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SDMO R 340 U - User Manual

SDMO R 340 U
287 pages
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User and maintenance manual
for generating sets
R
3
4
0
U
33504081101NE_0_1

Table of Contents

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SDMO R 340 U Specifications

General IconGeneral
Acoustic pressure level @7m68 dB(A)
Displacement296 cc
FuelDiesel
Power factor0.8
Voltage230 V
Weight120 kg
Frequency50 Hz
Starting systemElectric
Engine TypeDiesel
Fuel TypeDiesel
Fuel Tank Capacity25 L

Summary

1. Preface

1.1. General recommendations

General advice for operating and maintaining the generating set correctly, including safety instructions.

1.2. Pictograms and their meanings

Explains safety notices and symbols used on the equipment for danger identification and action.

1.3. Instructions and safety regulations

Essential safety guidelines and regulations for installing and maintaining generating sets.

1.3.1 General advice

Advice on personnel training, facility operation, safe practices, and maintenance procedures for generating sets.

1.3.2 Risks related to exhaust gases and fuels

Details risks associated with carbon monoxide in exhaust gases and safe handling of fuels, emphasizing ventilation.

1.3.3 Risks related to toxic products

Covers hazards from corrosion inhibitors, anti-rust products, and glycol, emphasizing safety precautions.

1.3.4 Risk of fire, burns and explosion

Outlines dangers of operating near explosive products and risks associated with hot parts, fuel, and battery gases.

1.3.5 Risks related to electrical networks

Discusses electrical safety, compliance with standards, cable types, and correct connection procedures for generating sets.

1.3.6 Dangers presented by electric currents (first aid)

Provides first aid instructions for electric shock victims, including resuscitation and moving the victim safely.

1.3.7 Risks related to moving the set

Safety procedures for unloading and moving generating sets, ensuring proper lifting equipment and ground support.

1.4. Identifying sets

Explains how to identify generating sets and their components using identification plates.

2. General description

2.1. Description

Identifies major components of the generating set through a diagram and numbered list.

2.2. Technical specifications

Details technical specifications for the generating set, including dimensions, weight, noise level, and output data.

2.3. Fuel and consumables

Information on recommended fuel types and consumables, including oil grades and coolant specifications.

2.3.1 Specifications

Provides detailed specifications for oil grades, including properties and uses.

2.3.1.2. Specifications of coolants

Details specifications for cooling fluids, including properties, approvals, and handling recommendations.

3. Installation

3.1. Unloading

Instructions and safety measures for safely unloading generating sets from transport supports.

3.1.2 Instructions for unloading

Detailed steps for unloading generating sets using slings or a forklift truck.

3.3. Choice of location

Guidelines for selecting an appropriate location for the generating set, considering ventilation, access, and noise.

3.4. Electricity

Information on electrical connections, cable sizing, and safety guidelines for generating sets.

3.5. Special arrangements

Discusses protection against power surges and the potential installation of lightning conductors.

4. Trailer

4.1. Trailer linkage

Steps for correctly coupling a trailer to a tow vehicle, including safety checks.

4.2. Check before towing

Pre-towing checklist for trailer and generating set enclosure, including wheel tightness and lights.

4.3. Operation

Details operation procedures for "on-site" and "on-road" trailers, including speed limits and tyre checks.

4.5. Implementation for installation

Steps for implementing the trailer installation, including ground preparation and positioning.

4.7. Faults and repairs

Table listing common trailer faults, their origins, and recommended repair solutions.

4.8. Electrical connection diagram

Visual representation of the electrical connections for the trailer lighting system.

4.9. Complete wheels technical information

Technical data for complete wheels, including dimensions, load, and pressure.

5. Preparation before operating the set

5.1. Installation checks

Checks to verify that all installation requirements and general recommendations are met.

5.2. Checks after starting the generating set

Post-start checks on the generating set, covering mechanical, electrical, and safety aspects.

6. Using the generator set

6.2. Generator set with TELYS control panel

Detailed guide to operating the generating set using the TELYS control panel, covering all functions.

6.2.1 Control panel presentation

Details the presentation and components of the TELYS control panel, including buttons and indicators.

6.2.1.3. Description of the pictograms in zone 1

Explains pictograms displayed in zone 1 of the TELYS control panel screen and their activation conditions.

6.2.1.4. Description of the pictograms in zone 2

Details alarm and fault pictograms displayed in zone 2 of the TELYS control panel screen.

6.2.1.5. Description of the pictograms in zone 3

Explains pictograms and data displayed in zone 3 of the TELYS control panel screen for different operating states.

6.2.1.6. Display of messages in zone 4

Describes messages and information displayed in zone 4 of the TELYS control panel screen.

6.2.2 Starting

Step-by-step guide for starting the generating set, including pre-start checks and system operations.

6.2.3 Switching off

Procedures for safely switching off the generating set, including manual and automatic methods.

6.2.4 Alarms and faults

How to view and interpret alarms and faults displayed on the generating set control panel.

6.2.4.2. Activation of an alarm or fault

Explains how alarms and faults are displayed on the screen and how to access help messages.

6.2.4.3. Activation of an alarm and a fault

Describes how the system indicates simultaneous alarms and faults, and how to navigate the fault list.

6.2.4.4. Engine fault codes display

Explains engine fault code standardization and terminology used by different manufacturers.

6.2.4.5. Horn reset

Procedure for resetting the horn after an alarm or fault activates it.

6.3. Generator set with KERYS control panel

Introduction to the MICS Kerys system, its modules, and operating conditions.

6.3.1 Presentation of the KERYS

Overview of the MICS Kerys system architecture, modules, and operational modes.

6.3.1.1. Operating conditions

Specifies the environmental and mechanical conditions for operating the MICS Kerys system.

6.3.1.2. Conformity to legal and regulatory requirements

Lists the standards and directives to which the MICS Kerys system components comply.

6.3.2 Description of the KERYS

Details the description of the KERYS system, identifying hardware components.

6.3.2.1. Identification of the hardware components

Explains how to identify MMI module, base module, and their respective references and batch numbers.

6.3.2.2. Identification of the software components

Describes how to identify software versions for the base, MMI, regulation, and protection modules.

6.3.3 Description of the Man Machine Interface (IHM;MMI)

Details the specifications and features of the Man Machine Interface (MMI) display and keypad.

6.3.3.2. Navigation in the screens

Explains the different types of screens (home, navigation, operation) and how to navigate through the MMI.

6.3.4 Configurations

Outlines the operating principles of different configurations for solo and power plant generating sets.

6.3.4.1. Operating principle

Outlines the operating principles of different configurations for solo and power plant generating sets.

6.3.4.3. Configuration in solo generating set

Describes the configuration for a solo generating set without an inverter, detailing automatic and manual operation.

6.3.4.4. Power plant configuration (Several generating sets in parallel)

Explains power plant configurations with multiple generating sets in parallel, including coupling principles and wattmetric control.

6.3.5 Connections of the generating sets

Details recommendations and procedures for connecting generating sets according to various configurations.

6.3.5.1. Recommendations before the connections

Crucial safety recommendations to follow before performing any work on the generating set connections.

6.3.5.2. Connections according to the configurations

Table outlining connection requirements for different generating set configurations (solo, power plant).

6.3.5.3. Earthing system (Standard only)

Explains the importance and method of earthing generating sets, including rod length based on ground type.

6.3.5.6. Power

Guides on passing power cables through access hatches and connecting them to busbars and the application.

6.3.5.7. Client terminal block

Refers to wiring diagrams for client terminal block connections based on selected configurations.

6.3.6 Operation and setting menus

Overview of the operation and setting menus, including the layout of main menus.

6.3.6.1. Layout of the menus

Displays the hierarchical structure of the main menus and sub-menus for operation and settings.

6.3.6.2. Setting of regional parameters

Instructions for setting regional parameters such as display language, date, and time.

6.3.6.3. Information on the KERYS

Screen that enables project identification for customer service queries, providing site and connection details.

6.3.6.4. Operating menus

Explains the main screen displaying electrical parameters and how to navigate through operating menus.

6.3.7 Rental configurations

Guide for choosing application configurations for solo generating sets and power plants, including specific settings.

6.3.7.1. Choice of application configuration

Guide for choosing application configurations for solo generating sets and power plants, including specific settings.

6.3.8 Use

General section on using the generating set.

6.3.8.1. Choice of priority generating set in power plant (if equipped)

Procedure for selecting the priority generating set within a power plant configuration.

6.3.8.2. Starting, tests and stop

Detailed instructions for starting, performing tests, and stopping the generating set in manual and automatic modes.

6.3.8.3. Rental options

Information on optional features for rental configurations, such as damper valve and air preheating.

7. Maintenance schedule

7.1. Reminder of use

Reminder about the importance of the maintenance schedule and how environmental conditions affect intervals.

7.2. Engine

Detailed maintenance tasks for the engine, specifying inspections (I) and replacements (R) at various intervals.

7.3. Alternator

Maintenance recommendations for the alternator, including bolt tightness, general condition, and electrical connections.

8. Battery

8.1. Storage and transport

Guidelines for storing and transporting batteries, emphasizing cool, dry conditions and vertical positioning.

8.2. Battery setting into service

Procedure for putting batteries into service, including filling with acid and initial connections.

8.3. Check

Table detailing battery checks based on acid density, charge status, and voltage.

8.4. Load preconization

Information on charging batteries, especially those that are highly discharged or sulphated, to prevent damage.

8.5. Faults and remedies

Lists common battery faults, their probable origins, and recommended measures or observations for correction.

Introduction

Safety Information

Crucial safety information, including warning symbols and their meanings, and general safety precautions.

Safety Rules for operation and maintenance

Detailed safety rules for daily checks, carbon monoxide poisoning, cooling system, fuel system, and operation.

Care and maintenance

General advice on care and maintenance, including starting the engine, lifting, fire/explosion risks, and batteries.

Presentation

Instruments and Controls

DCU (Diesel Control Unit)

Describes the Diesel Control Unit panel, its buttons, and navigation elements.

Menus

Explains the main menu structure and sub-menus available on the DCU, including engine data and setup options.

Preheat

Instructions on how to use the preheat function, including its activation and timing.

Governor mode

Explanation of the governor mode and its settings for controlling engine speed.

Diagnostics

How to access and interpret diagnostic information, including fault codes and error messages.

Trip Data Reset

Procedure for resetting trip data, such as fuel consumption and engine hours.

Setup

Guide to setting up various parameters in the engine's control system, including language and customer parameters.

Display setting

Instructions for adjusting display settings, including contrast and backlight brightness.

Information

Information displayed on the DCU, related to engine hardware, software, and dataset identifiers.

Engine

Displays engine data such as RPM, coolant temperature, and fuel level.

Multi

Describes the multi-mode display, showing information in different windows and toggling between them.

Trip

Details how to display trip data, including fuel consumption and engine hours.

Graph

Explains how to display engine data in graph format and select the desired information.

Configuration menu

Accessing the configuration menu to set units, alarm status, service, and system parameters.

Alarm Status

Lists active alarms and provides information on fault messages and their status.

Settings

Configuration options for language, display settings, and system parameters like time synchronization.

SYSTEM

System settings including demo mode, fault resetting, and viewing hardware/software information.

Starting

Before Starting

Essential pre-start checks for oil, fuel, coolant levels, and general engine inspection.

Starting the Engine

Step-by-step instructions for starting the engine, with and without pre-heating, and explanations of indicator lights.

Starting in Extreme Cold

Preparations and precautions for starting the engine in cold weather conditions.

Starting Using Auxiliary Batteries

Instructions and warnings for starting the engine using auxiliary batteries, including connection procedures.

Operation

Engine Shutdown

Before Engine Shutdown

Steps to take before shutting down the engine, including warm-up and turbocharger cooling.

Stop the Engine

How to stop the engine using the controls, including disengaging the clutch and pressing the stop button.

Extra Stop

Information about the location and function of the extra stop control.

Fault Handling

Fault Tracing

A table correlating engine symptoms with possible causes and solutions for troubleshooting.

CIU (Control Interface Unit)

Explains the function of the CIU unit for displaying fault codes and managing diagnostic lamps.

DU (Display Unit)

Describes the DU display unit, its pop-up messages, and how to reduce engine speed.

Display Control Unit (DCU)

Details the DCU display, showing engine data, faults, and how to access diagnostic information.

Erasing fault codes

Procedure for resetting the diagnostic function memory and erasing fault codes.

Fault Code Register

Maintenance

Orientation

Identifies major engine components and their locations using a numbered diagram.

Location of Sensors

Diagram showing the location of various sensors on the engine.

Engine, General

General inspection procedures for the engine, covering leaks, belts, and hoses.

Air Filter, Check and Change

Instructions for checking and changing the engine's air filter, including replacement criteria.

Charge Air Pipe, Leakage Check

Guidance on inspecting the charge air pipe for leaks and tightening clamps.

Drive Belt and Alternator Belt, Inspection

Procedures for inspecting drive belts and alternator belts for tightness and condition.

Drive Belt, Change

Step-by-step instructions for changing the drive belt and alternator belt.

Lubrication System

Information on oil change intervals, recommended oil types, and procedures for checking and topping up oil.

Engine Oil, Change

Detailed steps for changing the engine oil, including draining and filter replacement.

Oil Filter;By-pass Filter, Change

Instructions for changing the oil filter and by-pass filter, including cleaning and tightening.

Fuel System

Information on the fuel system, including warnings for fire hazards and fuel filter replacement procedures.

Fuel Pre-filter, Change

Steps for changing the fuel pre-filter, including seal lubrication and leak checks.

Draining condensate, fuel system

Procedures for draining condensate and fuel from the system, including using electric drain nipples.

Bleeding the Fuel System

Steps for bleeding the fuel system to remove air and ensure proper fuel flow.

Cooling System

Information on the engine's internal cooling system, coolant types, and maintenance recommendations.

Coolant, Mixing

Instructions for mixing coolant with water, emphasizing correct proportions and safety warnings.

Coolant Level, Checking and Topping Up

Procedures for checking and topping up the coolant level in the system.

Coolant, Draining

Steps for draining the coolant from the system, including safety precautions and checking for deposits.

Charge Air Cooler, External Cleaning

Instructions for cleaning the charge air cooler, recommending mild detergents and avoiding high-pressure washers.

Coolant Filter, Change

Procedure for changing the coolant filter, including safety measures and leak checks.

Cooling System, Cleaning

Guidelines for cleaning the cooling system to maintain performance and prevent freezing.

Electrical System

Information on the engine's electrical system, including main switch, fuses, and electrical connections.

Main switch

Instructions for using the main switch, including safety warnings about disconnecting power.

Fuses

Information about the engine's fuses, their location, and troubleshooting for tripped fuses.

Electrical Connections

Checks and recommendations for electrical connections, emphasizing dryness and secure tightening.

Battery, Maintenance

Safety measures and procedures for battery maintenance, including handling, cleaning, and charging.

Filling

Instructions for filling the battery cells with electrolyte, including level marks and resting time.

Battery, Charging

Safety precautions and procedures for charging batteries, including charger suitability and connection methods.

Storage

For up to 8 months stoppage

Procedures for preparing the generating set for storage up to 8 months, including fluid conservation.

More than 8 months stoppage

Procedures for preparing the generating set for storage exceeding 8 months, focusing on lubrication and fuel systems.

Bringing out of storage

Steps for preparing the generating set after storage, including checks and restarts.

Conservation of the lubrication and fuel systems for more than 8 months stoppage

Specific conservation steps for lubrication and fuel systems for extended storage periods.

Technical Data

Engines

Technical specifications for various Volvo Penta engine models.

Lubrication System

Details of the lubrication system, including oil capacity, pressure, filter types, and oil recommendations.

Fuel System

Information on the fuel system, including feed pressure, pump valve status, and fuel specifications.

Cooling System

Information on the cooling system, including pressure cap, coolant quantity, thermostat, and water quality standards.

Electrical System

Technical data for the electrical system, including system voltage, alternator specifications, and battery capacity.

Identification Numbers

Explains how to identify engine components using chassis and engine serial numbers, and product designations.

SAFETY MEASURES

1 - RECEIPT

1.1 - Standards and safety measures

Outlines compliance with international standards and essential safety measures for alternator use.

1.2 - Inspection

Instructions for inspecting the alternator upon receipt for any transit damage.

1.3 - Identification

How to identify the alternator using the nameplate and understanding its definition criteria.

1.4 - Storage

Recommendations for storing alternators to prevent damage, especially to bearings.

1.5 - Applications

Describes the primary applications for which these alternators are designed.

1.6 - Contraindications to use

Lists restrictions on using the machine outside of compatible operating conditions.

2 - TECHNICAL CHARACTERISTICS

2.1 - Electrical characteristics

Provides details on the electrical features of the LSA 46.2 alternator, including winding types and options.

2.2 - Mechanical characteristics

Outlines the mechanical construction of the LSA 46.2 alternator, including frame and bearing details.

3 - INSTALLATION

Covers the installation process for the alternator, including assembly and coupling procedures.

3.1 - Assembly

Instructions for assembling the alternator, emphasizing mechanical handling and tool requirements.

3.2 - Checks prior to first use

Essential checks to perform before the first use of the alternator, focusing on electrical and mechanical aspects.

3.3 - Terminal connection diagrams

Diagrams illustrating terminal connections for different alternator configurations.

3.3.3 - Option connection diagram

Diagrams for optional connection setups, including interference suppression kits and remote voltage potentiometers.

3.3.4 - Connection checks

Checks to ensure electrical installations and connections comply with regulations and diagrams.

3.4 - Commissioning

Procedures for testing and setting up the machine for initial use after installation.

3.5 - Setting up

Guidance on adjustments made during testing, including drive speed and AVR settings.

4 - SERVICING - MAINTENANCE

Guidelines for servicing and maintaining the alternator, including safety measures and routine procedures.

4.1 - Safety measures

Crucial safety measures to follow during servicing and troubleshooting to prevent accidents.

4.2 - Routine maintenance

Routine maintenance tasks, including checks after start-up and bearing lubrication.

4.3 - Fault detection

Procedures for identifying the source of malfunctions if the alternator does not operate normally.

4.4 - Mechanical defects

Lists common mechanical defects in alternators, such as bearing issues and vibration, with their causes and actions.

4.5 - Electrical faults

Identifies electrical faults in alternators, their effects, and check/cause procedures.

4.5.1 - Checking the winding

Procedure for checking alternator winding insulation using a high voltage test.

4.5.2 - Checking the diode bridge

How to check the diode bridge's functionality by verifying current flow direction.

4.5.3 - Checking the windings and rotating diodes using separate excitation

Procedure for checking windings and diodes using separate excitation, with assembly diagrams.

4.6 - Dismantling, reassembly

Instructions for dismantling and reassembling the alternator, with warnings for warranty.

4.6.1 - Tools required

Lists the necessary tools for dismantling and reassembling the alternator.

4.6.5 - Replacing the NDE bearing

Steps for replacing the Non-Drive End (NDE) bearing, including tool usage and heating procedures.

4.6.6 - Replacing the DE bearing

Steps for replacing the Drive End (DE) bearing, including shield and screw removal.

4.6.7 - Dismantling the rotor assembly

Procedure for dismantling the rotor assembly, emphasizing care and potential rebalancing.

4.6.8 - Reassembling the machine

Steps for reassembling the alternator machine after component replacement.

4.6.9 - Dismantling and reassembly of the filters

Procedure for dismantling and reassembling filters, including cleaning the filter element.

4.7 - Installation and maintenance of the PMG

Instructions for the installation and maintenance of the Permanent Magnet Generator (PMG).

4.8 - Table of characteristics

Table of average values for the alternator, including resistances, voltages, and weights.

5 - SPARE PARTS

Information on spare parts for alternators, including emergency kits and technical support.

5.1 - First maintenance parts

Lists available first maintenance and emergency repair kits for alternators.

5.2 - Technical support service

Details how to contact technical support for information and spare part orders.

5.3 - Accessories

Describes available accessories for alternators, such as space heaters and temperature sensors.

5.4 - Exploded view, parts list and tightening torque

Provides exploded views and parts lists for single-bearing and double-bearing alternators.

Declaration of CE compliance and incorporation

R250 A.V.R.

SAFETY MEASURES

Essential safety measures and warnings for installing, using, and servicing the R250 AVR.

1 - SUPPLY

Explains the SHUNT excitation system and its auto-excitation with the R250 voltage regulator.

1.1 - SHUNT excitation system

Explains the SHUNT excitation system and its auto-excitation with the R250 voltage regulator.

2 - R250 A.V.R.

Details the R250 AVR, including its characteristics, U/F and LAM functions, and options.

2.1 - Characteristics

Lists the operating and storage temperatures, voltage regulation, and supply range for the R250 AVR.

2.2 - U;F Fonction and LAM

Explains the U/F function and LAM settings, including threshold positions and their effects.

2.3 - R250 A.V.R. option

Describes R250 AVR options, including voltage setting potentiometers and external connections.

2.4 - LAM characteristics (Load Acceptance Module)

Details the characteristics of the Load Acceptance Module (LAM), including voltage drop and its role in speed variation.

2.5 - Typical effects of the LAM with a diesel engine or without a LAM (U;F only)

Illustrates the typical effects of the LAM on voltage, frequency, and power during load changes.

3 - INSTALLATION - COMMISSIONING

Covers the installation and commissioning of the R250 AVR, including electrical checks and settings.

3.1 - Electrical checks on the AVR

Ensures proper electrical connections and rotating switch selections for AVR installation and commissioning.

3.2 - Settings

Step-by-step guide for setting up the R250 AVR, including initial potentiometer settings and engine speed adjustments.

3.3 - Electrical faults

Lists common electrical faults related to AVR operation, their effects, and check/cause procedures.

4 - SPARE PARTS

Information on spare parts for the R250 AVR, including designation and technical support contacts.

4.1 - Designation

Specifies the designation, type, and code for the R250 AVR spare part.

4.2 - Technical support service

Details how to contact technical support for information and spare part orders.

9.3. Appendix C - Common spare parts

ALTERNATORS

Spare parts for Leroy-Somer LSA462VL12 alternators, including diode bridge and varistor.

9.4. Appendix D - List of John Deere - Volvo and Perkins fault codes

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