Service training: Generators

Product Service Manager

Christophe Vanderzielen
Agenda
• A bit of history
• Generators Main Components
• What is Electricity
• Basic principles of current production
• How does an AC generator work ?
• Voltage regulation
• “Need to know” electrical concepts
• Generators controls types:
• Operation
• Testing and troubleshooting
• Programming the digital controller
• Digital controller improvements
• Maintenance
• Product Identification
•

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Service training: Generators
A Bit of History
A bit of history

1986: E-Series
(only 3 Models)
2001: GenPower Series

2004: GenPower II
Bauma 2007

2005: PowerSource
launchCompany
in USAConfidential
A bit of history

Bauma 2007 Stage IIIA

From 2012 onwards

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A bit of history

Stage II Prime Power Stage II Prime

Stage IIIA Models Stage IIIA Models
Models kVA Models kVA
G20 G20 interim 20 G160 G150 SIIIA 150
G30 G30 interim 30 G200 G200 SIIIA 200
G40 G40 SIIIA 40 G250 G250 (was already SIIIA) 250
G60 G60 SIIIA 60 G400 Not released 400
G80 G80 SIIIA 80 G500 G500 SIIIA 500
G100 G100 SIIIA 100

Company Confidential
A bit of history

Stage II Prime Power Stage II Prime

Stage IIIA Models Stage IIIA Models
Models kVA Models kVA
G20 G20 interim 20 G160 G150 SIIIA 150
G30 G30 interim 30 G200 G200 SIIIA 200
G40 G40 interim 40 G250 G250 (was already SIIIA) 250
G60 Not released 60 G400 Not released 400
G80 G80 SIIIA 80 G500 Not released 500
G100 G100 SIIIA 100

Company Confidential
A bit of history

• GIIIA Project:

• Change engines from Stage II to Stage IIIA

• Opportunity to have a re-design

• Steps:
1. G150-SIIIA & G200-SIIIA – Released to production
2. G80-SIIIA & 100-SIIIA – Released to production
3. G400-SIIIA & G500-SIIIA – Under development
4. G60-SIIIA – under development
5. G20-30-40 – under development, already SIIIA engines fitted but re-
design still to happen
6. G250 (Only re-design as the engine is already Stage IIIA compliant)

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A bit of history

Company Confidential
Service training: Generators
Generators Main Components
Generator’s Main components

Building of a generator
Canopy
Exhaust
Cooler
Diesel Engine

Generator

Panel

Chassis + Fuel tank

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Generator’s Main components: engines

G10: Mitsubishi S3L2 (out of production):

• 4-cycle, water-cooled, diesel
• Inline 3 Cylinders
• Total displacement: 1.318 Liters
• Natural-aspirated
• Prime output: 10 kW @ 1500 rpm

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Generator’s Main components: engines

G20: Mitsubishi S4Q2 – Y162SD

(out of production):
• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 2.505 Liters
• Natural-aspirated
• Prime output: 21 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G20: Mitsubishi S4Q2 - Z361SD:

• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 2.505 Liters
• Natural-aspirated
• Prime output: 21 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G30: Mitsubishi S4S – Y262SD (out of

production):
• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 3.331 Liters
• Natural-aspirated
• Prime output: 29 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G30: Mitsubishi S4S - Z361SD:

• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 3.331 Liters
• Natural-aspirated
• Prime output: 29 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G40: Mitsubishi S4S – DT (out of

production):
• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 3.331 Liters
• Turbocharged
• Prime output: 38 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G40: Mitsubishi S4S - Z3DT61SD:

• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 3.331 Liters
• Turbocharged
• Prime output: 38 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G60: John Deere 4045TF270

• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 4.5 Liters
• Turbocharged
• Prime output: 55 kW @ 1500 rpm
• Stage II Compliant

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Generator’s Main components: engines

G80: John Deere 4045TF275 (out of

production):
• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 4.5 Liters
• Turbocharged
• Prime output: 75 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G80-SIIIA: John Deere 4045HFG82

• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 4.5 Liters
• Turbocharged
• Prime output: 75 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G100: John Deere 4045TF279 (out of

production):
• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 4.5 Liters
• Turbocharged
• Prime output: 94 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G100-SIIIA: John Deere 4045HFG82

• 4-cycle, water-cooled, diesel
• Inline 4 Cylinders
• Total displacement: 4.5 Liters
• Turbocharged
• Prime output: 94 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G160: John Deere 6068HF279 (out of

production):
• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 6.8 Liters
• Turbocharged
• Prime output: 139 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G150-SIIIA: John Deere 6068HFG82

• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 6.8 Liters
• Turbocharged
• Prime output: 139 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G200: John Deere 6068HF475 (out of

production):
• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 6.8 Liters
• Turbocharged
• Prime output: 207 kW @ 1500 rpm
• Stage II compliant

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Generator’s Main components: engines

G200-SIIIA: John Deere 6068HFG82

• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 6.8 Liters
• Turbocharged
• Prime output: 207 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G250: Cummins QSL9-G3

• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 8.9 Liters
• Turbocharged - Aftercooled
• Prime output: 227 kW @ 1500 rpm
• Stage IIIA compliant

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Generator’s Main components: engines

G400: Cummins QSX15-G6

• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 15 Liters
• Turbocharged - Aftercooled
• Prime output: 358 kW @ 1500 rpm
• Stage II Compliant

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Generator’s Main components: engines

G500: Cummins QSX15-G9

• 4-cycle, water-cooled, diesel
• Inline 6 Cylinders
• Total displacement: 15 Liters
• Turbocharged - Aftercooled
• Prime output: 444 kW @ 1500 rpm
• Stage II Compliant

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 Generator’s Main components: engines

Model Make Model Emission level Rated speed Prime output @

met rpm rated speed kW
G20 Mitsubishi S4Q2-Z361SD E.U. Stage III A 1500 21
G30 Mitsubishi S4S-Z361SD E.U. Stage III A 1500 29
G40 Mitsubishi S4S-Z3DT61SD E.U. Stage III A 1500 38
G60 John Deere 4045TF270 E.U. Stage II 1500 55
G80-SIIIA John Deere 4045HFG82 E.U. Stage III A 1500 75
G100-SIIIA John Deere 4045HFG82 E.U. Stage III A 1500 93
G150-SIIIA John Deere 6068HFG82 E.U. Stage III A 1500 139
G200-SIIIA John Deere 6068HFG82 E.U. Stage III A 1500 188
G250 Cummins QSL9-G3 E.U. Stage III A 1500 227
G400 Cummins QSX15-G6 E.U. Stage II 1500 358
G500 Cummins QSX15-G9 E.U. Stage II 1500 444

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Generator’s Main components: alternators

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Generator’s Main components: G20–G500 Analog Control
• Panel Lamp
• AC voltage phase-phase
• AC amperes per phase
• Frequency meter
• Ammeter selector switch

• Running hours
• Output Voltage Adjustment
• Indicators/Shutdown/Warnings
Panel (see next slide)
• Battery voltage
• Fuel level

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Generator’s Main components: Control Panel

Engine running
Preglow
ECU status
Low oil pressure shutdown
High coolant temperature
shutdown
Engine general alarm
Engine overspeed shutdown
Engine overcrank
Low fuel warning/shutdown
Battery charge fail warning
High containment level
warning
Start Stop/Reset Auto start/stop
Auto On indicator
Button Button Button

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 Generator’s Main components: G20–G500 Digital Controller

Mode selection button

Start Button
Stop Button
Reset Button

Navigation buttons

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Generator’s Main components

Voltage adjusting potentiometer 4-pole circuit breaker

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Generator’s Main components

Rigid bus bar terminal (5 poles)

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Generator’s Main components

Adjustable Earth leakage protection

(Standard for G60 to G500)

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Company Confidential
Service training: Generators
What is Electricity
 What is electricity?

• Every material on earth is made of electrons

• Every electron is made of a nucleus and electrons orbiting around the nucleus

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 What is electricity?

• Electricity is made of electrons freely travelling into a conductor

• Electrons are driven through a conductor by a potential difference – similar to a

pressure difference in hydraulics

Single electrons in the outer, or valence, shell are free to

move among similar atoms.

Copyright © 2004 Mentor Graphics Corporation. This document contains information that is proprietary to Mentor Graphics Corporation and may be duplicated in whole or in part by the original recipient for
internal business purposed only, provided that this entire notice appears in all copies. In accepting this document, the recipient agrees to make every reasonable effort to prevent the unauthorized use of this
information. Mentor Graphics is a registered trademark of Mentor Graphics Corporation. All other trademarks are the property of their respective owners.

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 What is electricity?

• Electrons are driven through a conductor by a potential difference – similar to a

pressure difference in hydraulics
Electrical potential difference Potential difference water analogy

R v

- +
D.C
BATTERY

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 What is electricity?
• Voltage represents the potential difference – similar to the pressure difference in
hydraulics

Electrical potential difference Potential difference water analogy

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 What is electricity?
Electrical potential difference: Volts Hydraulics analogy: Pressure

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 What is electricity?
Current represents the amount of electrons – similar to the flow in hydraulics

Electrical potential difference Potential difference water analogy

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 What is electricity?
Electrical flow: Amperes Hydraulics Flow: liters/minute

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 “Need to know” electrical concepts : Ohm’s & power’s law

Ohm’s law

• Ohm’s Law is the relationship between

i current, voltage and resistance, U = I x R

+ • Voltage drop across the resistor equals the

product of the current and the resistance
+
R U
Voltage • Voltage drop can be compared to pressure
v Source drop in a hydraulic circuit
-
- Power’s law

• P=UxI
p=vxi
• At any instant, power equals the product of the
voltage and current

• Power in this example is said to be dissipated,

implying energy consumption or use

• Power can be compared to pressure x flow in

a hydraulic circuit
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Service training: Generators
Basic principles of current
production
Course Objectives

• How is electricity created?

• How does a generator work?

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How is electricity created: Magnetism

MAGNET

MAGNETIC
N S FLUX

Magnetism is the essential force which produces the

electro motive force (EMF) in a Generator.

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How is electricity created: Magnetism

- +
D.C
BATTERY COPPER COIL
Magnetic field

MAGNETIC
N S FLUX

When a D.C supply is connected to a copper coil, current will flow ( + to - ) through the
coil, creating a magnetic field.
If an iron core is placed into the magnetic field, it will become magnetized.
The magnetic strength is determined by the D.C power in the coil.
This is the principle of ELECTRO-MAGNETISM, which is used to control the magnetic
fields in an A.C Generators.
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How is electricity created: Magnetism

MICHAEL FARADAY 1791 - 1867

In 1831, Michael
Faraday, using a
simple magnet and a
coil of wire,
discovered that
mechanical energy
could be converted
into electrical energy.

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 How is electricity created: Faraday generator

Rotating copper disk

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How is electricity created: Magnetism

Current
Magnet

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 How is electricity created: Simple Faradey Generator

ELECTRIC
LIGHT BULB
WATCH THE
LIGHT BULB !

MAGNET

COPPER COIL
(CONDUCTOR)

N S
When the magnet is stationary, no action is being performed, so no electricity is generated.
When the magnet is moved passed the coil, this will generate the electro motive force (EMF
or VOLTAGE) into the coil.
Company Confidential
Service training: Generators
How does an AC generator
work ?
How does an AC generator work: basic principles

0
+ -

N
S
S Voltmeter

SS
SNN

S N
N
N

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Refresh on electricity production principles

0
+ -

Voltmeter
N

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How does an AC generator work: basic principles

Company Confidential
 How does an AC generator work: basic principles

Permanent Magnet Field

Magnetic Field
(Flux)
N
Shaft
Copper Slip-rings
loop and Brushes

S
+VE Output

-VE
THE OUTPUT IS SINUSOIDAL, ALTERNATING CURRENT (A.C)

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How does an AC generator work: basic principles

Period / Frequency

Voltage

One Phase of a Generator

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 How does an AC generator work: basic principles

Electro- Magnetic Field

Magnetic Field
(Flux) ADJUSTABLE
D.C SUPPLY

Shaft
Copper Slip-rings
loop and Brushes

+VE Output

-VE
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How does an AC generator work: basic principles

+VE

-VE

THE OUTPUT VOLTAGE CAN BE CONTROLLED BY

ADJUSTING THE D.C. FIELD VOLTAGE

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How does an AC generator work: Voltage

The output Voltage is a result of:

• The strength of the magnetic field

• The length of conductors in the A.C
armature
• The velocity (speed) of the conductors
cutting the magnetic lines of force.
• The angle at which the conductor cuts the
magnetic field

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How does an AC generator work: basic principles

0
+ -

Voltmeter

1 revolution = 2 periods

Period / Frequency

+
Voltage

-
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How does an AC generator work: Frequency
• 50 Hz = 50 periods/second with 2poles rotor
= 3000 periods / minute  3000 rpm

• 60 Hz = 60 periods/second with 2poles rotor

= 3600 periods / minute  3600 rpm

• Number of poles in our alternators = 4  2 periods / revolution

• Engine speed:

 50 Hz: 3000/2 = 1500 rpm

 60 Hz: 3600/2 = 1800 rpm

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How does an AC generator work: 3 phases
0
+ -

Voltmeter

0
+ -

0
+ -

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How does an AC generator work: basic principles

120°

1 cycle

3 phase alternating current

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 How does an AC generator work: Stator windings
Standard generator alternator has a stator with a 6 windings & 12 wires re-
connectable configuration allowing to configure 3-phases 230 or 400 VAC

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How does an AC generator work: Stator windings

Factory wye configuration : 380 – 415 Volts 3-phases connection

L1

L-N : 220 – 240 Volts

L-L : 380 – 415 Volts

L2
L3
3-phases configuration

There are different ways to connect the neutral pole (IT / TN-S / TN-C / TT)

Factory configuration with

guaranteed operator protection
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How does an AC generator work: Stator windings

Depending on the size and type of the generator,

there are 3 or 6 windings

Look at the wiring

numbers of the windings!

Doosan does not have any generators with 3 windings in his fleet!
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NEXT
How does an AC generator work: Stator windings
•How to remember the wiring numbers of windings
T1

T4

T7

T10

T12

T9 T11
T5
T8
T6
T2

T3

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How does an AC generator work: Stator windings

With 6 windings (or 12 wire) generators we have the ability to change

the output voltage by changing the configuration of the windings.

Parallel - Star Delta

It ’s advisable to choose the Delta-configuration because

the max. voltage in Parallel-star is limited to 220 Volt!
BACK Company Confidential
 How does an AC generator work: basic principles

CARBON
D.C. FIELD POLES OUTPUT
BRUSHES

A.C.ARMATURE

SLIPRINGS
BEARINGS
ADJUSTABLE
D.C SUPPLY

30 years ago, A.C Generators were designed with SLIPRINGS and CARBON
BRUSHES
These had a tendency to wear out, and burn, with vibration or transient load
currents.
Therefore Leroy Somer switched over to Brushless Generator design
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How does an AC generator work: basic principles

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 How does an AC generator work: basic principles

OUTPUT A.C D.C SUPPLY

- +
MAGNETIC A.C STATOR CARBON
FLUX BRUSHES

SHAFT D.C.FIELD (ROTOR)

SLIPRINGS
BEARINGS

• Generators were then equipped with a rotating field (rotor), which was supplied
with D.C via two slip-rings.
• The output is taken from the static A.C windings ( Stator),
• This design is still popular today, as the rotating field is easier to design and
more economical to manufacture than a rotating armature.
• The ‘BRUSHLESS GENERATOR’ is similar in design, and became popular in
the late 1960’s, following the invention of the SILICON DIODE.
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How does an AC generator work: basic principles

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How does an AC generator work: basic principles

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Company Confidential
Service training: Generators
How does an AC generator
work: The excitation
How does an AC generator work: Excitation System

Main Stator
Exciter
Stator

Bearing

Main Rotor

Shaft
Exciter & Rotor
Rotor

Rectifier Fan

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How does an AC generator work: Excitor stator

E
+ From A.V.R Terminals
E-

COIL CONNECTIONS

N S N S

• High-remanence steel core

• Stores Residual Magnetism
• 8 pole magnet field
• High frequency Generator

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How does an AC generator work: Excitor stator

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 How does an AC generator work: Excitor rotor assembly

W
U

SHAFT V

U
W
• 3 Phase A.C output, each Phase connected to 2 diodes on Main Rectifier.
• High Frequency output, ( from 8 Pole Exciter Stator ).
• An Exciter generator is a magnetic power amplifier for the main rotor current.
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How does an AC generator work: Excitor rotor assembly

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How does an AC generator work: Excitor rotor & rectifier

Windings Exciter Rotor

W
U

Rectifier
Assembly
V

SHAFT
SHAFT V

Rectifier Assembly Mounted on Exciter Rotor.

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How does an AC generator work: Diode bridge assembly

Exciter Rotor 3 Phase

with Internal Star Point

SHAFT

Varistor Surge
Suppressor
Diodes
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How does an AC generator work: The silicone diode

DIODE CIRCUIT RECTIFIER CIRCUIT

+

A.C
A.C INPUT 3 PHASE MAGNETIC
POWER
FIELD
SUPPLY

1/2 WAVE D.C FULL WAVE D.C FULL WAVE 3 PHASE D.C
MAGNETIC
FIELD

The SILICON DIODE acts as an ELECTRONIC ‘ONE WAY VALVE’ to A.C.

A SINGLE SILICON DIODE will allow ONLY ONE HALF OF THE A.C CYCLE to pass
through to the magnetic field.
A FULL WAVE RECTIFIER converts BOTH HALVES of the cycle into DIRECT
CURRENT, ( D.C).
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How does an AC generator work: The diode bridge

DC

AC

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 How does an AC generator work: Operation of a diode

A.C Input to Rectifier Diodes (100 Hz)

D.C output to Main Rotor

-
Full wave 3 Phase rectification will produce a D.C. output of
1,35 time A.C input voltage
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How does an AC generator work: Main rectifier
connections to main Rotor

Main Rectifier  Main Rotor

Aluminium
Heat-sinks

SHAFT D.C

The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks
This is fed to the Main Rotor windings

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How does an AC generator work: Metal Oxide
Varistor (Surge Suppressor)

Diode Protection Device

For Transient Suppression

Main Rotor
SHAFT SHAFT
Connections

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 How does an AC generator work: Metal Oxide
Varistor (Surge Suppressor)
Direction
of Typical high voltage transient created
transient by fault condition in the distribution
system.
Up to 2- 3000V (peak voltage)

Energy absorbed High Transient surges can be created by:-

by Varistor.
‘ Crash’ Synchronising onto live bus-bars.

Electric storm, (lightning), and field effects

on overhead lines (distribution systems).
Varistor clamping
Arcing, caused by faulty switching, motor
(Protection) level.
failure, short circuits in the distribution
system.
Full load D.C
t = µ sec's. D.C supply
output from
to Main rotor
main Rectifier

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How does an AC generator work: Diode bridge assembly

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How does an AC generator work: Rotor assembly

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How does an AC generator work: Rotor assembly:
excitation end

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Company Confidential
Service training: Generators
Voltage regulation
Course Objectives

• Description of the Automatic Voltage Regulator

(AVR)
• How is the produced voltage regulated?
• Shunt and AREP regulation

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Description of the Automatic Voltage Regulator (AVR)

Automatic Voltage regulator

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Description of the Automatic Voltage Regulator (AVR)
P2 Voltage P3 stability P5 Exitation ceiling F1 Slow fuses
250 V 10A

To AREP Windings
(Pwr supply)

To exitation

ST3 Hz selection
50 Hz / 60 Hz

Sensing

Connection for the voltage P1 Droop

adjustment potentiometer Company Confidential
Shunt & AREP

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Voltage regulation (shunt)
Supply 110 Vac
½ phase

UVW
AC output
Sensing 400 V

AVR
Excitation DC

Main Rotor

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Overload Characteristics Shunt

LOW OVERLOAD HIGH OVERLOAD - SHORT CIRCUIT

SUSTAINED
VOLTAGE (V)

UN

SUSTAINED
VOLTAGE DIP

LOAD %

100% 200% 300%

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AREP

Auxiliary winding

Regulation

Excitation

Principle
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Voltage regulation (AREP)

AC output

UVW

Sensing 400 V

Supply H1
Supply H3
Excitation DC

Main Rotor

AREP windings H1 and H3

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Overload Characteristics AREP

LOW OVERLOAD HIGH OVERLOAD - SHORT CIRCUIT

SUSTAINED
VOLTAGE (V)

UN

SUSTAINED
VOLTAGE DIP

LOAD %

100% 200% 300%

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Voltage regulation (AREP)
L1
L2
L3
N

Amps dependant supply winding

X1
X2
Z1 Voltage
Z2 sensing

N E+
E-
AVR wires

0V
S

380 V
N Voltage dependant supply winding

N N

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 Construction summary

Main Main + Excitor Rotor + Rectifier bridge

Terminals
Main Stator
Drive end
A.V.R. Fabricated
Bracket
Frame
Non drive
end Bracket
& Exciter
Stator assy

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Company Confidential
Service training: Generators
“Need to know” electrical
concepts : Voltage, Current,
active/reactive power
 “Need to know” electrical concepts : Voltage, Current

We have seen that the Power is the product of voltage and current:
P=UxI

3 phases configuration :

P in VA = U x I x √3
√3 is the 3 phase multiplication factor.

Therefore, the theoretical power in kVA = U x I x √3

1000

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“Need to know” electrical concepts : active/reactive power

Many electrical circuits induce a delay in the current sinusoid versus the
voltage, they are called the INDUCTIVE circuits

Others induce a advance in the current sinusoid versus the voltage, they are
called the CAPACITIVE circuits

The angle between the voltage and the current sinusoids is called φ (Phi)

This angle influences the power required to power up an application, the

Cosinus of the angle φ is called the POWER FACTOR and is involved in the
power calculation

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“Need to know” electrical concepts : active/reactive power

When the angle φ equals 0, the Cosinus φ equals 1.

This is what happens in pure resistive loads, for example, glowing lamps, or
a load bank

The power calculation then equals P = U x I x √3

Angle φ

Current

Voltage

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“Need to know” electrical concepts : active/reactive power

When the angle φ equals, for exemple, 28°, the Cosinus φ equals 0.88.

The power calculation then equals P = U x I x √3 x 0.88

Angle φ

Current

Voltage

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 “Need to know” electrical concepts : active/reactive power

The APPARENT power is the product of voltage and current, not taking into
account the POWER FACTOR.

The APPARENT power unit is Volt-Amps, or VA, or kVA for easier use and is
noted with the letter “S”

S (kVA) = U (Volts) x I (Amps) x √3 (3 phase factor)

1000 (for kVA)

This is the number we use for our model names, i.e. a 100 kVA machine is
named G100.
It is also the only value with which you can compare generators powers
without the application influence.

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 “Need to know” electrical concepts : active/reactive power

The ACTIVE power is the product of voltage and current and taking into
account the POWER FACTOR.

The ACTIVE power unit is Watts, or W, or kW for easier use and is noted with
the letter “P”

P (kW) = U (Volts) x I (Amps) x √3 (3 phase factor) x Cos φ

1000 (for kW)

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 “Need to know” electrical concepts : active/reactive power

The REACTIVE power is the product of voltage and current and taking into
account the Reactive part of the power.

The REACTIVE power unit is Volt-Amps Reactive, or VAR, or kVAR for easier
use and is noted with the letter “Q”

Q (kVAR) = U (Volts) x I (Amps) x √3 (3 phase factor) x Sin φ

1000 (for kVAR)

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“Need to know” electrical concepts : active/reactive power

How to express the relation between Apparent, Active and Reactive power : 3 equations

kW = kVA X COS ɸ

Reactive power
kVAR = kVA X SIN ɸ kVAR
ɸ

kVA = (kW² + kVAR²) Active power

kW

In industrial reality Power Factor COS ɸ = 0,8 or close to this value for most of the loads

Alternators are rated as follows : 500 kVA under 400Volts with a Power Factor COS ɸ = 0,8

kW = 500kVA X 0,8 400 kW

Limited by engine
=
output and stator
current
kVAR = 500kVA X 0,6 = 300 kVAR Limited by rotor excitation
current

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“Need to know” electrical concepts : active/reactive power
• The reactive power is used in the reactive elements such as:
– Coils in motor stators, solenoids, and transformers
– Capacitive elements such as capacitors used in variable frequency drives and
un-interruptible power systems
• The reactive power is used by the reactive component and returned to the
electrical power source.

Close to purely resistive / ɸ close to 0° Close to purely inductive / ɸ close to 90°

COS ɸ close to 0

ɸ kVAR

kW For purely inductive loads

kVAR Phase angle, ɸ = 90°
Power Factor = Cos ɸ = cos 90° = 0
COS ɸ close to 1 kW = kVA x PF = kVA x 0
kVA = kVAR and Active Power (kW) = 0
For purely resistive loads
Phase angle, ɸ = 0°.
Power Factor = Cos ɸ = cos 0° = 1
kW = kVA x PF = kVA x 1
ɸ
kW = kVA and Reactive Power (kVAR) = 0
kW
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“Need to know” electrical concepts : active/reactive power

G500 engine is rated 444 kW, you will not be able to supply more than 420 kW pure resistive load
! even if alternator is able to supply 500 kW (ƞ alt = 94,5% = alternator’s efficiency)

If load real power is 400 kW with power factor COS ɸ = 0,6 you will need an alternator sized like follows :

! kW 400 kW
kVA = = = 670 kVA 700 kVA alternator
COS ɸ 0,6

COS ɸ impact must be considered seriously when sizing a generator  $$$

Considering a wrong load COS ɸ  alternator overload  breakdowns

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Analogies to explain reactive power

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Analogies to explain reactive power

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Analogies to explain reactive power

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Analogies to explain reactive power

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Company Confidential
Service training: Generators
Generators controls types:
Analog controls
Course Objectives

• Functions description
• Operation

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Analog AutoStart Controls

• The AutoStart controls come in two versions:

• “Mechanical” for the G10 up to the G60
• “Electronic” for G80 and larger

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Analog AutoStart Panel – Mechanical Engine

Engine Running
Auto Mode Preheat
LED
Low Oil Pressure
High Eng Temp

Overspeed
Overcrank/Start Fail
Low Fuel
Charge Fail
High Containment Level

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Analog Autostart Panel – Electronic Engine

Auto Mode Engine Running

Preheat
LED
ECU Status
Low Oil Pressure
High Eng Temp
Eng Fault
Overspeed
Overcrank/Start Fail
Low Fuel
Charge Fail
High Containment Level

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Analog AutoStart Operations

• Operations
• The panel powers up in the manual mode only.
• Press start to initiate the start sequence
• Press stop to stop the generator set
• Press Auto to place the generator set in the Auto /
Standby mode and the LED by the Auto Button will be lit.

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Analog AutoStart Setpoints

• Crank Attempts – 3 • Oil Pressure By Pass Timer

• Crank timer – 10 seconds – 10 seconds
• Crank Rest Timer – 15 • Energize To Stop Timer – 5
seconds Seconds
• Start Delay Timer (Auto • Overspeed – 110%
Mode Only) – 10 seconds • Underspeed – 80%
• Preheat Timer – 10 seconds • Low Battery Voltage
Setpoint – 10.5 VDC
• High Battery Voltage
Setpoint – 14.5 VDC

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Sensing

• The AutoStart Controller for the mechanical engines senses

speed from the charging alternator.
• While the AutoStart Controller for the electronic engines
senses speed from the ECU.
• High Engine Coolant Temperature opens at 104° C and
increasing.
• Low Oil Pressure switch opens at 0,85 Bars and decreasing.

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Company Confidential
Service training: Generators
Generators controls types:
Digital controls
Course Objectives

• How to display menus

• How to view and edit settings
• Functions description

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 Basic Digital Controls Operation

• Doosan’s Digital Controller is a comprehensive generator

set controller that is used as the primary interface between
the operator and the generator set. It provides a high
degree of engine and generator protection. Multiple real-
time parameters can also be viewed. The parameters
include, but are not limited to kW, KVA, kVAr, power factor,
oil pressure, coolant temperature, engine speed, and
diagnostic history.

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Operator interface

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 How to display menus?

1. Use repeatedly PAGE button to select the MEASUREMENT menu.

2. Use and to select the screen with requested data.

Frequency, voltage
and current phase to
neutral and phase to
phase

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How to display menus?

Engine oil pressure,

water temperature, fuel
level and battery
voltage

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How to display menus?

Active and reactive

power, power factor

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How to display menus?

Running hours and

service time

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 How to view and edit settings?

1. Use repeatedly PAGE button to select the

ADJUSTMENT menu.
2. Use ↑ or ↓ to select requested set points
group.
3. Press ENTER to confirm.
4. Use ↑ or ↓ to select requested set point.
5. Set points marked “*” are password protected.
6. Press ENTER to edit.
7. Use ↑ or ↓ to modify the set point. When ↑ or ↓
is pressed for 2 sec, auto repeat function is
activated.
8. Press ENTER to confirm or PAGE to leave
without change.
9. Press PAGE to leave selected set points group.

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How to view and edit settings?

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Summary

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 How to view and edit settings?
The following sub-menus are available in the controller
Basic settings Engine params Engine protect
Gen-set name Starting RPM Eng prot del
Nomin power 1 Starting POil Alarm Horn
Nomin power 2 Preheat time Overspeed
Nomin current1 MaxCrank time Oil Pressu Wrn
Nomin current2 CrnkFail pause Oil Pressur Sd
CT ratio Crank attempts Oil Pressu Del
PT ratio Idle time Engine Temp Sd
Nomin Volt1 Min stab time Engine Tem Wrn
Nomin Volt2 Max stab time Wrn EngTempLow
Nominal freq 1 Cooling speed Engine Tem Del
Nominal freq 2 Cooling time Wrn FuelLevel
Gear teeth AfterCool time Sd FuelLevel
AlternatorFreq Stop time Fuel Level del
Nominal RPM 1 Fuel solenoid Batt overvolt
Nominal RPM 2 Fuel PullCoil Batt undervolt
ControllerMode D+ function Batt volt del
FltResGoToMAN ECU FreqSelect NextServTime
DispBaklightTO ECU SpeedAdj
IL Power Off WtBfAcceptRPM
Contr. addr
COM1 Mode
COM2 Mode
ModemIniString
ModbusComSpeed Company Confidential
 How to view and edit settings?
The following sub-menus are available in the controller (continued)
Gener protect Date/Time Sensors spec
Overload Time stamp per Calibr AI 1
Overload Wrn #SummerTimeMod Calibr AI 2
Overload del #Time Calibr AI 3
Ishort #Date CalibrAInIOM 1
Ishort del Timer1 repeat CalibrAInIOM 2
2Inom del Timer1 ON time CalibrAInIOM 3
Curr unbal Timer1Duration CalibrAInIOM 4
Curr unbal del Timer1OFF time
Gen >V Sd Timer2 repeat
Gen >V Wrn Timer2 ON time
Gen <V Wrn Timer2Duration
Gen <V SD Timer2OFF time
Gen V del
Volt unbal
Volt unbal del
Gen >f
Gen >f Wrn
Gen <f Wrn
Gen <f
Gen f del Company Confidential
 Function description

1. OFF mode: No start of the gen-set is possible. Outputs STARTER, and

FUEL SOLENOID are not energized. No reaction if buttons
START,STOP are pressed.

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 Function description

2. MAN mode: START. - starts the gen-set. STOP stops the gen-set.

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 Function description

3. AUTO mode: The controller does not respond to buttons START,

STOP. Engine start/stop request is given by binary input REM
START/STOP.

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Gen-set operation states

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 Digital controller clock start setting: time setup

1. From the start page press the “PAGE” button

2. You get to the sub-menus list

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 Digital controller clock start setting: time setup

3. By using the down arrow, select the “Date/Time” menu, then press
“ENTER”

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 Digital controller clock start setting: time setup

4. By using the down arrow, select the “#Time” menu, then press
“ENTER”. A “duplicate” time appears

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 Digital controller clock start setting: time setup

5. By using the up or down arrow, adjust the “duplicate” time to your

local time. Press “ENTER”, the time set in the controller adjusts
accordingly. Use the same procedure for the date, if adjustment is
needed.

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 Digital controller clock start setting: start time setup

6. Using the same principle, select the “Timer1 repeat” menu, press
“ENTER” and adjust the days you need the machine to start.
Choices are day by day, Monday to Friday, Monday to Saturday,
Monday to Sunday, Saturday to Sunday. Press “ENTER” to validate
your choice.

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 Digital controller clock start setting: start time setup

7. Using the same principle, select the “Timer1 ON time” menu, press
“ENTER” and adjust the hour you need the machine to start at.
Press “ENTER” to validate your choice. Same procedure for
“Timer1 OFF time

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 Digital controller clock start setting: start time setup

8. Your timer is now all set up. It will apply whenever you set the
controller in “AUTO” mode.

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 How to use the controller software

Connect your PC through the RS232 port to the back of the controller and
start the Comap software.

If your PC doesn’t have a RS232 connection, you can source a USB

to RS232 converter from Doosan, CPN is 46551205 , to be used together
with a female – female RS232 DB9 NULL cable.

Switch the controller on (green button) and get connected.

Save the history file using the generator’s serial number and date number
as file name.

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Company Confidential
Service training: Generators
Operation
Course Objectives

• Connecting the load

• Pre-start checks
• Starting the generator
• Stopping the generator

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Connecting the load

• Make sure the wires are not

cracked or damaged in any way
• Connect the proper phase wire to
its corresponding bar L1–L2–L3.
Mixing phases connections can
result in equipment damage,
accidents causing injuries or even
death
• Always use the 5 connections, 3
phases, neutral and ground

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Pre-start checks

Before starting:
• Ensure load wiring connections are tight
• Check for fluid leaks
• Check for fluid level in container base
• Check engine oil and coolant level
• Check proper grounding circuit. Refer to Safety-Grounding.
• Check for frayed or loose fan belts, hoses or wiring insulation
• Check for leaves, paper, debris in air vents
• Check Fuel Level. Add CLEAN diesel fuel.

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Pre-start checks

Before starting:
• Ensure load wiring
connections are tight
• Check for fluid leaks

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Pre-start checks

Before starting:
• Check for fluid level in
container base
• Check engine oil and coolant
level

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Pre-start checks

Before starting:
• Check for frayed or loose fan
belts, hoses or wiring
insulation
• Check for leaves, paper,
debris in air vents
• Check Fuel Level.

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Pre-start checks

• Check Fuel Level. Add CLEAN

diesel fuel if necessary.

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Starting

• Switch the battery switch on

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Starting

• On G10, turn the starting key to

the position “I”
• Move it on to the pre-heating
position and keep it there for a
few seconds – 5 to 10 seconds
during summer time – up to 1 ½
minute during winter time while
freezing.
• If the engine doesn’t start after
15 seconds cranking, wait 1
minute before trying again.
• If the engine doesn’t start after 3
attempts, go through the
troubleshooting procedure

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Starting

• On G20 to G500, push the start

button – the control will do the
pre-heat and start procedure on
its own.
• If the engine didn’t start after 3
attempts, the control will show
the overcranking alarm  go
through the troubleshooting
procedure.

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Generator operation recommendations

Engine duty cycle:

Running the generator at low loads for an extended period of
time will result in:
• Fuel Dilution of the lubricating oil
• Carbon build up in the cylinder and turbocharger
• Cylinder head valve sticking
• Reduced performance

The average load should not be below 40 % of the generator

nominal power

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Generator operation recommendations

Load unbalance:
Load unbalance between phases should not exceed 30% of the
nominal load

Power factor:
• The closer PF is to 1.0, the closer apparent power is to real
power
• IMPORTANT!!!! The smaller the PF is, the larger the current
must be to produce the same amount of real power. The
alternator must be capable of providing excess current.
• Generators are designed for and rated at 0.8 PF to give them
the capability to withstand higher current demand from loads
with 0.8 PF.

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Generator operation recommendations

Power factor example:

185 kW load at 400 volts.

• Remember 3 phase kW = Volts x Amps x PF x √3/1000, and

Amps = kW x 1000 / Volts / PF
• If the load’s PF = 1.0, the current that the load demands is:
Amps = 185kW x 1000 / 400 volts / √3 / 1.0 = 267 amps
• A G200 can do the job

• If the load’s PF = 0.8, the current that the load demands is:
Amps = 185kW x 1000 / 400 volts / √3 / 0.8 = 334 amps to get
the same 185kW of real power!
• A G250 is required to do this job

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Generator operation recommendations

Power factor example Continued):

The alternator must be capable of delivering even more current

than this for limited amounts of time

It is crucial to take the power factor into account before

selecting the right generator for the job

When troubleshooting a generator performance problem, this also

needs to be checked upfront to clearly know what the generator is
really facing.

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Company Confidential
Service training: Generators
Testing and troubleshooting
Course Objectives

• Testing the AVR

• How to check the windings Integrity
• How to check diodes
• No voltage, what can be the cause?
• The control’s alarms
• Troubleshooting and fixes

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 AVR (Auto Voltage Regulator) testing

Disconnect the AVR wires, engine at stop, and test the auxiliary windings and field resistances

X1 – X2 connections (Ω)

Z1 – Z2 connections (Ω)

E+ – E- (Field) (Ω)

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 AVR (Auto Voltage Regulator) testing

With the AVR wires connected, engine running, test the auxiliary windings voltage

X1 – X2 connections: U
(VAC) at no load

Z1 – Z2 connections: U
(VAC) at no load

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Testing of a Generator

Be careful!
Use certified protection equipment rubber soles shoes,
rubber gloves.

And more than never, ………..

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Testing of a Generator

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 Checking windings integrity

FLUKE 87

200
230 V
231
N T12 Neutral

W T3 Ω
mV

mA

V T2 3 Phase
V

Output V
µA

U T1 OFF

1. Check the voltage between U/N – V/N – W/N with a Multi-meter

2. The voltage should be 3 x the same: Max. voltage difference: 1 to 2 Volt
3. If the difference is more than 1 to 2 Volt, perform the following test:
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 Checking windings integrity

EARTH

N Neutral

W
400 V sensing

V 3 Phase
Output
U
EARTH
FRAME

1. Disconnect the sensing wires of the AVR before you carry out this test.
2. Disconnect the connections from Neutral to Earth.

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 Checking windings integrity

MΩ
N Neutral

W
Test
V 3 Phase M Ω 1KV

M Ω 500V
Output
U
EARTH MEGGER
FRAME

3. Test the Stator insulation (One phase – earth) with an Insulation tester.
4. The MINIMUM insulation value is 1.0 Meg-Ohm to Earth.
Windings must be dried out if below 1 Meg-Ohm
5. If after drying, the value is good, there is still a possible fault (phase to
phase)
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 Checking windings integrity

N T11

W
V
U
EARTH

Disconnect ALL wire-ends and isolate them from each other.

Measure the windings mutual.
T1 against all others (except T4 which must be 0 meg ohm)
Value must be above 1 Meg Ohm
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 Checking diodes

FLUKE 87

Diodes Negative Plate

Anode Stud
Ω.--
mV

mA
V

SHAFT V
µA

OFF

Diode Positive Plate

Cathode Stud

Switch the Multi-meter to the position indicating ‘diode’ test position.

With the Positive test lead on the Anode side of the diode, the meter
should give a reading, indicating electron flow
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 Checking diodes

FLUKE 87

Diodes Negative Plate

Anode Stud
Ω.--
mV

mA
V

µA
SHAFT V
OFF

Diode Positive Plate

Cathode Stud

Reverse the Multimeter leads, so that the Positive lead is on the Anode
side of the diode; the Multimeter should now read OL, (Over Load - no
electron flow). A faulty diode will give a short circuit reading in both
directions, or an open circuit reading in both directions.
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 Checking the varistor
FLUKE 87

Ω. --
mV

mA
SHAFT V

µA
V
OFF

Switch the Multimeter to the position indicated for resistance ‘Ω’ testing
The Varistor should read Infinity in both directions, and has no polarity
A faulty Varistor will be short circuit, or burnt (‘blown’) by fault current
A blown Varistor will not affect the operation of the generator!
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 Testing of Excitation Stator

E+ FLUKE 87

E-

Ω. --
mV

mA
V

µA
V
OFF

Check the Exciter Stator resistance across E+ & E- with a multi-meter set
on the Ω range.
The correct resistance figures are given in the Operation and Maintenance
Manual supplied with the Generator.
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Loss of remnant magnetism

Engine runs but:

No Voltage!!

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Loss of remnant magnetism

AC output

UVW
400 V
300 V
200 V
100 V
Sensing 400 V
0V

Supply H1 Volts
Supply H3
Excitation DC

Disconnect the
excitation wires
E+ and E-
Connect the
+
12V DC
- excitation wires
E+ and E- to an
Battery
alternative current
Main Rotor
source, engine
Or battery, or 9 VDC

9V DC
Battery

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Loss of remnant magnetism

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Loss of remnant magnetism

If we disconnect the battery, connect the AVR again, start

the engine and….

We have normal voltage:

this indicates that the remnant magnetism was lost in the
excitor.

We have still no voltage:

this indicates that the AVR is probably broken and needs to be
changed.

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Reading the analog control’s information

Engine Running
Preheat
ECU Status (for electronic engines)

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Reading the analog control’s alarms

• Low oil pressure alarm

• Shuts down the engine

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Reading the analog control’s alarms

• High water temperature alarm

• Shuts down the engine

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Reading the analog control’s alarms

• Engine fault alarm

• Have the engine dealer
reading the ECU to check
what the fault is

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Reading the analog control’s alarms

• Engine overspeed alarm

• Can be caused by a
sudden load drop
• Start the engine again and
check the engine speed
stability
• If the alarm goes off again,
or if the engine runs
erratically, check the fuel
line for air
• If the problem persists
have the engine ECU
checked.
• If the ECU is OK, change
the generator controller

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Reading the analog control’s alarms

• Overcrancking alarm: the

engine didn’t start after 3
attempts and the controller
gave up

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Reading the analog control’s alarms

• Low fuel level alarm: the

fuel level in the tank is
lower than 10 % of total
volume
• Shuts down the engine

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Reading the analog control’s alarms

• Battery charge fail:

Indicates battery voltage is
low or not being charged.
• Does not shut down the
engine

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Reading the analog control’s alarms

• Full bunded base alarm

• Indicates the bunded base
is close to full
• Does not shuts down the
engine

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Setting up the analog controller
• Eleven LEDs separated into two banks (see below) are provided on the
faceplate.
•The LEDs Bank 1 includes 6 LEDs and Bank 2 includes 5.
• In Setup mode, these banks form a binary code to indicate either the
controller setup configuration or error status, which is indicated by the
last 8 (red) LEDs

Parameter #
LEDs
bank 1

LEDs

Value
bank 2

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Setting up the analog controller

• To enter the SETUP MODE, first remove DC power to

the controller (Battery switch) and wait until the
controller is completely switched off. Use the start and
stop buttons to check if the controller still reacts, and
also to speed-up the discharge of its internal capacitor.
• On the back of the controller are four DIP switches,
set switch #1 to ON (see schematic at right) then
restore DC power.

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Setting up the analog controller

•The AUTO mode LED will blink to indicate that the controller is in the
SETUP MODE.
•When in the SETUP MODE, pressing the “START” button steps up thru the
entire list of parameters. The pattern of the LEDs Bank 1 (see below), is
used to indicate which parameter is selected. The pattern will change once
each time the “START” button is pressed.

Parameter #
LEDs
bank 1

LEDs

Value
bank 2

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Setting up the analog controller

•Pressing the “STOP” button steps up thru all the available values for each
parameter.
•The pattern of the LEDs Bank 2 (see below), is used to indicate which value
is selected. The pattern will change once each time the OFF button is
pushed.
•Pressing the “AUTO” button stores the displayed value.
•If any value is changed, it will blink until stored, except a value of zero.

Parameter #
LEDs
bank 1

LEDs

Value
bank 2

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Setting up the analog controller

•If any value is changed but not stored, and then the parameter is changed,
the value will still be what was shown originally.
•If you accidentally go past a desired parameter or value, you can step back
by pressing the down arrow button.
•The parameter/value list and corresponding LED indication are shown on
Table 1 – Parameter Values and Corresponding LED Indication.
•When you are finished with setup, set switch #1 to in the Normal Operating
Position (OPEN), remove DC power for 10 seconds, then restore DC power.

Parameter #
LEDs
bank 1

LEDs

Value
bank 2

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Setting up the analog controller
•Required values for G20 to G60:

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Setting up the analog controller
•Required values for G20 to G60 (Continued):

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Setting up the analog controller
•Required values for G80 to G200:

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Setting up the analog controller
•Required values for G80 to G200 (Continued):

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Setting up the analog controller
•Required values for G250 to G500:

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Setting up the analog controller
•Required values for G250 to G500 (Continued):

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Setting up the analog controller

• To exit SETUP MODE, first remove DC power to the

controller (Battery switch) and wait until the controller
is completely switched off. Wait until the AUTO mode
LED has completely stopped to blink.
• On the back of the controller, set back switch #1 to its
original position then restore DC power.

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 Reading the digital control’s alarms

Alarms display location

Mode selection button
Start Button
Stop Button
Reset Button

Navigation buttons

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Reading the digital control’s alarms

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Reading the digital control’s alarms

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Reading the digital control’s alarms

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Reading the digital control’s alarms using the computer
• Install the LiteEdit software by double-clicking the application – follow the
instructions

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Reading the digital controller using the computer
• Connect the computer to the controller

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Reading the digital controller using the computer
• Open the LiteEdit software

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Reading the digital controller using the computer
• Open direct communication to the controller

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Reading the digital controller using the computer
• Open direct communication to the controller

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Reading the digital controller using the computer
• Open direct communication to the controller

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Reading the digital controller using the computer
• IMPORTANT : Save the controller’s archive before any other action

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Reading the digital controller using the computer
• IMPORTANT : Save the controller’s archive before any other action

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Reading the digital controller using the computer
• IMPORTANT : Save the controller’s archive before any other action

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Reading the digital controller using the computer
• Control menu

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Reading the digital controller using the computer
• Set points menu

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Reading the digital controller using the computer
• Actual values menu

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Reading the digital controller using the computer
• History menu

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Reading the digital controller using the computer
• Configuration menu

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Reading the digital controller using the computer
• Inputs / outputs configuration menu

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Reading the digital controller using the computer
• Inputs / outputs configuration menu

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Reading the digital controller using the computer
• Password set points menu

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Reading the digital controller using the computer
• Password set points menu

Page 240
Reading the digital controller using the computer
• Not used

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Reading the digital controller using the computer
• Engine ECU configuration menu

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Reading the digital controller using the computer
• Engine ECU configuration menu

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Reading the digital controller using the computer
• Units choice menu

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Reading the digital controller using the computer
• Units choice menu

Page 245
Service training: Generators
Programming the digital
controller
Programming the digital controller using the computer
• Unlock the controller using the master password

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Programming the digital controller using the computer
• Unlock the controller using the master password

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Programming the digital controller using the computer
• Unlock the controller using the master password

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Programming the digital controller using the computer
• Unlock the controller using the master password

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Programming the digital controller using the computer
• Select the Configuration

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Programming the digital controller using the computer
• Select the Configuration file

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Programming the digital controller using the computer
• Confirm the Configuration selection

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Programming the digital controller using the computer
• Write to the controller

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Programming the digital controller using the computer
• IMPORTANT : The controller will be switched off during programming,
therefore the controller power hold will be released.
• To avoid power shut off and loss of controller data:
• It is compulsory to power-up the controller from an external source
• An alternative is to keep the power-up green button pushed in during
the programming time

• Failing to keep the controller powered-up will cause programming

interruption and may cause the controller firmware to be corrupted. The
controller can then become unusable and will need to be replaced

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Programming the digital controller using the computer
• Write to the controller

Page 256
Programming the digital controller using the computer
• Write to the controller – push the green power button before hitting “Yes”
button

Page 257
Programming the digital controller using the computer
• Write to the controller: the controller shows the writing progress

Page 258
Programming the digital controller using the computer
• Write to the controller: the programming is complete when seeing this
screen

Page 259
Programming the digital controller using the computer
• Write to the controller: The history keeps track of programming

Page 260
Programming the digital controller using the computer
• Importing a language

Page 261
Programming the digital controller using the computer
• Importing a language: select the language you want import

Page 262
Programming the digital controller using the computer
• Write to the controller – push the green power button before hitting “Yes”
button

Page 263
Programming the digital controller using the computer
• Write to the controller: the controller shows the writing progress

Page 264
Company Confidential
Service training: Generators
Digital controller improvements
 Digital controller improvements

When starting up a generator equipped with an electronically governed

John Deere engine and the digital controller, we have experienced issues
with the engine speed information communication from the ECU to the
controller.

Company Confidential
 Digital controller improvements

Upon our request, the manufacturer recommended a solution involving a

temporization holding the engine RPM measurement for 3 seconds

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 Digital controller improvements

While the firmware had to be modified, we also asked for a modification to

trip the main breaker on emergency shutdowns, meaning any detected fault
which would trigger a generator shutdown.

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 Summary

• While the firmware had to be modified, we also asked for a modification

to trip the main breaker on emergency shutdowns, meaning any
detected fault which would trigger a generator shutdown.

• These features are included in the latest firmware 1.3

• Firmware 1.3 and new settings files can be implemented in all digital
controllers with Hardware version 1.2 and higher

Company Confidential
Service training: Generators
Maintenance
Course Objectives

• Inspections
• Maintenance
– Break-in, 100 hours
– 250 hours
– 500 hours
– 1000 hours
– 1500 hours
– 2000 hours

Company Confidential
Inspections

WARNING!
Before attempting any repair service, disconnect engine battery
Cables and all leads to electrical power requirements. Failure to do
so can result in severe personal injury, death or damage to the
equipment.

Company Confidential
Inspections

General:
In addition to periodic inspections, many of the components in this
unit requires periodic servicing to provide maximum output and
performance. Servicing may consist of pre-operation and post-
operation procedures to be performed by the operating or
maintenance personnel. The primary function of preventive
maintenance is to prevent failure and consequently, the need for
repair. Preventive maintenance is the easiest and the least expensive
type of maintenance. Maintaining your unit and keeping it clean at all
times will facilitate servicing.

Company Confidential
Inspections

Hoses:
Each month it is recommended
that the intake hoses from the air
cleaner and all flexible hoses
used for water and fuel be
inspected for the following:
1. All rubber hose joints and the
screw type hose clamps must
be tight and the hoses
showing no signs of wear,
abrasion or deterioration
2. All flexible hoses must be free
of wear, deterioration and
vibration abrasion. Routing
clamps must be secure and
properly mounted.

Company Confidential
Inspections

Fuel/Water Separator:
Daily check for water in the fuel
filter/water separator unit. Some
engines have a translucent bowl for
visual indication, and others have a
drain valve below the primary
element. Every six months or 500
hours, or less if fuel is of poor quality
or contaminated, replace the bowl
element(s).

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Inspections

Air Vents
Daily clean the air vents of any
obstruction or debris.

Company Confidential
Inspections

Air Cleaner
Proper maintenance of the air cleaner
provides maximum protection against
airborne dust.
Squeeze the rubber valve (precleaner
dirt dump) periodically to ensure that
it is not clogged).

Company Confidential
Maintenance

Scheduled Maintenance
The maintenance schedule is based on normal operation of the unit.
In the event unusual environmental operating conditions exist, the
schedule should be adjusted accordingly.

Company Confidential
Maintenance

Break-in, 100 hours – G10 up to G40

Change the oil and filter after the first 100 hours of operation of a new
or rebuilt engine.
These diesel engines must be used with heavy duty lubricating oil in
compliance with the requirements of the standards API CC,
DEF2101D, Mil-I-2104C or Mil-L-46152A/B for L.E. + S.L + S.Q
engines and API CD for S.S engines. Straight mineral oils are not
suitable, neither are oils of less detergency than specified.

Company Confidential
Maintenance

Break-in, 100 hours – G60 up to G200

Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
Use oil viscosity based on the expected air temperature
range during the period between oil changes. The
following oil is preferred:

Oils meeting ACEA Specification E4/E5

Other oils may be used if they meet one or more of the
following:
• API Service Classification CI-4
• API Service Classification CH-4
• ACEA Specification E3
Multi-viscosity diesel engine oils are preferred.

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Maintenance

Break-in, 100 hours – G250 up to G500

No break-in maintenance for these models

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Maintenance

250 hours or 3 months G10 to G40

• Change the engine oil and filter
• Change the fuel filter element
• Change the air filter element

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Maintenance

500 hours or 1 year G60 to G200

• Change the engine oil and filter
• Change the fuel filter element
• Change the air filter element

Company Confidential
Maintenance

500 hours or 6 months G250 to G500

• Change the engine oil and filter
• Change the fuel filter element
• Check the Cooling System
• Replace the Coolant Filter
• Check the Batteries
• Check the Battery Cables and
Connections

Company Confidential
Maintenance

500 hours or 6 months G250 to G500

Engine oil requirements:
A sulfated ash limit of 1.85 percent has been placed on all engine
lubricating oils recommended for use in Cummins engines. Higher
ash oils can cause valve and/or piston damage and lead to excessive
Oil consumption.
The use of quality engine lubricating oils, combined with appropriate
oil drain and filter change intervals, is a critical factor in maintaining
engine performance and durability.
Cummins Inc. recommends the use of high-quality SAE 15W-40
heavy-duty engine oil, such as Valvoline® Premium Blue®, which
meets performance specifications as listed below.
NOTE: In areas where CH-4/SJ or CG-4/SH oils are not available,
refer to Oil Drain Intervals in Section 2.

Company Confidential
Maintenance

500 hours or 6 months G250 to G500: oil specifications

Company Confidential
Maintenance

500 hours or 6 months G250 to G500: oil specifications

Company Confidential
Maintenance

1000 hours or 1 year G10 to G40

(On top of 250 hours maintenance)
• Check the starter and charge
alternator
• Clean the radiator
• Have the injection pump checked by
a certified engine dealer
• Clean the generator set
• Retighten the nuts and bolts

Company Confidential
Maintenance

1000 hours or 1 year G60 to G200

Same as 500 hours maintenance
• Change the engine oil and filter
• Change the fuel filter element
• Change the air filter element

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Maintenance

1000 hours or 1 year G250 to G500

(On top of 500 hours maintenance)
• Drive Belts - check
• Fan Hub Belt Driven - check
• Cooling Fan Belt Tensioner - check

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Maintenance

2 year G10 to G40

• Flush and Refill Cooling System

Company Confidential
Maintenance

2000 hours or 2 years G60 to G200

• Flush and Refill Cooling System
• Test Thermostats
• Check and Adjust Valve Clearance

Company Confidential
Maintenance

2000 hours or 2 year G250 to G500

• Flush and Refill Cooling System

Company Confidential
Company Confidential
 Product Identification
• It is critical to properly identify the machine you’re considering before
any inquiry on service or parts.

• Over the years, more than 1 machines has carried the same name,
which leads to confusion when advising the right part or the right service
action to perform.

• Also, the serial number informs us of which specification the machine

was built to, including the factory fitted options.

Company Confidential
Service training: Generators
Product Identification
 Product Identification
As an example, a 3 way fuel valve for a G200 looks like this:

….. Or like this:

Company Confidential
 Product Identification

….. Or like this:

Just depending on the serial number of the machine

Company Confidential
 Product Identification
Generators

• Genpower Range (2001 to 2007): XXX XXXXXXXX

Model 8 digits

• Example: 55001003886

• PowerSource from Unicov (2007 to 2008): XXGXXX XXXX

Year Model 4 digits

• Example: 07G2500001

Company Confidential
 Product Identification
Generators

• PowerSource from Airpower: GXXX X1XX

Model 4 digits
• Example: G2500101
Range starting at 101 for
differentiation

• Stage IIIA PowerSource from Airpower: GXXX3XXXX

Model 4 digits

"3" digit for "Stage IIIA"

• Example: G15030002

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 Product Identification

Light Towers
• EMEA Light Towers: use the latest 6 digits:

• LT6K 366XXX or 367XXX

• V9: 368XXX

Company Confidential
 Product Identification
• Another important point on product identification is on specification changes within
a same range.

• Example: G20, G30 and G40 engines were changed to Stage IIIA engines as we
ran out of engines before the new model was ready.

• Also, Leroy-Somer is changing their alternators design and discontinuing the

supply of the old design

Company Confidential
 Product Identification
A serial number has been recorded for the first machine affected by the
change and reflected in a parts manual revision, as shown below:

Company Confidential
 Product Identification
A serial number has been recorded for the first machine affected by the
change and reflected in a parts manual revision, as shown below:

Company Confidential
Thank you very much for
your kind attention

Company Confidential
Company Confidential