Generator Set Control Module Operation Guide
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The generator set control module plays a crucial role in power supply, especially during emergencies and power outages. Proper operation and maintenance of the generator set are essential not only for ensuring safe and reliable operation but also for extending its lifespan. Below is a detailed guide on the operation of generator set control modules, including wiring, starting procedures, preparation for automatic operation, daily maintenance and inspection, and data and system parameter settings.
Generator Wiring Operations
Correct wiring is fundamental to ensuring the safe operation of the generator. Follow these specific steps to ensure reliable performance.
1. Output Cable Connection
Connect the generator's output cables to the switch II position inside the control panel. Secure each wire in the order of U, V, W, N. Ensure all connections are tight and secure to prevent loosening or poor contact during operation.
2. Control Wiring Harness Connection
Insert the control wiring harness into the socket on the operation panel and tighten it. Ensure a secure connection to avoid poor signal transmission or control failures.
3. Battery Connection
Connect the battery cables to ensure the battery provides adequate power to the control module. Check the tightness of the battery connections to prevent disconnection.
4. Mains Input Wiring
Connect the mains input cables to the ATS switch I position on the control panel, matching the phase sequence U, V, W, N with that of the generator. Connect the output cables to the lower part of the ATS switch, ensuring the U, V, W three-phase main lines pass through the generator's current transformer to monitor load current on the operation panel.
5. Manual Mode Preparation
Set the control mode switch to the manual position and close the battery switch. Then, connect the mains power to the controller. If the ATS switch is in the generator power supply position, manually switch it to the A-end mains power supply position to ensure normal power supply for the user.
Generator Startup Procedures
After completing the wiring operations and ensuring all connections are correct, proceed with the startup of the generator. The startup process not only ensures the equipment operates correctly but also involves real-time monitoring of its operating status.
1. Pre-Startup Check
Before starting the generator, carefully check the levels of engine oil, anti-rust fluid, and fuel. Ensure all wiring connections are secure and not loose or detached. Only proceed with the startup if all checks are satisfactory.
2. Manual Startup
Press the manual start button to start the generator. Once started, adjust the throttle within 20 to 30 seconds to increase the speed to 1500 RPM. This step ensures the generator reaches its normal operating state.
3. Monitor Operating Parameters
Close the generator's circuit breaker and observe the data parameters on the operation panel, including voltage, frequency, oil pressure, and water temperature. If any parameter deviates significantly, immediately shut down and inspect for faults before resuming operation.
4. Normal Shutdown Procedures
Before shutting down, switch the ATS switch to position I (mains power supply side). After allowing the generator to cool for 1-2 minutes, press the manual shutdown button and release it only after the machine has completely stopped.
Preparation for Automatic Operation
After starting the generator and ensuring it operates normally, prepare to switch to automatic operation mode. This mode allows the generator to start automatically during a power outage and switch back to mains power once it is restored.
1. Set Fixed Speed
Adjust the throttle to fix the generator speed at 1500 RPM and ensure it is secured (units with electronic speed controllers do not require this step). This ensures the generator quickly and stably reaches normal operating speed in automatic mode.
2. Close Generator Power Circuit Breaker
Ensure the generator's power circuit breaker is closed to prepare for automatic operation.
3. Switch to Automatic Mode
Rotate the control mode switch to the module position and press the automatic button on the control panel. If the module is in a deceleration delay period, the automatic and start buttons will be disabled. Wait for the delay to end before pressing the buttons. When the indicator light above the automatic button is lit, it signifies that automatic mode is activated and functioning correctly.
4. Automatic Switching and Monitoring
During a mains power outage, the automatic controller will start the generator after 5 seconds and check the electrical parameters. If the parameters are acceptable, the ATS switch will automatically switch to load supply after 10 seconds. If mains power is restored, the ATS switch will automatically switch back to mains supply after about 15 seconds, followed by a 60-second cooling delay and a 20-second shutdown delay, after which the generator will automatically shut down, ready for the next power outage.
5. Automatic Protection Function Testing
Test the automatic protection functions after the generator has been running successfully for 3 minutes (bypass delay). Simulate low oil pressure protection by short-circuiting the oil pressure sensor leads with its housing, and simulate high water temperature protection by short-circuiting the water temperature probe leads with its housing. Test other protection functions, such as overspeed protection, by adjusting the settings (e.g., changing the speed limit from 1650 RPM to 1490 RPM). After testing, restore the settings to their original values.
Daily Maintenance and Inspection
To ensure the generator's long-term stable operation, perform regular daily maintenance and inspections.
1. Regular Checks
Regularly check the engine oil, coolant levels, fuel levels, and battery status to ensure there is no shortage of oil, water, or fuel, and that the battery is fully charged.
2. Regular No-Load Testing
Perform no-load testing regularly, with a minimum duration of 5 minutes. This helps in promptly identifying potential issues and carrying out necessary maintenance and repairs.
By following this detailed operation guide and maintenance recommendations, you can ensure the safe, stable, and efficient operation of your generator. Adhering to these procedures will help maintain the reliability of the power supply system and ensure continuous performance under various conditions.
