Scania Generator set en-GB 2 374 139. Instruction — part 3
Generator set design
Cooling system
An external radiator is connected to the engine
cooling system.
Some generator sets are equipped with an expan-
sion tank.
To drain the coolant some generator sets have a
External coolant drainage point
hose that feeds from the radiator drain valve to an
external drainage point in one of the longitudinal
beams.
Generator set with canopy
There are two alternative hatches on the canopy
roof for filling the cooling system with coolant.
Filling coolant
32
Generator set design
Intake and exhaust system
Air cleaner
For the engine air cleaner, see the Industrial En-
gine instruction instruction.
Silencer
The silencer is equipped with a condensation
separator with drain valve for draining water
from the exhaust system. The condensation sep-
arator can be accessed from the underside of the
generator set.
Condensation separator
Generator set with canopy
On generator sets with a canopy the silencer is
located in its own space. The silencer can be ac-
cessed through a bolted hatch on the end plate
section.
Silencer with hatch removed
33
Generator set design
On generator sets with a canopy the exhaust pipe
discharges out through the roof and is equipped
with a rainguard.
Exhaust pipe
Battery system 24 V
The generator comes delivered with a 24 V elec-
trical system for starting the engine and the gen-
erator set control system.
Batteries
WARNING!
Wear gloves and eye protection when handling
batteries. Batteries contain a highly corrosive
battery sulphuric acid.
WARNING!
Batteries contain and emit oxyhydrogen gas, par-
ticularly during charging, and this gas is flamma-
ble and highly explosive. There must be no
smoking, naked flames or sparks near the batter-
ies or the battery compartment.
IMPORTANT!
Make sure you connect the batteries correctly
when they are connected. If the batteries are not
connected correctly, this can cause serious dam-
age to the electrical system. Sparking may occur
if the terminals are short-circuited.
The generator set is provided with two 12 V bat-
teries connected in series. The batteries are in-
cluded in the delivery.
• When the batteries are connected, connect the
positive cable before the negative cable.
• When the batteries are disconnected, discon-
nect the negative cable before the positive ca-
ble.
Two 12 V batteries connected in series
34
Generator set design
Battery master switch (option)
If the generator set is equipped with a battery
master switch, this is located next to the batter-
ies. It is used to disconnect the batteries during
maintenance and when the generator set is not
being used.
Battery charger (option)
The instrument panel and other stand-by func-
tions can drain power from the batteries. Scania
therefore recommends that a battery charger is
fitted to trickle charge the batteries. To power the
battery charger there must be access to a fixed
230 V electrical power network or other 230 V
energy source. Electrical power supply cables
are connected in the central electric unit.
The battery charger controls the battery charging
current and charges the batteries when neces-
sary. When the batteries are fully charged the
battery charger switches to trickle charging.
IMPORTANT!
If the generator set does not have a battery charg-
er or if the generator set is not run for a long time,
the batteries must be charged by connecting
them to an external battery charger.
35
Generator set design
24 V and 230 V central electric unit
1
WARNING!
Before opening the central electric unit front
hatch to reset tripped circuit breakers, the 230 V
InSight3250
Mode
Mode
Star t
voltage must be interrupted. Otherwise there is a
Horn
F ault
Stop
reset
reset
risk of serious personal injury.
o
Pa g e
2
G
I
Enter
A central electric unit is located on one end plate.
The generator set instrument panel, a circuit
3
breaker for the 24 V electrical system and an
DANGER
THIS MACHINE IS
emergency stop are located on the central elec-
REM OTE LY CONT R OLLED
AND MAY START
tric unit front hatch.
WITHOUT WARNING
On generator sets with a canopy, the hatch has a
window for viewing the instrument panel display
1. Instrument panel 3250
without having to open the hatch.
2. Emergency stop
3. Circuit breaker
A battery charger (option) and heating element
for the central electric unit (option) are located
inside the central electric unit. In order for the
heater element to receive electric power, there
1
2
3
must be access to a fixed 230 V electrical power
network or another 230 V power source. Then
the heater element keeps the inside of the central
electric unit free of condensation. Electrical
power supply cables are connected to the central
electric unit.
Circuit breakers for the instrument panel and en-
gine control unit as well the circuit breakers for
any options are also located inside the central
electric unit.
If the generator set has additional options there
will be more circuit breakers inside the central
electric unit. These are described in the Instru-
mentation Operator's instruction.
5
4
1.
Circuit breaker for instrument panel
2.
Circuit breaker for engine control unit
3.
Place for battery charger (option)
4.
Circuit breaker for engine heater
5.
Circuit breaker for battery charger
36
Generator set design
Emergency stop
In addition to the emergency stop on the central
InSight3250
Mode Mode Start
Hornreset
Fault
resetStop
electric unit, there is a further emergency stop lo-
o
Page
G
cated on the end plate on generator sets with a
Enter
canopy.
D ANGER
When one of the emergency stops is depressed,
the engine switches off.
The emergency stops must be reset before the
generator set can be restarted.
Emergency stop on canopy
Engine heater (option)
The generator set engine can be preheated with a
block heater with thermostat (option).
To power the engine heater there must be access
to a fixed 230 V electrical power network or oth-
er 230 V energy source. Electrical power supply
cables are connected in the central electric unit.
Block heater on 9 and 13 litre engines
37
Generator set design
Block heater on 16 litre engine
The generator set with a 16 litre engine may have
a coolant heater (option) as shown in the illustra-
tion.
Coolant heater (option)
38
Generator set design
Central electric unit for cur-
rent consumers
The current consumers are supplied with electri-
cal power via a central electric unit, which is lo-
cated on one of the end plates to the right of the
24 V central electric unit.
Busbars for connecting the current consumer
power cables are located in a protected position
behind a bolted hatch.
The illustration shows a 3-pin circuit breaker in
the generator set, which is the standard specifica-
tion. A 4-pin circuit breaker is available as an op-
tion.
Busbars with the hatch removed (example)
The generator set circuit breaker, which can be
instructionly activated as shown in the illustration,
or equipped with a motor for automatic control,
is located on the hatch.
An ground fault circuit breaker is available as an
option, which trips the circuit breaker at very
SACE S6
small currents in the event of a fault in the elec-
trical cables or current consumers.
on
I
O
off
Instruction circuit breaker
39
Generator set design
Operation
InSight3250
Instrument panel
Mode
Mode
Star t
Horn
Fault
Stop
reset
reset
There are three variants of instrument panel: In-
o
Sight 3250, 4000 and 6000. Which type of in-
Pa g e
strument panel the generator set is equipped with
G
depends on the type of operation.
Enter
The instrument panel runs and monitors different
parameters. The operating status and alarm mes-
sages are displayed on the instrument panel.
Example of instrument panel: InSight 3250
The current instrument panel is described in the
Instrument panel Instruction.
5
Automatic transfer switch
6
When the generator set is on stand-by in a current
7
consumer network, an automatic transfer switch
4
is located in the current consumer network
switchgear.
2
When the instrument panel detects a power fail-
3
ure in the electrical power network, a signal is
1
sent to the generator set requesting it to start and
take over the load from the electrical consumers.
When the instrument panel detects that the mains
1. Electrical power network
voltage is back up, the generator set is switched
2. Power supply from electrical power network
off.
3. Automatic transfer switch
4. To electrical consumer
Note:
5. Control signal
To be able to run the generator set with an auto-
6. Generator set
matic transfer switch, the generator set instru-
7. Power supply from generator set
ment panel must be set to automatic operating
mode.
ATSc
V
Hz
h
1
2
3
STOP
Automatic transfer switch
40
Generator set design
Operating modes
It is possible to set three operating modes on the
generator set instrument panel:
• Instruction mode when the engine and circuit
breaker are run via the instrument panel dis-
play.
• Automatic mode when all the functions for
the engine as well as the circuit breakers in
the generator set and automatic transfer
switch are run automatically.
• Stop mode when neither the engine nor cir-
cuit breaker can be run. This only applies to
instrument panels InSight 4000 and 6000.
Application modes
The instrument panels can be configured to four
application modes:
•
{0}starting and switching off of engine.
•
{1o}starting and switching off of engine, in-
terrupts the circuit breaker in the generator
set.
•
{1oc}starting and switching off of engine, in-
terrupts and ends the circuit breaker in the
generator set.
•
{2oc}starting and switching off of engine, in-
terrupts and ends the circuit breakers in the
generator set and automatic transfer switch.
Note:
Not all instrument panels can be configured to all
four application modes.
41
Generator set design
Operation
Before operation
Check that
• all power cables and ground cables are un-
damaged and correctly connected
• the fuel tank is full
• any battery switch is in the On position
• the circuit breaker on the 24 V central electric
unit is in position I
• the generator set circuit breaker is in the On
position. Applies to generator sets with man-
ually activated circuit breaker.
Operation
See the Instrument Panel Operator's Instruction.
Refuelling
WARNING!
During refuelling there is a risk of fire and explo-
sion. The engine must be switched off and smok-
ing is prohibited.
WARNING!
Only use recommended fuel according to the In-
dustrial Engine Operator's Instruction. The wrong
fuel grade can cause breakdowns or stoppages by
causing the injection system to malfunction. This
can cause damage to the engine and, possibly, in-
jury.
42
Generator set design
Filling the internal fuel tank
1
WARNING!
Never overfill the fuel tank as the fuel needs
space to expand. Make sure that the refuelling
cap is fully closed. Risk of fire and explosion.
The refuelling point is located on one of the long
sides.
2
The fuel tank has a capacity between 800 l and
1,100 l.
1. Fuel gauge
2. Refuelling
43
Maintenance
Maintenance
IMPORTANT!
This Operator's instruction does not describe the
maintenance items which apply to the engine it-
On delivery a Scania engine is optimised for its
self. Instead, these are described in the Industrial
application. However, regular maintenance is
engine Operator's instruction.
necessary to
•
prevent unplanned stops
WARNING!
•
extend the service life of the engine
•
maximise the long-term emission perfor-
Block the starting device when working on the
mance of the engine
engine. If the engine starts unexpectedly, there is
•
give the best possible operating economy.
a serious risk of injury.
The maintenance programme includes the fol-
lowing:
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive mainte-
nance.
• L maintenance: Includes nearly all mainte-
nance items.
• XL maintenance: Includes all maintenance
items.
During a period, the sequence is S-M-S-L-S-M-
S-L-S-M-S-XL.
XL
L
L
M
M
M
S
S
S
S
S
S
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
44
Maintenance
Generator sets with few hours
of operation
IMPORTANT!
On generator sets with few hours of operation,
maintenance must be carried out according to the
maintenance interval annually or every 5 years.
Stand-by generator sets and the like that are not
used regularly should be test run and checked in
accordance with the manufacturer's instructions.
The following maintenance items must be car-
ried out once the engine has been warmed up to
operating temperature.
1. Checking oil level.
2. Checking coolant level.
3. Checking vacuum indicator.
4. Checking fuel level.
5. Check for engine leaks.
45
Maintenance
Maintenance intervals for
generator set
Daily
Interval (hours)
At least once every
500 S
1,000
2,000 L
6,000
month
year
5 years
M
XL
Battery
Checking electrolyte level
X
Cleaning
X
X
X
X
X 1
Checking state of charge
X
X
X
Exhaust system
Draining condensation separa-
X
X
X
tors
Engine
Retightening of screws for en-
X
gine brackets
Running
X
Generator
Retightening screws for connec-
X
X
tors
Retightening connectors
X
X
Removal of condensation
X
X
Cleaning
X
X 1
Generator set
Cleaning
X 1
1. More often if required.
46
Maintenance
Batteries
General
WARNING!
Do not carry out battery care or store batteries
near naked flames or anywhere there is a risk of
sparks. When the batteries are charged, oxyhy-
drogen gas is formed which is flammable and ex-
plosive.
WARNING!
Wear gloves and protective goggles when charg-
ing and handling batteries. The batteries contain
a highly corrosive acid.
WARNING!
Make sure you connect the batteries correctly
when they are connected. If the batteries are not
connected correctly, this can cause serious dam-
age to the electrical system. Sparking may occur
if the terminals are short-circuited.
Environment
Used batteries must be disposed of as specified
in national and international law.
47
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