: 30 degrees
Dimensions and Weight:
The manual provides a diagram of the generator with numbered components, including the soundproof casing, alternator access door, engine access door, instrument panel, anchoring brackets, exhaust exchanger, exhaust, air intake, internal fuel tank, external fuel tank, and emergency stop button. The total mass (weight) of the generator is also specified.
Usage Features
The Silent 12 is designed for straightforward operation, with an instrument panel that houses controls and indicators for monitoring and managing the generator.
- Instrument Panel: Equipped with a magnetothermal switch, DC thermal switch, "RUN" light for engine started, pre-heating function, automatic panel connection, and sockets.
- Starting and Stopping: The manual details procedures for starting and stopping the generator, including checks for oil level, coolant level, fuel level, and battery charge.
- Adjustments:
- RPM Adjustment: The alternator's RPM can be adjusted by loosening the counternut and turning the screws until the desired number of revolutions is reached.
- Lock and Handle Adjustment: The doors and handles can be adjusted to ensure proper closure and prevent excessive movement.
- Electrical System: The electrical system includes a magnetothermal switch (AC circuit breaker), 12V line thermal switch, engine wiring, battery charger alternator, engine electromagnet, and starter motor. The manual provides test methods and remedies for issues related to these components.
Maintenance Features
Regular maintenance is crucial for the longevity and optimal performance of the Silent 12. The manual outlines a detailed maintenance schedule and procedures.
Maintenance Schedule:
The manual provides a table for maintenance operations with corresponding hours:
- Engine oil level check: 10 hours
- Coolant level check: 10 hours
- Check that there are no oil leaks: 10 hours
- Check that there are no fuel leaks: 20 hours
- Check that there are no coolant leaks: 20 hours
- V-belt tension adjustment: 100 hours
- Battery charger check: 200 hours
- Clean the fuel filter: 200 hours
- Belt tension adjustment: 200 hours
- Engine oil change: 200 hours
- Check the seawater pump rotor: 400 hours
- Check the engine rpm: 400 hours
- Check integrity of the electrical connections: 400 hours
- Fuel filter replacement: 400 hours
- Oil filter replacement: 400 hours
- Check the injectors: 400 hours
- Check the injecting timing: 400 hours
- Intake/exhaust valve play adjustment: 400 hours
- Check the fuel injection pump: 1,000 hours
- Battery electrolyte level check: Monthly
- Clean and deoxidise the metallic parts: Yearly
- Air filter cleaning: Yearly
- Complete coolant change: Yearly
Lubrication:
- Engine Oil: Use API Service Class CC or higher. Oil should be changed after 50 hours initially, then at intervals of 250 hours. The manual provides a chart for recommended SAE gradations based on ambient temperature.
- Lubrication System Diagram: A detailed diagram illustrates the lubrication system, including the oil filter, pressure switch, safety valve, oil pump, intermediate gear, cylinder block main duct, camshaft bearing, main bushing, connecting rod bushing, oil sump, and equalizer.
Fuel System:
- Fuel Quality: Use diesel fuel of a quality equivalent to ISO 8217 DMA, BS 2869 Part 1 Class A1 or Part 2 Class A2.
- Fuel Filter Cartridge: Replace according to the maintenance chart.
- Fuel System Diagram: A diagram shows the fuel system, including the injector, high-pressure injection pipe, fuel return pipe, injection pump, fuel filter, and fuel pump.
Cooling System:
- Closed-circuit/seawater cooling system: The manual includes a diagram of the cooling system, highlighting the radiator/exchanger.
Sensors:
- Thermostatic Valve: Test by immersing in water and heating to check continuity at specific temperatures (69.5-72.5°C). Replace if faulty.
- Closed-circuit Engine Thermal Switch: Test by immersing in antifreeze fluid or oil and heating to check continuity at 107-113°C. Replace if faulty.
- Oil Pressure Switch: Test by starting the engine and checking continuity with a tester. Replace if faulty.
Disassembly:
The manual provides detailed instructions for disassembling various components:
- Casing: Remove side doors and the top panel. Unscrew anchor screws and remove panels. Detach connectors, unscrew panel screws, disconnect cables, and remove the under instrument panel. Remove fixing screws.
- Engine-Alternator Group: Remove the engine-alternator group, fuel tank, and fuel level sensor.
- Alternator: Remove the 4 screws of the alternator cover. Remove the retaining screws of the alternator cover on the side. Use an extractor to remove the cover. Use a winch to lift the stator casing. Remove anchor screws and slide the fan and rotor from the flywheel housing.
Troubleshooting:
The manual includes comprehensive troubleshooting tables for both engine and electrical system issues, providing possible causes and remedies.
This comprehensive manual ensures that users can effectively operate, maintain, and troubleshoot the Silent 12 generator set, maximizing its lifespan and performance.
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