GEKO 640000ED-S/MEDA Operating And Maintenance Manual

GENERATING SET

STROMAGGREGATE

OPERATING AND MAINTENANCE MANUAL

BETRIEBSANLEITUNG

MODEL: 640000ED-S/MEDA

YEAR OF MANUFACTURE: 2004

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INDEX:

3.0 SAFETY SIGNS

4.0 SAFETY RULES AND DEVICES

5.0 MACHINE COMPONENTS

• description and identification of the generating set

• diesel motor - starting system - cooling system - alternator - base and tank - vibration dampers - silencer and

exhaust system - electric panel aboard machine - electric control board - housing - container

6.0 TECHNICAL SPECIFICATIONS

• general technical specifications

• specific technical specifications

7.0 PACKING, LOADING AND TRANSPORTATION

• packing

• lifting

• transportation and handling

• unpacking

8.0 INSTALLATION

• installation area

• vibration dampers

• aeration

• cooling and forced and environmental ventilation

• exhaust system

• connection

9.0 COMMISSIONING

• running in and low-load operation

11.0 DAILY TANK AUTOMATIC FILLING SYSTEM

• components

• assembly and connections

• operation

12.0 MAINTENANCE

• routine maintenance

• diesel motor maintenance

• alternator maintenance

• starting battery and battery charger maintenance

• daily maintenance

• weekly maintenance

• monthly maintenance

• six-monthly maintenance

• storage for long period of idleness

• failures and possible causes

13.0 TECHNICAL DOCUMENTATION

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3.0 SAFETY SIGNS

3.1 GRAPHIC CAUTION AND WARNING SYMBOLS

Suitable symbols for attracting the attention of those who must work on the machine are used in

this manual.

These symbols and their meanings are listed below:

ACCIDENT-PREVENTION RULES FOR THE OPERATOR AND THOSE WORKING IN THE VICINITY

POSSIBILITY OF CAUSING DAMAGE TO THE MACHINE AND/OR ITS COMPONENTS

FURTHER INFORMATION REGARDING THE OPERATION IN PROGRESS

WARNINGS

ANY MECHANICAL, HYDRAULIC, PNEUMATIC, ELECTRICAL AND ELECTRONIC TAMPERING OR

FAILURE TO OBSERVE THE ABOVE INSTRUCTIONS SHALL IMMEDIATELY NULLIFY THE WARRANTY

AND RELIEVE Geko OF ALL AND ANY CIVIL OR CRIMINAL RESPONSIBILITY FOR ANY DAMAGE OR

INJURY CAUSED BY THE MACHINE.

TO OPERATE, START UP, MANAGE AND MAINTAIN THE MACHINE IN QUESTION, THE USER MUST

SCRUPULOUSLY FOLLOW THE INSTRUCTIONS GIVEN IN ALL THE CHAPTERS OF THIS OPERATING

MANUAL.

ALL MAINTENANCE OPERATIONS AND WORK REQUIRED FOLLOWING ANY MACHINE FAILURE MUST

BE CARRIED OUT SOLELY BY RESPONSIBLE, PROFESSIONALLY QUALIFIED PERSONNEL.

THE MACHINE MUST BE INSTALLED AND USED WITH THE PROTECTIVE DEVICES MOUNTED AND THE

SAFETY DEVICES ACTIVATED, AS DESCRIBED IN CHAPTER 4.0 (SAFETY RULES) OF THIS MANUAL.

- THIS INSTRUCTION MANUAL MUST BE TREATED WITH CARE AND PUT IN A PLACE

THAT IS KNOWN AND EASILY ACCESSIBLE TO AUTHORISED PERSONNEL.

-THIS MANUAL MUST BE CAREFULLY READ BEFORE COMMENCING ANY OPERATION

ON THE MACHINE.

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4.0 SAFETY RULES AND STANDARDS

The safety standards which must be observed are all those deriving from standard EN-292 1st and 2nd part, EN-294, EN-

414.

Technical standards refer to all the UNI-EN standards applicable to the machine in question. There are therefore three

conditions of obligation and compliance:

a) those relating to the actual machine;

b) those of the system in which the machine is inserted;

c) those deriving from the way of running the plant.

Point a is dealt with in particular in this section of the manual, since points b and c are the responsibility of both the

installer and the end user.

a) THOSE RELATING TO THE ACTUAL MACHINE

Those relating to the actual machine means the operating methods related to maintenance activities. The instructions

provided, the sequence and the indicated conditions must be understood as compulsory conditions in compliance with

standards, laws and decrees on the safety of persons, both from an environmental point of view and the relationship with

the means in the forms allowed and explicitly stated in this manual.

ATTENTION

All incomplete and/or missing parts and actions in this manual related to points b and c given below:

b) those of the system in which the machine is inserted;

c) those deriving from the way of running the plant

are documents, decisions and actions which in terms of competence and responsibility must be made and printed out on the

headed paper of the issuer, who must take direct responsibility, by presumption of professional competence, deriving from

the carrying out of the activities whether as installer or as end user.

Operator safety is one of the main concerns of those who design and make a machine.

When creating a new machine, the utmost is done to try to foresee all possible situations of danger and naturally to adopt

appropriate safety measures. There is still the possibility of accidents, however, caused by imprudent, inexpert use of the

machine.

Also pay attention to the danger signs in the machine. Under no circumstances may they be removed or made illegible.

Clean them when dirty and replace them immediately whenever they have become detached or are damaged.

CAREFULLY READ ALL THE SAFETY PRECAUTIONS AND WARNINGS BEFORE CARRYING OUT

ANY OPERATION TO START UP OR MAINTAIN THE GENERATING SET. THIS MANUAL MUST BE READ

THROUGHOUT AND THE GENERATING SET USED CORRECTLY IN ORDER TO OPERATE THE MACHINE IN

SAFETY.

FAILURE TO OBSERVE THE ABOVE CONDITIONS AND THE SAFETY AND ACCIDENT-PREVENTION

RULES DESCRIBED BELOW, RELIEVES Geko OF ALL AND ANY LIABILITY. NEITHER CAN GEKO BE

HELD RESPONSIBLE FOR ANY DAMAGE OR INJURY CAUSED BY IMPROPER USE OF THE MACHINE OR

BY UNAUTHORISED ALTERATIONS MADE TO THE SAME.

Users must be informed and warned about residual hazards,

i.e. hazards for which attempts made to reduce the danger through design and protective techniques are not - or have not

been fully - effective; instructions and warnings must specify the procedures and methods of use laid down to overcome

such dangers and if necessary indicate particular training and also if necessary specify personal means of protection to be

used (see points 5.1.1 and 5.1.3 of UNI EN 292/2).)

BEFORE STARTING UP THE GENERATING SET, CHECK THAT ALL GUARDS, PROTECTIVE DEVICES

AND SAFETY DEVICES PROVIDED ARE CORRECTLY INSTALLED.

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IF THE CUSTOMER INSTALLS THE MACHINE, GEKO IS NOT LIABLE FOR ANY SITUATIONS OF

HAZARD CAUSED BY FAILURE TO COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS MANUAL.

DO NOT REMOVE AND/OR TAMPER WITH PROTECTIVE AND SAFETY DEVICES.

IF THE GENERATING SET IS OUT OF ORDER, PLACE A DANGER SIGN ON IT AND DISCONNECT

THE NEGATIVE OF THE BATTERY.

FIRE-PREVENTION SAFETY DEVICES

Fuel, vapours and smoke, in association with the generator may be inflammable and potentially explosive.

Careful attention in treating and handling these materials can limit the risks of fire and explosion.

MAKE SURE THAT THE ROOM IN WHICH THE GENERATING SET IS INSTALLED IS PROPERLY

VENTILATED.

KEEP THE GENERATING SET AND THE PLACE WHERE IT IS INSTALLED CLEAN. IF NECESSARY

REFUEL THE SET AND TOP UP THE LUBRICATING OIL, BATTERY ELECTROLYTE LIQUID OR WATER FOR

THE MOTOR. ANY SPILLS SHOULD BE CLEANED IMMEDIATELY.

UNDER NO CIRCUMSTANCES KEEP INFLAMMABLE LIQUID SUPPLIES NEAR THE GENERATING

SET.

DO NOT SMOKE OR CREATE SPARKS/FLAMES NEAR THE FUEL OR BATTERIES.

UNDER NO CIRCUMSTANCES FILL THE TANK WHILE THE GENERATING SET IS WORKING.

MECHANICAL SAFETY DEVICES

The generating set has been made with safety devices for the moving parts. Also take additional precautions to protect

personnel and equipment from dangerous mechanical parts when working near the generating set. Under no

circumstances whatsoever touch moving parts. Prolonged use of the generating set causes overheating of some parts of

the engine and the exhaust pipe; do not touch these elements during and immediately after use.

DO NOT START UP THE GENERATING SET IF SAFETY DEVICES HAVE BEEN REMOVED.

DO NOT REMOVE SAFETY DEVICES FOR MAINTENANCE OR FOR ANY OTHER REASON WHILE THE

GENERATING SET IS OPERATING.

KEEP HANDS, ARMS, LONG HAIR, LOOSE CLOTHING AND JEWELLERY AWAY FROM PULLEYS,

BELTS AND OTHER MOVING PARTS.

Certain moving parts cannot be clearly seen when the generating set is operating.

KEEP THE ENTRANCE TO THE ROOM RESERVED FOR THE GENERATING SET, OR THE CONTAINER

CLOSED AND THE DOOR LOCKED WHEN MAINTENANCE IS NOT REQUIRED.

AVOID CONTACT WITH OIL AND HOT WATER, EXHAUST FUMES WITH A HIGH TEMPERATURE,

HOT SURFACES. DO NOT REMOVE THE RADIATOR CAP WHILE THE WATER IS HOT.

CHEMICAL SAFETY DEVICES

Fuels, motor water, lubricants and battery acids used in the generating set are industrial products. They may be a hazard for

persons if used improperly.

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DO NOT SWALLOW OR TOUCH DIESEL FUEL, OIL, ENGINE WATER, LUBRICANTS AND BATTERY

ACID. IF SWALLOWED, SEEK FIRST AID IMMEDIATELY. IF THESE SUBSTANCES COME INTO CONTACT

WITH THE SKIN, WASH IMMEDIATELY WITH SOAP AND WATER.

DO NOT WEAR CLOTHES SOILED WITH DIESEL FUEL OR LUBRICATING OIL.

WEAR ACID-PROOF APRONS AND PROTECTIVE SHIELDS OR GOGGLES FOR THE FACE WHEN

CARRYING OUT MAINTENANCE ON THE BATTERY. SHOULD ACID COME INTO CONTACT WITH THE

SKIN, RUN COPIOUS QUANTITIES OF WATER OVER THE AFFECTED AREA.

NOISE LEVEL

The engines used in the generating sets are noisy machines. It is therefore necessary:

- in the case of cased and sound-proofed generating sets to position the machine in a room reserved specifically for the

plant. The room must be distant from places which personnel frequent continuously or occasionally. Should this not be

possible, the walls of the room must be soundproofed with sound-proofing material.

ONLY AUTHORISED P150

ERSONNEL WITH PROTECTIVE HEADGEAR AGAINST THE NOISE ARE ALLOWED ACCESS TO THE ROOM

CONTAINING THE GENERATING SET.

ONLY AUTHORISED PERSONNEL WITH OBLIGATORY PROTECTIVE MEANS ARE ALLOWED TO OPEN OR

HAVE ACCESS INSIDE THE HOUSING OR CONTAINER.

- if the generating set without casing is a continuous duty type and is used on sites in the open, all the persons operating

near the machine must be equipped with noise-proof headgear. This generating set may produce a noise level of 118dB(A).

Prolonged exposure to a noise level of just 85dB(A) is dangerous for human hearing.

USE THE PROTECTIVE HEADGEAR WHEN WORKING IN THE VICINITY OF THE GENERATING SET.

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USING THIS SIGN FOR THE SAFETY PROCEDURES. NORMALLY IT IS INSTALLED ON THE CANOPY. IF THE GEN-SET IS OPEN

THIS SIGN IS WITH THE MANUALS FOR TO INSTALL OUTSIDE OF THE GEN

-SET LOCAL .

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ELECTRICAL SAFETY DEVICES

If the electrical equipment of the generating set is correctly installed, used and maintained, operations are safe and efficient.

THE GENERATING SET SHOULD ONLY BE STARTED UP BY QUALIFIED, TRAINED PERSONNEL

WHO ARE AUTHORISED TO WORK AND IN COMPLIANCE WITH THE LAWS IN FORCE IN THE COUNTRY

OF INSTALLATION.

MAKE SURE THAT THE TRAILER-MOUNTED GENERATING SET IS EFFICIENTLY EARTHED IN

COMPLIANCE WITH THE LAWS IN FORCE IN THE COUNTRY OF INSTALLATION.

DO NOT TOUCH LIVE ELECTRICAL PARTS OF THE GENERATING SET OR WIRES WITH PARTS OF

THE BODY OR WITH NON-INSULATED CONDUCTIVE OBJECTS.

CONNECT THE GENERATING SET TO THE PLANT WHICH CORRESPONDS TO ITS ELECTRICAL

CHARACTERISTICS.

KEEP ALL ELECTRICAL PARTS CLEAN AND DRY. REPLACE WIRING WHERE THE INSULATION IS

BROKEN, CUT, CORRODED OR OTHERWISE DETERIORATED. REPLACE WORN OR CORRODED

TERMINALS AND KEEP THEM CLEAN AND TIGHT.

INSULATE ALL CONNECTED LEADS. ELIMINATE LOOSE, DISCONNECTED LEADS..

DISMANTLING AND DEMOLITION

ALL RECOVERED MATERIALS SHOULD BE TREATED AND DISPOSED OF IN COMPLIANCE WITH

WHAT IS LAID DOWN BY THE LAWS IN FORCE IN THE COUNTRY OF USE AND/OR ACCORDING TO THE

REGULATIONS INDICATED IN THE ENCLOSED TECHNICAL DATA SHEETS REGARDING SAFETY OF

CHEMICAL PRODUCTS.

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FIRST AID IN THE EVENT OF ELECTROCUTION

In an emergency, while waiting for the first-aid personnel to arrive, follow the general instructions given below to give

immediate aid.

DO NOT TOUCH THE VICTIM WITH BARE HANDS UNTIL THE VOLTAGE HAS BEEN ANNULLED.

• Cancel the voltage, if possible, by switching off the switches upstream of the point where the fault is

• If this is not possible, move the plug or the cable away from the victim

• If the victim is alive, turn him to the recovery position described below

• If the victim is unconscious, treat him as described below

Open the respiratory tract

1. Tilt the head of the victim backwards and raise his chin

2. Remove any object that may be in his mouth or throat (including false teeth, cigarette or chewing gum)

If the victim is conscious

1. Check the heart beat

If the victim is conscious but there is no heart beat

1. Check the pulse on the victim’s neck

2. Firmly close the victim’s nose and open his mouth

3. Take a deep breath and close your own mouth over that of the victim

4. Blow out slowly, checking that the chest of the victim inflates. Let the air come out of the victim and repeat the

operation for 10 minutes.

5. If it is necessary to leave the victim in order to go for help, do the above respiration 10 times first and continue

upon your return.

6. Check the pulse every 10 respirations.

7. When the victim regains consciousness, put him in the recovery position described below.

If the victim is unconscious and has no pulse

1. Call the nearest casualty department

2. Carry out two respirations and begin compressing the chest

3. Put two fingers of one hand on the space between the thoracic cage and the sternum

4. Put the other hand on top and intertwine your fingers

5. Keeping your arms straight, push down 4-5 cm for 15 times

6. Repeat the series of respirations and compressions until help arrives

7. If the victim’s condition improves with a return of the heart beat, continue with the respiration. Check the pulse

every 10 respirations.

8. When the victim regains consciousness, put him in the recovery position.

Recovery position

1. Turn the victim onto one side

2. Keep the victim’s head tilted back with his jaw free to keep the respiratory tract open.

3. Make sure that the victim cannot roll over

4. Check that the victim is conscious and that his pulse is regular, otherwise proceed as described above.

DO NOT GIVE THE VICTIM ANYTHING TO DRINK, EVEN IF HE IS CONSCIO

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5.0 GENERAL DESCRIPTION

fig. 5.02

Generating set with separate control board for emergenc

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5.2 DIESEL ENGINE (POINT 2)

The engines used in making Geko generating sets are chosen from among the most renowned automotive companies in

the world. The characteristics of use, environmental conditions, place of installation and any special requests by the

customer are concomitant factors in choosing the engine to be used. As far as the characteristics of the diesel engines in

detail are concerned, consult the enclosed engine operating handbook. Each prime mover is generally equipped with the

following accessories:

electrical system complete with starter, battery charging set

engine high temperature sensor

low oil pressure sensor

stop electromagnet or electrovalve+

mechanical or electronic speed governor

The following are also generally mounted on engines used for automatic-activation generating sets:

heater for heating the water and/or oil, and therefore the engine in stand-by periods

water/oil temperature control thermostat (only for certain versions)

oil pressure control pressure switch (only for certain versions)

5.2 COOLING SYSTEM (POINT 5)

Air or water-cooling systems may be used for the diesel engine. The latter system usually consists of a closed circuit where

the water is cooled by means of a radiator fitted with a mechanical fan directly activated by the engine.

On request or due to particular installation requirements, however, other types of cooling systems may be provided:

• with separate electric radiator

• with heat exchanger

There is a fan inside the alternator for cooling its components.

5.3 ALTERNATOR (POINT 1)

As for the prime mover, also the alternators used in making Geko generating sets are of different makes and types,

chosen from among the most qualified manufacturers. The alternator is a synchronous electric machine, the synchronous

speed of which is determined by the number of pole pairs that are present in the machine excitation circuit. The

synchronous speed is usually 1500rpm, except for small sets when it is sometimes 3000 rpm. The alternator has a junction

box where the power terminals and the voltage regulating card are situated. Refer to the enclosed alternator handbook for a

more detailed description.

5.4 BASE (POINTS 8)

The generating sets have a sturdy base frame consisting of two side members made from pressed bent sheet

metal channels, rigidly connected together by bolts to form a resilient support for the generating set and in any

case easily replaceable in the event of damage to one or more parts.

5.5 TANK (POINTS 9)

In order to allow a certain functional independence, the base contains a suitably sized tank in relation to the capacity and

consumption of the machine. In the case of particular customer requirements or for high power sets, the tank may be

separate. The fuel tank housed inside the base frame can have a capacity of 50, 120, 300 or 500 litres according to

customer requirements and the power of the machine. Limitations to these capacities depend on the applicable safety

regulations in different countries.

The fuel tank is made in steel sheet and has the following accessories:

• manual filler

• couplings for engine fuel feed and return unit

• connection for tank overflow

• connection for fuel pump delivery

• minimum fuel level warning sensor

• maximum fuel level warning sensor (optional)

• automatic filling pump start and stop sensors (optional

• optical level indicator (optional)

• drain plug

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5.6 VIBRATION DAMPERS

VIBRATION DAMPERS are inserted between the alternator/engine supports and the base to reduce and attenuate engine

vibrations transmitted to the base.

Alternatively in other models, the engine/alternator unit is rigidly mounted onto the base and the vibration dampers are

installed between the base and the floor.

5.7 BATTERIES

The dry-charged lead-acid batteries supplied with the generating set have a high initial capacity and the electrolyte in a

separate container. The voltage of one battery is 12V and depending on whether the diesel engine electrical auxiliaries

require a voltage of 12 or 24V, the generating set is supplied with just one battery or two connected in series. For start-up

refer to chapter 9.0. Batteries other than those described (NiCd batteries or maintenance-free batteries) may be supplied on

request.

5.8 MANUALLY-OPERATED ELECTRIC CONTROL BOARD

The manually operated control board for generating sets has been designed and made to unite all the controls and

protective devices of both the engine and the generator in one single unit. The control board is generally equipped with:

• starting and stopping key

• battery charge indicator light

• high engine water temperature and low oil pressure indicator light

• electronic protection with automatic stop for high water temperature and low oil pressure (if installed)

• protection against excess speed (if installed)

• hour counter

• electrical parameters display instruments

• machine magnetothermal cut-out

5.9 ELECTRIC CONTROL BOARD (EMERGENCY GENERATOR)

The automatic generating-set control board ensures automatic supply to the user from the generating set, without the

intervention of personnel, within a few seconds of mains supply failure, and a return to mains power when it is restored.

The basic functions performed by the panel are::

• automatic start of the diesel engine when the three-phase voltage of the external mains supply does not enter

within the limit values of the control threshold

• automatic insertion of the generating set onto the power user as soon as the generator reaches the rated voltage

and frequency value

• automatic supervision of the diesel engine and the alternator through special protective devices

• automatic disconnection of the generator from the user when mains power is restored

• delayed stop of the generating set for gradual cooling of the engine

• possibility for a new electric control is supplied separately to the generating set due to its dimensions. In this case

a junction box is mounted on the generating set.

All the signals and shunts necessary for engine and alternator operation are brought to a terminal board inside the box,

which is interfaced to another terminal board, situated in the control board, for managing the modes of intervention of the

machine.

The electric control board must be installed in the immediate vicinity of the generating set.

5.10 PROTECTIVE HOUSING

The generating set, for particular requirements such as: outdoor operation, building site generating set, etc., may be fitted

with a waterproof protective housing. The housing is made in suitably thick, polyester powder paint stove-enamelled sheet

metal. It has suitable flaps or doors for routine maintenance operations and two rain-proof dampers at the ends fitted with

animal-proof wire mesh, which are necessary for the normal cooling air flow. To keep the cased generating set in good

conditions, it is advisable to shelter it, e.g. under a protective canopy, so that in the event of rain, water is prevented from

infiltrating the intake side and damaging the alternator and the electrical apparatus in general.

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5.11 SOUND-PROOFED HOUSING

The sound-proofed generating sets use the same housing as those with protective housing. In this case the housing is

completely insulated with special

fire-resistant acoustical material. The discharge of combustion gases is silenced with an appropriate silencer with a high

sound-reducing power. Silencers are plated on the cooling air intake and outlet side, providing effective reduction in

sound.

5.12 CONTAINER

The containers designed and manufactured by Geko are made with steel sections obtained from very thick pressed, bent

sheet steel, with corner blocks at the top and bottom ends. The walls and roof consist of a double layer of prepainted sheet

metal with highly efficient insulating material inserted between the layers. The floors are normally made in steel chequered

plate resting on a strong base made from very thick steel sections. Using a container for specific applications, despite

greater expense, has many advantages. The container is designed to be weather-proof and therefore to be installed

outdoors.

5.13 RAILER-MOUNTED GENERATING SETS

Geko generating sets may be trailer-mounted or encased. The trailer used is the type for multi-purpose slow towing and

is intended to allow handling of the generating set within a buildiing site or private space. Under no circumstances may

the trailer-mounted generating set be towed on the road, since it has none of the necessary organs or accessories for

regular circulation on the road, as provided for by traffic control authority regulations, which are indispensable for

guaranteeing the safety of the user and that of other persons.

5

4

2

1

3

1 – AIR FRESH INLET

2 – HOT AIR OUTLET

3 – BASEFRAME

4 –INSPECTION DOORS

5 - SILENCERS

Fig.5.03

External view of a generating set with sound-proofed cabin. For dimensions up to 3200x 1100x1800mm

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6.0 TECHNICAL SPECIFICATIONS

6.1 GENERAL TECHNICAL SPECIFICATIONS

• Dimensions (L x W x H)

3720x1610x2300 mm

• Weight

5400 kg

• Electric power supply

24 Vdc

• Working temperature

25 °C

• Relative humidity

60÷80 %

• Continuous power

640 kVA

• Emergency power

715 kVA

• Rated current

924 A

• Frequency

50 Hz

• Voltage

231/400 Vac

• Type of connection

STAR WITH NEUTRAL

• Noise level

101 dB(A) to 7 m

• Type of duty

CONTINUOUS

• Height of installation

100 m

6.2 SPECIFIC TECHNICAL CHARACTERISTICS

ENGINE

• Type

12V 2000 G22

• Make

MTU

• Power

565 kW

• Type of speed regulator

ELETTRONIC( 0,25% precision )

• Type of starting

ELECTRIC

• Engine auxiliaries voltage

24 Vdc

• Type of cooling

BY WATER WITH RADIATOR

• Fuel type

DIESEL

ALTERNATOR

• Type

ECO40 2L/4

• Make

MECC ALTE

• Power

680 kVA

• Number of revs

1500 rpm

• Type of excitation

BRUSHLESS

• Type of voltage regulation

ELECTRONIC

• Degree of protection

IP 21

• Working temperature

40

°C

• Class of insulation

H

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7.0 PACKING, LOADING AND TRANSPORTATION

Packing and transportation are referred to the methods used in transferring the machine from our place of business to

another destination. The machine, for the purpose of shipment, is disassembled into parts:

• generating set

• electric control board

• accessories

7.1 PACKING

Packing of the generating sets is carried out suitably and correctly by Geko personnel.

Whenever transportation is necessary, due to changes in the place of installation, the following instructions must be

observed:

• protect the generating set from the elements by sealing it in nylon wrapping;

• protect the external control board instruments with spongy or similar material to avoid them being accidentally

damaged;

• protect the electric control board from the elements, sealing it in nylon wrapping, if possible blister packing;

• if the electric control board is small, position and fix it on a pallet to facilitate transportation;

• carefully position and fix the remaining parts of the generating set (muffler, connection pipes, control board-

generator wiring, etc.) on pallets to avoid any damage during transport.

1 - Lifting points

GEN-SET

CONTROL

PANEL

2 - Lifting points

7.2 LIFTING

The generating set base, housing or container are designed and made, taking into account problems related to the handling

and lifting of the actual generator. Lifting points have therefore been provided and are highlighted by special indicator

plates.

Inappropriate use of lifting means could damage the machine and its components. The modes of lifting and handling are

shown in fig.7.01 and fig.7.02.

All lifting and handling operations must be carried out by expert personnel who have full knowledge of the operating

methods of the work in hand and the rules of prevention and protection to be implemented. For the purpose of keeping

persons safe from possible injury it is indispensable to observe the safety margins of carrying capacity of the means used

for transportation and handling.

Loading operations of the generating set should be carried out following the procedures listed below:

a) prepare and use lifting equipment and accessories that are suitable for the weight of the generating set (see chap.6

of the manual);

b) lift, move and put the generating set down avoiding dangerous swaying;

c) place the set on a suitable loading surface with regard to stability and strength;

d) firmly secure the parts to the supporting surface.

DO NOT LIFT THE GENERATING SET USING THE ENGINE AND ALTERNATOR AS SUPPORTING OR LIFTING POINTS.

THE CAPACITY OF THE LIFTING MEANS MUST BE >/ = THE WEIGHT

Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193

Stromerzeuger & Telefax: 07267 / 806 198

Industriestr. 1 www.metalwarenfabrik.com

D – 75050 Gemmingen [email protected]

KEEP UNAUTHORISED PERSONS AT A SAFE DISTANCE FROM HANDLING AREAS.

PREPARE AND USE SUITABLE LIFTING EQUIPMENT.

CIRCULATE WITH LOWERED LOADS.

Max 60°

fig.7.01

Examples of ways of lifting

-The lift of generaring set can be made without

p

allet or glut blocks

- The capacity of lifthing must be >= the weight

of generating set.

-During handling should be to respect all the

safety regulations related to this operation.

Gen-set with canopy Open Gen-set

Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193

Stromerzeuger & Telefax: 07267 / 806 198

Industriestr. 1 www.metalwarenfabrik.com

D – 75050 Gemmingen [email protected]

fig.7.02

Examples of ways of lifting

The support cables have to be long for exclude any

deterioration on control panel or on other

p

rotruding components.

Sling lifting Sling lifting

Get by the support cables below the corner lugs of the baseframe.

fig.7.03

Examples of ways of lifting

Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193

Stromerzeuger & Telefax: 07267 / 806 198

Industriestr. 1 www.metalwarenfabrik.com

D – 75050 Gemmingen [email protected]

7.3 TRANSPORTATION, HANDLING AND UNLOADING

During transportation anchor the generating set and the electric control board to prevent them from moving or being

knocked; for this purpose fasten everything to the truck body with nails, using the holes in the lower cross member

When this is impossible, use wooden cross beams or ropes.

The electric control board should be positioned so that its instrument parts cannot accidentally come into contact with each

other.

ONLY AUTHORISED PERSONNEL MAY MOVE OR STAY BETWEEN THE GENERATING SET AND THE

TRANSPORTATION VEHICLE.

LOADING AND UNLOADING OF THE MEANS OF TRANSPORT, AS WELL AS THE TRANSFER TO THE

PLACE OF INSTALLATION MUST BE CARRIED OUT USING SUITABLE LIFTING MEANS.

IN THE EVENT OF UNLOADING AND WAITING BEFORE UNPACKING, PLACE THE MACHINERY IN A

SHELTERED PLACE WITH A RELATIVELY LOW RATE OF HUMIDITY.

PREPARE SUITABLE MEANS FOR TRANSPORTATION OF THE MACHINE IN QUESTION

Unloading operations should be carried out in full observance of the following points, taking into account: weight and

dimensions of the parts.

a) prepare and use suitable lifting equipment;

b) prepare and use for lifting: ropes, hooks, suitable chains for the stress required;

c) release the generating set from its securing devices;

d) lift, move and put down avoiding dangerous oscillations;

e) place on surfaces or supports that are suitable for the load;

f) make sure that the load is stable.

7.4 UNPACKING

The machine undergoes a final test and a meticulous inspection of all its parts before being packed and sent to the

customer.

The machine must be unpacked, in the case of a cage or wooden crate, with the help of suitable tools by personnel who

have already been instructed on the subject, also from a safety aspect.

THE PACKAGING MATERIAL MUST BE KEPT SEPARATE AND DISPOSED OF ACCORDING TO THE

LAWS IN FORCE IN THE COUNTRY OF USE.

During unpacking, the machine should be checked for any damage that may have been caused during transportation.

If any damage is found, the user shall:

- make a note on stamped paper that the machine is accepted under reservation

- inform Geko that the damage will be reported to the insurance company, which shall immediately send an

inspector;

- keep the machine available for the insurance company inspector in the state in which it was when the damage was

discovered, suspending any further operation of unpacking, handling, installation etc..

Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193

Stromerzeuger & Telefax: 07267 / 806 198

Industriestr. 1 www.metalwarenfabrik.com

D – 75050 Gemmingen [email protected]

8.0 INSTALLATION

This chapter contains the procedures to be observed in order to choose the site, the base, the position and the connection of

the various parts of the generating set correctly.

THE MACHINE MUST BE INSTALLED IN COMPLIANCE WITH THE ENCLOSED INSTRUCTIONS AND

RULES OF GOOD WORKMANSHIP

8.1 AREA OF INSTALLATION

The appropriate place for installing a generating set should be regular in shape and if possible should rest on solid ground

above groundwater level. It should be easily accessible from the outside through an entrance door of suitable dimensions

for introducing the generator.

The room should have the following requisites:

• sufficient dimensions to contain the generating set and its accessories, allowing enough space around the

machine to carry out maintenance;

• adequate natural or forced ventilation (see chapter 8.4);

protection from the elements such as rain, snow, hail, wind, flooding, very low or very high temperatures;

• protection from exposure to noxious substances such as abrasives, smoke, dust, vapours and such like;

• a clear area surrounding the generating set that ensures sufficient space for a person to pass and to facilitate

aerationof the generating set. The measurements required by regulations and standards are at least 60 cm on

three sides ofthe generating set;

• presence of a drain pit for collecting any leaks;

• limited access to authorised personnel only;

• observance of the engine fire-prevention rules.

fig.8.01

8.2 FOUNDATION

Whenever it is necessary to eliminate the residual vibrations of the generating set transmitted to the structure of the

building, it is advisable to create a foundation block, which is the responsibility of the customer.

Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193

Stromerzeuger & Telefax: 07267 / 806 198

Industriestr. 1 www.metalwarenfabrik.com

D – 75050 Gemmingen [email protected]

8.3 VIBRATION DAMPERS

To minimise engine vibrations transmitted to the building, the generating set is fitted with vibration dampers. The position

of the vibration dampers depends on the type of alternator support.If the alternator has a monobloc support, the vibration

dampers are inserted between the alternator/engine unit and the base.

During installation it is advisable to insert a 1cm thick rubber shim between the base and the foundation.

If the generating set is fixed directly to the base, the vibration dampers should be mounted between the base supports and

the ground. In any case the generating set must be firmly fixed to the ground (through the base or the vibration dampers) to

prevent any shifting.

The generating set is fitted with some devices which serve to dampen vibrations transmitted to external connections: in

particular the bellows, which is used in the hot air outlet and the flexible stub pipe used in the smoke discharge system.

Plants with natural circulation of the air which is introduced into the room through apertures connecting with the outside.

1- Air inlet

2- Air outlet

fig.8.02

8.4 AERATION

The air for combustion of the engine must be as clean and fresh as possible, since correct operation of a diesel engine is

basically in direct ratio to the quantity and quality of the air which is mixed with the fuel. The air is normally taken in from

the area surrounding the generating set through suction filter and in any case always far from heat sources. These

precautions are necessary to avoid drops in the power output of the engine, increase in consumption and a strong grade of

smoke.

Metallwarenfabrik Gemmingen Telefon: 07267 / 806 193

Stromerzeuger & Telefax: 07267 / 806 198

Industriestr. 1 www.metalwarenfabrik.com

D – 75050 Gemmingen [email protected]

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GEKO 640000ED-S/MEDA Operating And Maintenance Manual

GEKO 640000ED-S/MEDA Operating And Maintenance Manual

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