Operation Manual 500KW

Operation Manual of Gas Generator Set

Table of Contents
Introduction..................................................................................................................................................... 4
Cautions........................................................................................................................................................... 5
Special Attentions............................................................................................................................................ 6
Chapter 1 Safety Rules and Precautions of Gas Generator Set........................................................................7
1.1 —Safety introduction - danger classes...................................................................................................... 7
1.2 Safety rules................................................................................................................................................ 8
1.3 General safety precautions.......................................................................................................................13
Chapter 2 Overview....................................................................................................................................... 19
2.1 Description of gas generator set...............................................................................................................19
2.2 Performance characteristics of gas generator set..................................................................................... 20
Chapter 3 Main Parts of Gas Generator Set and Characteristics................................................................ 21
3.1 Introduction of gas engine....................................................................................................................... 21
3.2 Engine operating principle.......................................................................................................................23
3.3 Installation and connection requirements of gas generator set................................................................ 24
3.4 Engine diagram........................................................................................................................................27
Chapter 4 Circuit System...............................................................................................................................31
4.1 Starting system.........................................................................................................................................31
4.2 Electronic ignition system....................................................................................................................... 36
4.3 Electronic speed governing system..........................................................................................................38
4.4 Process of air/fuel rate control system..................................................................................................... 42
Chapter 5 Lubrication System....................................................................................................................... 43
5.1Engine oil pump........................................................................................................................................43
5.2 Engine oil filter........................................................................................................................................ 43
5.3 Engine oil cooler......................................................................................................................................44
5.4 Oil pan..................................................................................................................................................... 44
5.5 Lubricating system flow chart................................................................................................................. 46
Chapter 6 Cooling System............................................................................................................................. 49
6.1 Water pump..............................................................................................................................................50
6.2 Radiator................................................................................................................................................... 50
6.3 Fan........................................................................................................................................................... 51
6.4 Thermostat............................................................................................................................................... 51
6.5 Cooling system flow chart....................................................................................................................... 53
Chapter 7 Air Intake and Exhaust System..................................................................................................... 54
7.1 Air intake system..................................................................................................................................... 54
7.2 Air intake system flow chart.................................................................................................................... 57
7.3 Air exhaust system................................................................................................................................... 58
Chapter 8 Operation Instructions for the Control System..............................................................................60
8.1 Cautions................................................................................................................................................... 60
8.2 Overview................................................................................................................................................. 60
8.3 Outer appearance of the control system...................................................................................................62
8.4 Operation Procedure................................................................................................................................ 63

8.5 Protection and Warning............................................................................................................................82
8.6 Failure Processing....................................................................................................................................83
8.7 Appendix..................................................................................................................................................85
Chapter 9 Use and Operation Procedures of Generator Set...........................................................................87
9.1 Selecting the fuel gas, engine oil and coolant..........................................................................................87
9.2 Conditions for the location for installing and using the gas generator set............................................... 93
9.3 Floor requirements...................................................................................................................................95
9.4 Fixing and shockproof devices of generator set...................................................................................... 96
9.5 Generator Operation Procedure............................................................................................................. 102
Special Notice..............................................................................................................................................106
Introduction
Thank you for using our gas generator set. This manual is formulated to enable you to properly
use and maintain your generator set so as it can serve you reliably.
This document mainly describes the technical specifications, use, calibration and maintenance of
the general models of gas generator set. With the development of the market, we will make
continuous improvements of the existing products and develop new models while revising the
relevant manuals. You are welcomed to provide us your valuable advice.
The gas generator set is made by combining the gas engine we develop with the generator set.
Technical improvements and innovations are made to the structure of the engine to adapt it to the
performance of the gas generator, including our proprietary technology. The gas engine drives the
LEROY-SOMER generator on the same chassis, and form a gas generator set together with a
control panel, which will be described further in this document.
As improper installation, maintenance or part placement will cause serious injury and even death,
operation and maintenance staff of devices must receive and pass professional training before they
are allowed to operate the set and install the electrical and mechanical components.
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Cautions
Read carefully the use and maintenance manual of gas generator set before using the product to
learn the structural features and the operation methods of the gas generator set.
Engine oil specific to engines is used for the generator set (at the grade of 15W40 CD or above) at
the general ambient temperature, and lubricant must be clean to make the engine oil waterproof. In
changing to a different type of engine oil, wash the lubricating system before adding the new
engine oil. Never mix up different types of engine oil.
To use the generator set in a cold environment (at an ambient temperature of below 5℃), the
antifreeze liquid with a condensation point suitable for the ambient temperature should be chosen
(generally, with a freezing point of 10℃ lower than the lowest temperature in the place of use ).
Alternatively, add hot water before the set is started up and discharge the water once the set is
stopped.
All failures and losses caused due to overload and over-speed of the gas generator set are not
covered by the warranty.
Once a set is stopped because of any fault, switch off the gas valves, leave the set stopped for
several minutes until the fault is removed. After operating the jigger for several times, switch on
the gas valve and then start the set.
The gas valves on the gas pipe must be switched off when the generator set is in a stand-by status
for a prolonged time.
After several attempts of start, switch off the gas valves first and start the set. The residual gas
must be exhausted before the set is started.
In case of a gas leak in the generator room, cut off the gas valves and never start the set. Open the
door and ventilator to exhaust the inflammable gas from the room. All working equipment in the
generator room are explosion-proof. Do not smoke or light a fire inside and around the generator
room.
Learn the section "Safety Rules and Precautions of Engine", especially the parts marked with
"Danger" or "Warning" before reading the instruction of gas engine in order to prevent the engine
from being damaged and protect operators.
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Special Attentions
☆ Hang a board with such words as "Staff Only" outside the generator room.
☆ Check if there is leakage of the gas pipe regularly and keep the generator room well ventilated.
☆ Following the operation code to avoid causing economic losses and even casualty.
☆ Prepare complete operation records and assign dedicated staff for maintaining the set.
☆ Keep clean within and outside the generator room and the set under good working conditions.
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Chapter 1 Safety Rules and Precautions of Gas

Generator Set
1.1 —Safety introduction - danger classes
The danger class legends used in this document are also applied to our H-series generator set
products. Such legends cover all the dangers mentioned in this document.
Danger it indicates a danger with a high risk. Ignoring such danger will cause death or grievous
bodily harm.
Warning it indicates a danger with a medium risk. Ignoring such danger may result in death or
grievous bodily harm.
Caution it indicates a danger with a low risk. Ignoring such danger may result in minor or
moderate injuries.
Notice it indicates information directly or indirectly related to person safety or equipment
protection. Ignoring such tip may result in failure of the machine or physical losses.
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1.2 Safety rules
Before using the generator, read the operation manual and get familiar with your equipment. The
equipment will only run safely and effectively under correct operation and maintenance. Many
accidental injuries are resulted in incompliance with the general and safety rules. The following
symbols in this document are used to warn the operation and maintenance staff of potential
dangerous conditions:
Fuel gas and oil gas are inflammable and explosive.

☆ Do not smoke or light a fire near a generator set or gas pipe.
☆ The gas pipe must have an adequate safety guarantee without leakage. It must be firmly
connected with the engine.
☆ Ensure that all the inlet pipes of fuel gas are provided with control valves.
☆ Do not smoke when checking and repairing batteries. Lead-acid batteries will generate
hydrogen which will explode in contact with an electric arc or a flame of cigarette.
Air exhausted from the engine is fatal.

Provide a proper exhaust system to discharge waste gases. Check visually or by listening if there
is leakage in the exhaust system and follow the maintenance schedule. Ensure the exhaust pipes
are installed and fixed. Do not use the exhausted waste gases to warm the room. Make sure the
ventilation system is clear.
Turning parts will cause grievous bodily harm or death.

☆ When checking and maintaining the generator before start, disconnect the battery wires to
prevent the generator from unintentional start.
☆ Keep all parts safe. Check if they are fastened, supports and pipe clips are positioned, and
protective covers of turning parts such as belts and fans are closed.
☆ Do not approach parts that may turn or work on electric equipment wearing loose clothes or
metal ornaments as the loose clothes may be drawn into the turning parts and metal ornaments
may short circuit electric connections to cause personal shock or burn.
☆ When the set is running and needs calibrating, stay away from the hot or turning parts.
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☆ Keep hands, clothes and metal ornaments far away from turning parts and eclectic equipment.
☆ When checking and maintaining the generator set before start, disconnect the battery cables to
prevent the generator from unintentional start.
☆ Keep all parts safe. Check if they are fastened, supports and pipe clips are positioned , and
protective covers of turning parts such as belts and fans are closed.
Electric shock may result in personal injury or death.

☆ In maintaining or repairing the generator set, switch off the electric power first if the
protective cover of electric equipment needs to be opened;
☆ Place dry wooden plates on the metal or reinforced floor around the electric equipment, and
then apply rubber insulating pads on them.
☆ Do not attempt to solve an electric fault wearing wet clothes and shoes, or non-insulating
shoes, or wet on skin.
☆ A voltage of above 36V may result in personal injury or even death. Do not change any
electric circuit without authorization.
☆ Comply with relevant national standards or applicable local protection regulations.
☆ All electric installation operations must be performed by qualified electricians.
☆ A prominent label should be affixed onto a switch which is off to prevent other people's
misoperation to cause accidents on people and equipment.
☆ The generator set must be connected to the mains via a parallel control system instead of
directly. Otherwise the equipment and the electric power system will be damaged or burned.
Responses to be made when an alarm is heard.

☆ Emergency evacuation alarm (gas alarm, fire alarm and gas early warning)
☆ Leave the relevant place immediately. Go outdoor to have fresh air immediately.
☆ Close the safe gas plugs outside the generator room and the dangerous zone, and take
measures to prevent them from being opened accidentally.
☆ Call the fire brigade.
☆ Do not re-enter related areas.
☆ Wait until the fire brigade comes.
☆ Warn others of the danger.
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☆ Do not re-enter the related areas except in the following circumstance: with the help of the fire
brigade, the danger, failure or damage has been removed, all space has been ventilated
thoroughly, and the safety system re-sends a signal allowing entry into relevant areas.
☆ Note: as the environment and use conditions vary with devices, an emergency plan must be
made to take into account the specific environment and use conditions before any worker
operates on a device containing toxic gases. And pay attention to the provisions of applicable
laws. Every person operating the equipment must confirm that he has understood the
emergency plan.
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Personal Protection
☆ Only professionals who have received related electric or mechanical training can run or
operate the equipment.
☆ Only such people (professionals) can enter the generator room and they must have read and
understood the related safety regulations and observe such regulations.
☆ Under all circumstances, follow the instructions of prohibition, danger, indicative and warning
signs. Ignoring such signs may result in personal injuries or equipment damages.
☆ Wearing Personal Protection Equipment (PSA)！
☆ Wear protection equipment for the body, head, eyes, ears and respiratory system that is
accepted by relevant authorities. Do not wear loose clothes, jewelry or wear long hair loose
when staying beside the engine.
☆ Standard protection kits required for entering the generator room, or approaching or operating
the equipment outside the generator room, include goggles, protective suit, gloves and safety
shoes.
☆ Use hearing protective earplugs, helmet, fall-arrest system, mask or other person protection
kits based on the operation status, environment conditions, working method or place.
☆ Use your good judgment to avoid danger and wear applicable personal protection kits.
☆ Anyone drunk or under the effect of drug is not allowed in the generator room, since he may
do harm to not only himself but also others.
☆ You must comply with applicable local safety rules and regulations. JAP
☆ Injuries may be caused dependent upon the operation status or operation of equipment, so
wear proper personal protection kits.
The example below is for reference only. when the equipment is running,
☆ Put up earplugs for hearing protection, goggles, protection suit, safety shoes and protection
gloves！
☆ Assembling operation during maintenance and servicing:
☆ Note: Many parts of the equipment and engine are heavy. There is a potential risk of being
injured for the weight of such parts. Put up your safety shoes, protection suit and gloves！
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☆ Put up safety shoes, protection suit and gloves!
☆ On site or inaccessible points during installation:
There is a risk of serious injuries to your head caused
by falling, tilting or flying objects, swinging weights
and obstacles.
☆ Put up helmet and safety shoes！
☆ High-temperature surfaces and media (engine oil,
cooling water): The surface temperature on the surface
of the engine or pipe can be as high as 150 °C.
☆ Put up thermal insulating gloves and protection suit! JAP
☆ Pipelines and containers with pressure: Such media as cooling water and lubricating oil are of
a high temperature and have pressure.
☆ Put up goggles, protection suit and thermal insulating gloves！
☆ Operation exposed to dust: Change the air filter regularly, keep clean and change activated
carbon......
☆ Put up mask, goggles, protection suit and gloves！
☆ Using acids, starter batteries, detergents, engine oil, antifreezer and antiseptic, or chemicals:
☆ Put up acid or chemical resistance gloves and
protection suit, goggles and safety shoes. Pay
attention to the manufacturer's instruction！
☆ Working at heights (above 1.2 m): Even falling from
a low height may result in serious injury. To work
aloft (above 1.2m) when fall-arrest system (for
example, guardrail, working platform...) is
unable/unnecessary to be installed, then use the
personal fall-arrest system composed of safety belt and relevant kits (safety rope, spring
fastener, descent control device, descender or fall arrester)!
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1.3 General safety precautions
1) Prior observation
When receiving an engine of a gas generator set, read carefully the safety rules in the operation
and maintenance manual. Keep the manual properly for use when maintaining the engine. Where
the service network is appropriate, we adopt the standard rules for gas generator set and provide
test and maintenance services. Original parts are preferred to keep the machine running well when
the parts need replacing after the machine run for a period of time. Such parts are under strict
quality control and suitable for original equipment.
2) Fume discharge
Gases emitted from internal combustion engines contain toxins which can cause injury and even
death if being inhaled by accident. That is why an exhaust pipe is installed along with the engine
to exhaust the fume out of the engine. Any concealed space should be adequately ventilated with
fresh air flow.
3) Engine fuel
If the engine cannot be started after three attempts or more or it stops automatically, turn off the air
supply valve and then try to start the engine again until all the unfired gases left in the cylinders
are exhausted. Otherwise the gases may be fired to cause explosion when the engine is started.
As the engine fuel is inflammable and likely to cause explosion, it must go through a good piping
system without any leakage or crack. In addition, it must be designed to stand the break due to
shock. Maintain the natural ventilation in the generator room to prevent explosion caused by gas
leak.
4) Cutting off fuel supply
All installed engines must have a safe and reliable emergency device that can cut off the fuel
output. The inlet pipes with a pressure for fuels such as natural gas or liquefied gas must be
provided with a manually controlled system to cut off air supply (a manual or automatic valve).
The system must be separated from the mixer or the gas control system.
Operators are fully responsible for ensuring that there is no gas leak or residual gases in the engine,
and the engine conforms to the installation regulations.
5) Protection devices
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Safety protection devices should be installed along with the internal combustion engine to protect
the safety of persons and articles, especially the items close to the turning or engine parts.
Operators are responsible for installing an adequate protection mechanism.
6) Blowby gas
All gas engines include a crankcase breather and an exhaust pipe to mitigate the pressure
cumulating in the crankcase as the solid gas flows into the piston ring. Check whether the
crankcase breather and the pipe are installed at the right positions and not blocked.
7) Pressure cap of the cooling system and connections
When an engine is running or the water temperature is high, do not loosen the pressure cap. If the
cap is released by accident, the hot water will come out to cause serious burn since the pressure in
the cooling system is very high. Do not release the cap from the heat exchanger, thermometer box,
evaporator or radiator until the engine and the water are cooled. And regularly replace problematic
or aged hoses and cables for safety.
8) Ignition system
The ignition system is charged. Avoid direct contact with the system and circuits.
If the discharge capacitor of the electronic ignition module is still running, the spark plug is likely
to be fired as the electricity from the capacitor will activate the spark plug and the spark may light
up the residual gas in the cylinder to result in serious injury and an accident.
Switch off the power when rewiring the electric ignition module.
Protect the spark plug, coils and cables from storm and snow.
9) Generator
When operating a generator, avoid touching its electric power system as its voltage can cause
serious injury or even death of operators. Before the operation, make sure the power system is
properly grounded. Be more careful if the surroundings of the generator room is humid. When
maintaining the power system or connecting wires, do cut off the main power supply. When
cleaning or maintaining the generator, do switch off the engine.
In case of electric shock in an emergency, switch off the generator immediately. If it is impossible
to turn of the generator, remove the injured from the closed circuit with a dry board or stick or an
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insulating tool instead of by hand. If the victim is unconscious, perform necessary first aid on him.
Do not operate the generator with a current converter in an open-loop system.
10) Neatness and cleanliness
Keep the surroundings of the generator room neat and clean. A good work environment helps
reduce accidents.
11) Cleaning, servicing and maintenance
When doing the above jobs, do power off the engine and keep all control switches to the off
( STOP) position to avoid start by accident.
12) Fan blades of the engine
☆ Do not operate the engine if the any fan blade is found bent, missing, replaced or damaged;
☆ Do not operate the engine if the fan is found in touch with any part of the engine or the center
of the radiator;
☆ Do not attempt to repair or balance the blades, and consult the fan supplier if necessary;
☆ Check carefully if all the bolts are tightened using the torque suggested by the supplier;
☆ Install the fan at the right position and align it to the radiator exactly;
☆ Maintain the belt drive properly;
☆ Do not alter or change any part of the engine, particularly make alternations that will
accelerate the engine without content from the technical department for gas generator set;
☆ Do not install any fan unless it is necessary for the engine; And install the specified driving
fan only for the gas generator set;
☆ If the fan or fan rotor contains any plastic part, and the fan was or was working at a super-high
temperature (higher than 120 degrees centigrade), only authorized qualified technicians are
allowed to maintain the fan or fan rotor;
☆ Replace the fan if it is found eroded or corroded in an inspection;
☆ For fans that can turn reversely or with adjustable screw torque strength, do make sure that the
blade positions are right before starting the engine. And check if there is any unmelted ice or
dust or earth on the fan before starting the engine which can cause imbalance of the fan;
☆ Ensure that all the fans, drives and belts are provided with sufficient protection devices.
13) Fire protection
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Take precautions against fire in accordance with local regulations. Place qualified fire
extinguishers at accessible points. All emergency lamps and fire exits should conform to the fire
protection requirements.
14) Detergent
Use appropriate detergents and place them in a ventilated place. Do not breath in the smell of
detergents as it may cause injury to human body. Do not use gasoline and highly inflammable
products for cleaning.
15) Welding equipment
A broken welding cylinder may cause explosion to result in great damages. Thus such cylinders
must be stored in an appropriate place in accordance with the safety production instructions. If
ethyne is used for welding or cutting, install the fixed valve between the controller and the plastic
hose to keep the controller and fuel tank from the backlash flames which may cause the fuel tank
to explode. Keep the objects of high oil content away from oxygen-contained valves and hoses as
oxygen can cause violent burning as soon as mixed with such objects.
16) Grounding wire for electric welding
If electric welding is required for the engine, lay the grounding wire close to the welding spot. If
the wire is too far, the electric arc may be produced on a shaft to ignite the engine oil.
17) Electric tools
Ensure that all tools have been grounded. Use eye protection. Do not operate in a humid place.
The tools should perform well and with protection. Unplug the cable from the power supply
instead of pulling the cable.
18) Batteries
When using the battery on the engine or its device, remove the grounding wires from the battery to
avoid flames or damages resulted from accidental short circuit.
19) Pay attention to the followings when starting the engine if batteries and auxiliary cables (for
fastening) are used:
Do not use icebound batteries to start engine since they may cause explosion and breaking. If you
suspect that the batteries are icebound, check all the filler plugs. If any icebound mark is found or
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the electrolyte is invisible, do not use such auxiliary batteries or cables to start the engine. Take
good care of batteries.
The steps below help reduce the risk of causing flames and explosion by connecting one charged
battery to an uncharged one.
☆ Put down the battery, remove the battery cover, cover the upper part of the battery with a wet
cloth; keep in mind that the voltage of the auxiliary battery is the same as of the uncharged
one;
☆ The anode is marked by a '+' , usually in red, and larger than the cathode in diameter; the
cathode is marked by a '-', usually in black.
20) Compressed air
Never use compressed air or fuel gas to clean clothes or the body. Under a high pressure, a drop of
water can cause a
grievous and painful wound on skin through a hole.
21) Excessive alcohol and drug
Any one or any staff under the effect of excessive alcohol or drug will endanger other people.
22) Safe use of acid
It is common to use acidoids to clean casting or parts of equipment. Pay attention to the followings
when using acid detergents:
☆ Avoid contact with skin, eyes or clothes;
☆ Stay away from inflammable sources, sparks and flames in the derusting process;
☆ Do not let acid liquor flow onto cement floor as it will erodes the lime in cement. If the acid
liquor is poured onto the cement by accident, neutralize it with alkali liquor, or rinse the floor
with water;
☆ Acid liquor will react with some metals to produce smell. Generally speaking, the acid in
contact with lime and rusty metal will produce carbon dioxide, though this is harmless. If,
however, the acid contacts with aluminum, zinc, cadmium, tin, sulfur, arsenic and krypton,
toxic and explosive gas will be produced. When using acid in a concealed place, maintain
good ventilation in order to get rid of the smell;
☆ Seal the bottle cap and place the acid liquor in an appropriate place;
☆ Ensure that the components or containers cleaned by acid are free of damages and leaks since
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such damages and leaks will allow the acid liquor to flow to the reverse positions on the
components. In this case, use a lot of water to rinse the reverse positions;
☆ Use an acid-proof pump or disposable pump;
☆ When mixing acid with water, always add acid into water, and never add water into acid;
☆ After using acid, always use alkali for post rinsing and treatment to neutralize the acid and
prevent the residual acid from causing damages;
☆ Store acid liquor in a copper container with acid-proof wood or rubber;
☆ If possible, remove all the irrelevant metal objects before using the acid for cleaning to avoid
electrolysis. Never use acid to clean aluminum parts.
23) Hoisting the engine
☆ Better use the hemp rope to avoid damaging the engine;
☆ Be careful not to allow the sling to touch the sensitive components of the engine;
☆ Check all points of strength to ensure that there is no poor welding, loose bolt, etc.;
☆ Check all relevant structures to ensure that all supports or equipment can process a weight
more than ten percent of the weight of the engine;
☆ When the engine is lifted, ensure that all the equipment is balanced and kept horizontal;
☆ No one is allowed under the equipment when it is hoisted;
☆ Do not lift the equipment to above the required height.
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Chapter 2 Overview
A gas generator set includes a gas engine, generator, control cabinet, generator controller, ignition
control module, electronic speed governor, charging generator, common base and engine
mounting.
2.1 Description of gas generator set
The diesel engine is redesigned and produced with the gas engine concept based on the world
famous brands of diesel engines and taking into account the burning characteristics of gas in the
cylinder and the control features. Its key parts of the main body are manufactured in accordance
with the advanced international standards for materials, process and accuracy. The special design
and processes ensure sound stability and durability of the engine.
The gantry cylinder is made of high-strength cast iron and molded after a number of processes,
with sufficient mechanical strength and rigidity. This improves the stability of the machine as a
whole, facilitates its maintenance, extends its maintenance interval and useful life and saves
significantly the operating cost.
The crankshaft is forged in high-strength alloy steel which increases its holistic strength and
rigidity. The crankshaft has a long useful life and high coaxility to keep the machine running
stably.
The electronic mixer developed by our company is adaptive to various gases with a methane
concentration of 30%-50%. The optimal air/fuel ratio is achieved through the automatic electronic
adjustment after the air and the gas are mixed up. Together with the distinctive design of the
combustion chamber, it allows the gas to burn fully, hence reducing the gas consumption,
improving the thermal efficiency of the engine, reducing the emitted NOx hazardous gases and
achieving the world's leading emission standard.
The electronic ignition system jointly developed by Camda and specialized local manufacturers
comprises a Hall sensor designed for the gas generator set, and dedicated ignition modules,
ignition coils, and high-voltage wires, featuring accurate ignition timing and high ignition energy.
In addition, the spark plug has a long lifetime, improving the starting performance, lowering the
knocking risk and elevating the stability of the engine.
The high-accuracy speed governor for the gas generator set has the strengths of high accuracy
and fast recovery time, and can better adapt to different loads.
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2.2 Performance characteristics of gas generator set
The set has a generator of the most famous brand in the world, which has good matching
performance no matter evaluated by the electric, torque, mechanical fit structural features or
dynamic mechanical indicators:
(1) Adaptability to various environment, especially harsh environment like coal bed methane,
refuse landfill, sewage treatment plant and oil field.
(2) Optimized winding design ensures better performance of the engine. Regardless of 50Hz or
60Hz, a range of winding forms can adapt to the voltage requirement in different applications. The
standard design of the generator stator winding can perform well under distortion load.
(3) High electric efficiency ensures higher power output of the set.
(4) Wide scope of application
－telecommunication and Internet service;
－parallel operation of the generator set;
－renewable energy, refuse landfill, sewage treatment plant, etc.;
－oil field and natural gas development;
－military, and so on.
(5) Reliable AVR can ensure qualified voltage regulating rate to be delivered even under the
distortion load, and improve the generator's resistance to interference.
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Chapter 3 Main Parts of Gas Generator Set and

Characteristics
3.1 Introduction of gas engine
All the gas engines manufactured by Camda are designed based on diesel engines by the
principles of gas engine. The special-purpose parts to be altered are produced by specialized
manufacturers and assembled on the same line with that of the original diesel engines. The
ex-factory test is performed with biogas. Such products are not made merely by modifying
finished diesel engines, as a result, unmatched by modified engines regardless of the balance of
moving parts or resistance to thermal load (they are made of better materials than the diesel engine
or redesigned, capable of standing higher exhaust air temperature compared with the diesel engine.
Gas engines feature high temperature of exhaust air mostly due to their low combustion speed.
Engine cylinder
The gas engine is a four-stroke, spark ignition, water-cooled high-speed engine, and of the V type.
There is a cast-iron oil pan under the cylinder, a piston connecting rod for bowl combustion
chamber in the cylinder. The wheel-shaped combined crankshaft with main rolling bearing is
installed in the engine main bearing hole. The camshaft and gas distribution system are provided
internally on the right side facing the flywheel. The transmission gear is arranged in the front gear
housing of the engine. On the left, there are the ignition system, electronic governor system and
inlet system. On the right, there are the exhaust pipe, engine oil filter, engine oil cooler, start motor
and charged engine. The water pump is installed in the front and the oil pump in the front of the
engine in the oil pan.
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1) Our gas engines are designed and produced with the gas engine concept based on the world
famous brands of diesel engines and taking into account the burning characteristics of gas in the
cylinder and the control features. Its key parts of the main body are manufactured in accordance
with the advanced international standards for materials, process and accuracy. The special design
and processes ensure sound stability and durability of the engine.
2) The gantry cylinder is made of high-strength cast iron and molded after a number of processes,
with sufficient mechanical strength and rigidity. This improves the stability of the machine as a
whole, facilitates its maintenance, extends its maintenance interval and useful life and saves
significantly the operating cost.
3) The crankshaft is molded by high-strength alloy steel as a whole to improve its holistic strength
and rigidity and extend its useful life.
4) The Venturi electronic mixer developed by our company is adaptive to various gases with a
methane concentration of 30%-50%. The optimal air/fuel ratio is achieved through the automatic
electronic adjustment after the air and the gas are mixed up. Together with the distinctive design of
the combustion chamber, it allows the gas to burn fully, hence reducing the gas consumption,
improving the thermal efficiency of the engine, reducing the emitted NOx hazardous gases and
achieving the world's leading emission standard.
Fig.1-3 Mixer
5) The ignition system comprises the ignition control module, ignition coils, high-voltage line and
spark plug. The ALTRONIC ignition system adopted in our gas engines feature high ignition
power, accurate ignition time and easily adjustable ignition time to extend the useful life of the
spark plug, improve the engine's starting performance, lower significantly the knocking risk and
elevate the stability of the engine.
(6) The high-accuracy speed governor for the gas engine has the strengths of high accuracy and
fast recovery time, and can better adapt to different loads.
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3.2 Engine operating principle
Satisfactory results can only be achieved after you have full understood the engine operating
principle in operating our gas engine. Any part of the engine will affect the operation of the other
parts, and even the whole engine.
The operating process of the gas engine is divided into four strokes: intake stroke, compression
stroke, power stroke and exhaust stroke in order.
(1) Intake stroke
In this stroke, the connecting rod leads the piston to go down, the inlet valve opens and the outlet
valve closes. After the air filtered by the air filter and the fuel gas are mixed evenly in the mixer,
the mixture is suctioned into the cylinder. As the downgoing piston gets to the bottom dead center,
the cylinder is filled up with the gas mixture.
(2) Compression stroke
The crankshaft is turned under the inertia effect of the flywheel and moves from the bottom dead
center to the top dead center as the connecting rod pushes the piston. At the same time, the inlet
valve closes and the gas mixture is compressed.
(3) Power stroke
As the piston gets to the top dead center, the spark plug produces sparks under the high-voltage
current produced by the ignition coils and the ignition signal generator to fire the inflammable gas
inside the cylinder. The high-temperature, high-pressure gas produced during the combustion
pushes the piston to go down, and output power and transmit torque as the connecting rod leads
the crankshaft to rotate.
(4) Exhaust stroke
As the piston moves from the bottom dead center to the top dead center, the exhaust valve opens
and the inlet valve closes. The waste gas in the cylinder after the combustion is pushed out by the
piston and exhausted through the exhaust pipe.
The above process repeats to allow the engine to run continuously.
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3.3 Installation and connection requirements of gas generator set
Refer to relevant professional installation standards for the installation and connection
requirements of the gas generator set. This document only describes the installation and
connection of the land stationary engine.
3.3.1Bracket and foundation
There are 4 mounting brackets on both side of the engine gear housing and flywheel housing.
Each brackets takes four or two holes and can be mounted to the foundation with proper bolts. The
foundation of the land stationary engine has a structure varying with the application condition.
Generally, it is made of reinforced concrete. The foundation for stationing the engine should be
reliable as evidenced by inspection. Its bearing surface should be even. Use adjusting gaskets to
stabilize the engine mounting brackets on the foundation. If the conditions are suitable, install the
leveling guide rails on the foundation, in which case the engine brackets and the foundation are
connected by a base or shim plate.
3.3.2 Hoisting
There are 4 rings on each engine capable of bearing the whole weight of the engine. Use the chain
block or other lifting tools for hoisting. Pay attention: do not let the chain under force press any
parts with thin housing or instruments (try to prevent the rings from bearing bending moment).
Lift the engine mildly to keep it at a horizontal position. Place the engine on a special base or
stable block during the handling and hoisting to prevent the oil pan from directly bearing the
weight of the engine.
3.3.3 Connecting the inlet and exhaust pipes
Generally, there is an air filter on the inlet pipe. When an extended inlet pipe is used, ensure that it
has an adequate inlet section and it is preferably not too long or has any abrupt bent. Otherwise,
the inlet resistance will increase to affect the performance of the engine. In addition, pay attention
to the air tightness of the inlet pipe. Otherwise, the engine will be quickly worn.
There is a connecting flange at the outlet of the exhaust pipe. The exhaust connecting pipe outside
the engine generally leads to outdoor or the underground pipe. It is preferably not too long and has
no more than 3 elbows. The inside diameter of the connecting pipe generally is no less than
100mm to prevent from increasing the exhaust back pressure and reducing the output power. The
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exhaust back pressure is generally no more than 3kPa. Provide bellows, exhaust pipe supports and
connectors for measuring exhaust air temperature, etc. at proper positions on the outside
connecting pipe. Moreover, do not let the engine exhaust pipe bear the weight of the outside
connecting pipe. Take fireproof, thermal insulation and rainproof measures for the exhaust pipe
extending to the outdoor.
3.3.4 Power output of the engine
The power is output from the flywheel of the gas engine to drive the alternator. Do no install the
horizontal pulley dragging device directly on the flywheel. Do not make the crankshaft and main
bearing directly bear the horizontal force.
Do not start the engine with any load.
3.3.5 Main dimensions of the generator set and for installation
Main dimensions of the HGK38 generator set
3.3.6 LEROY-SOMER generator
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LSA 49.1 S4
The LSA49.1generator is designed for multiple typical power supply applications, e.g. standby
power supply, main power supply, regenerative power generation, power for ships, lease and
telecommunication, etc.
International standards complied with:
The LSA49.1generator complies with the following international standards and rules: IEC 60034,
NEMA MG1.22, ISO 8528, CSA, CSA/UL, and relevant classification society rules. It can be
used for CEc certified generator sets. The LSA49.1 generator is designed, manufactured and
promoted under the ISO9001 certified context.
Main ranges of electric performance
☆ Class H insulation
☆ Standard 6-line reconnectable winding No. 6, 2/3 pitch.
☆ Voltage range:
50HZ: 380V-400V-415V and 220V-230V-240V,
60HZ: 380V-416V-440V-480V and 220V-240V.
☆ High efficiency and high starting power of the motor.
☆ Choose a different winding for another voltage:
50HZ:440V(winding No. 7),500V(winding No. 9),600V(winding No. 22 or
23),690V(winding No. 10 or 52)
60HZ: 380V and 416V(winding No. 8), 600V(winding No. 9)
☆ Total harmonic component <4%
☆ The module R791complies with the (CE labeled) EN55011 GROUP 1 CALSS B in Europe.
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3.4 Engine diagram
The figure below shows the positions of main external parts of the engine, filter and other
maintenance points.
Front view
1. Inter-cooler water outlet 10. Vibration absorber
2. Left-row water outlet 11. Crankshaft pulley
3. Left-row thermostat housing 12. Charger drive pulley
4. Coolant filter seat 13. Fan idler wheel pulley
5. Coolant filter 14. Fan wheel hub
6. Fan pulley 15. Rocker lever cover
7. Front gear cover 16. Air crossover
8. Accessory drive pulley 17. Right-row thermostat housing
9. Rotating direction 18. Right-row water outlet
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Back view
1. Oil cooler plate 10. Cylinder head
2. Inter-cooler water inlet pipe 11. Flexplate
3. Inter-cooler assembly 12. Flywheel housing
4. Right-row exhaust manifold 13. Oil pan land
5. Water outlet passage 14. Oil pan
6. Intake manifold 15. Cylinder
7. Rocker lever cover 16. Left-row exhaust manifold
8. Rocker lever housing 17. Turbocharger
9. Sealing ring
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Right side view
1. Inter-cooler assembly 13. Oil pan
2. Turbocharger 14. Water inlet pipe connector
3. Intake manifold 15. Water pump
4. Rocker lever cover 16. Water pump drive
5. Lug 17. By-pass water pipe
6. Inlet pipe connector 18. Fan belt idler wheel pulley
7. Intake manifold 19. Crankcase breather
8. Camshaft follower cover 20. Fan belt idler wheel assembly
9. Flywheel housing 21. Thermostat housing
10. Manhole cover 22. Water outlet connector
11. Oil pan land 23. Inter-cooler water inlet pipe
12. Oil pan land cover 24. Inter-cooler water outlet pipe
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Top view
1. Inter-cooler assembly 12. Left-row exhaust manifold
2. Inter-cooler water outlet pipe 13. Rocker lever cover
3. Charger 14. Intake manifold
4. Right-row water outlet 15. Water pipe
5. Right-row thermostat housing 16. Right-row exhaust manifold
6. Fan wheel hub support 17. Oil cooler plate
7. Fan wheel hub bearing 18. Rear gear housing
8. Thermostat housing support 19. Flywheel housing
9. Left-row thermostat housing 20. Rocker lever housing
10. Left-row water outlet 21. Air crossover
11. Turbocharger 22. Inlet pipe connecto
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Chapter 4 Circuit System
4.1 Starting system
In the standard configuration, the starting system of gas engine starts at 24V direct current.
4.1.1 Starting motor
The most common starting approach applied to the engine is by motor, which is characterized by
compact structure, economy and reliability and applicable for long-distance operation and
automatic operation. Its disadvantage is slow power complement of its storage battery. The
battery's discharge capability is highly dependent upon the ambient temperature. In cold areas, if
no proper measures are taken, the engine can hardly be started and even cannot be started.
The motor starting system includes a motor, storage battery, rotary charger and start switch. The
emergency engine is equipped with an AC charger.
Starting motor
4.1.2 Storage battery
The batteries should be able to supply the starting current required by the technical specifications
of the engine. Lead batteries are an option. The batteries are exclusively for starting purpose.
Our gas engines have a engine-driven charge generator with automatic voltage adjustment to
ensure that the engine can charge the batteries as it is running.
The emergency gas engine should be equipped with a charger powered by mains to ensure that the
batteries are fully charged when the engine is standby.
Generally, the standard provides the longest charging time for the battery. The charging current is
calculated as follows:
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Charging current ＝(12×ampere-hours of battery)/charging time
In cold areas where batteries may be frozen, a battery heater is required to keep the battery
temperature to above10°C.
The battery capacity is determined by the expected minimum average temperature of the starting
environment.
The batteries should be placed for easy inspection of the liquid level, solution adding and cleaning,
and as close as to the starting motor to reduce the voltage drop in the circuit. At the same time,
keep the battery insulated as possible as you can to ensure that its capacity is enough for starting
the diesel engine. However, the battery temperature is preferably no more than 32°C .
Generally, the battery can be charged by the charge generator of the gas engine. In winter, the start
of the engine and the output capacity of batteries are affected by low temperature. The capacity at
-18℃ is approximately 46% of that at 27℃. Additionally, the increased viscosity of engine oil due
to low temperature results in increased power required for the engine to start (normally increased
by 2.5 times. That is why the engine oil should be appropriate in winter to ensure adequate battery
capacity.
Connecting the battery:
Dependent upon the voltage and capacity of the battery, the battery can be connected in series
or parallel to meet the starting requirements. The typical connections are as follows:
Parallel connection
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Series connection
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4.1.3 Battery charger by mains
There are various general-purpose battery chargers available. The type of chargers selected
depends on other electric devices on the gas engine. Most battery chargers are in one of the
following types:
Full-load repetitive charger
On a standby engine, if the charge generator is not available to charge the battery, a full-load
repetitive charger will be needed. With a high charge rate (3-30A charging current), this type can
be operated either manually or automatically. However, it may overcharge or heat the battery to
cause damages to the battery.
Complementary charger
A complementary charger can be used on a standby engine. This type can maintain the battery
capacity at a less than 2A current when the charge generator goes wrong.
Automatic charger
This charger has an adjustable strong charging function at a charging current of 6-10A, 6-20A or
6-30A) when the battery capacity is insufficient, and a function of maintaining the battery capacity
at trickle current (0.2-1A or 0.5-2A) when the battery has been charged.
Charger
4.1.4 Connecting the electric starting circuit
Pay attention to the followings when considering the connection of the electric starting circuit:
Try to reduce the resistance of the circuit, for example, by selecting the wires with suitable section
size and as short as possible to reduce loss from voltage drop. The maximum allowable resistance
for the starting circuit is listed on the performance data sheet of each engine.
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Mark the wires for circuit connection separately or use colored wires.
Minimize the number of connections on the circuit. Connections should be firm. The wire joints
must be soldered. Soldering with acidic flux may cause deterioration of joints. Use rosin flux
instead.
The operating voltage of the engine is 24V. Connect the starting battery in series or parallel
according to the required starting capacity.
When the starting electromagnetic switch is connected into the starting motor circuit, the voltage
drop caused by the total current through the starting motor coils should be more than 2V in the
24V system. If it is more than 2V, when the battery power decreases in winter, the engine may be
hardly started. To maintain the voltage drop within the required limit in the control circuit of the
starting motor, preferably keep the circuit resistance between the battery and the electromagnetic
switch in the 24V system below 0.030 ohms. For this purpose, choose a suitable type of wire to
keep the circuit resistance below the value specified above.
A standard engine is equipped with an on-line battery box and connecting cable.
The voltage drop of the connecting cable between the battery pack and starting motor in the 12V
system should be lower than 1V; in the 24V system, lower than 2V.
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4.2 Electronic ignition system
The world's most advanced electronic ignition system produced by Altronic is adopted,
comprising the ignition signal generator, ignition amplification module, ignition coil, high-voltage
line and spark plug. According to the requirements for each cylinder of the engine to work, the
signal generator produces a voltage pulse signal corresponding to the crankshaft position. The
ignition amplification module connects or disconnects the primary circuit of the ignition coil in
time according to the voltage pulse signal to activate the coil to produce a high voltage. Through
the high-voltage line, the spark plug produces sparks in the combustion chamber and fires the gas
mixture. This makes the engine to fire at an optimal angle and output the maximum power at the
minimum power loss, thus saving energy and reducing pollution.
Ignition system diagram
Once the power is on through the control center, the indicator begins to flash at an even interval.
After the engine starts, it flashes regularly according to the rotating speed. The flash point is the
ignition point of cylinder 1. Both off and solid on indicates the ignition signal generator center is
problematic. After the spark plug is working for a period of time, tighten the torque to fasten it
according to the standard. See the instruction for details.
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Ignition control module Ignition coil
High-voltage line
Spark plug
Cautions about the ignition part of gas generator set
(1) Do not conduct the cylinder fuel-cut test when the machine is running. Never take off the
high-voltage line when the machine is running. Otherwise, it may endanger people and the
machine.
(2) Keep clean the high-voltage parts such as high-voltage transformer, high-voltage line and
high-voltage cap to prevent them from discharging high voltage to the ground to cause the
machine on fire.
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4.3 Electronic speed governing system
The electronic speed governor has such functions as speed control, maximum current limitation
and protection, adjustable steady governor rate, high-low speed switch, and automatic parallel.
4.3.1 Composition of electronic speed governor

The electronic speed governor is made of three parts: electromagnetic actuator, speed sensor and
control.
发动机 Engine
执行器 Acturator
速度传感器 Speed sensor
控制器 Controller
电源 Power supply
Control
The control generally serve to test the engine speed, actuator drive and rack position to adjust the
engine speed.
Speed sensor
Speed sensor
The speed sensor is a single-coil electromagnetic sensor and fixed on the engine flywheel ring
gear or the outside edge of gear. The turning gear cuts the magnetic lines to produce electric pulse
signals. Whenever the turning engine passes a tooth, a pulse signal is generated.
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Electromagnetic actuator
Electromagnetic actuator
The control analyzes the engine status data collected by the speed sensor and sends corresponding
current signals to the actuator. By moving the draw bar controlling the opening of the butterfly
valve through the actuator, it adjusts the working status of the engine. The draw bar is stabilized at
different positions according to the current to control different air inlet volumes. After the power is
cut off, the electromagnetic force disappears, the draw bar returns to the original position, the
butterfly valve closes and the engine stops.
4.3.2 System functions
1）Speed control
The speed control by the close-loop method can accurately adjust the engine speed. The stability
of speed can be chosen through the status switch.
The dynamic status can be adjusted by the internal gain and differential potentiometer。
2) High-low speed switch and speed fine tuning potentiometer
The high-low speed switch generally performs switches of low-speed control and rated speed
control. The external speed fine tuning potentiometer can fine tune
the speed deviation and display the battery voltage and speed by setting the number of teeth for
39
the starting ring gear.
3) Auto-stop protection
When the speed sensor goes wrong, the speed feedback signal disappears or the power supply fails,
this function enables the engine to stop automatically.
Adjustable steady governor rate
The steady governor rate can be set to adjustable or nonadjustable.
Overspeed protection
In the case of overspeed of the set for various reasons, the control system can make the actuator
lose power to stop the engine. The speed for overspeed protection is set to 1650rpm.
Parallel
The speed governor receives input signals from the load distribution device, automatic
synchronizer and other auxiliary devices of the speed governor system to fulfill the parallel
function.
Other potentiometers and switches on the speed governor have been set by the manufacturer and
should not be adjusted unless by professionals.
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3.3.7 Control cabinet
The control cabinet is of a standard type, easy for
operation and repair. World's advanced intelligent
control for generator is chosen with high-performance
chips to allow modification to control programs and
protection parameters of the generator. It integrates
multiple functions such as measurement, protection,
remote control, etc. to fully accommodate the
automatic control requirement for various types of
generator sets from generator users or specialized
assembling factories. The control displays all electric
parameters for generator output, as well as the speed,
oil pressure, water temperature, DC power voltage
and operating time of the engine. In addition, proper
controls are selected and corresponding functional
modules are added to generator sets for parallel and
grid connection .
Generator set control cabinet
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4.4 Process of air/fuel rate control system
空气滤清器 Air filter

Φ200 4-20ma 控制 control
4-20ma 反馈 feedback
220V AC 电源 power source
电动蝶阀 Electric butterfly valve
缓冲混合器 Buffer mixer
涡轮增压器 Turbo
中冷器 Intercooler
1-10KPA 压力表 pressure gauge
Input 输入 10-50KPA
Output 输出 2KPA
稳压阀 Regulator valve
燃气入 Gas in
电磁执行器 Electromagnetic actuator
进气歧管 Intake manifold
空燃比控制流程图 Air-fuel ratio control flow chart
42
Chapter 5 Lubrication System

The frictional surfaces of the main moving parts of Camda gas engines are lubricated by means of
pressure and splash. The pressure lubricating oil is provided by the gear engine oil pump (engine
oil pump). The lubricating oil pump is on one side of the engine.
The engine oil pump is connected by an oil pipe connecting with the oil pan. An oil screen in the
oil pan filters the engine oil. The engine oil is suctioned out from the oil pan by the oil pump and
flows back into the cylinder through a full-flow or compound oil cooler. The oil filter can be
installed below the oil cooler or in a far distance. Then the engine oil flows into the main oil
passage through the passage inside the gear housing.
5.1Engine oil pump
A pressure control valve inside the lubricating oil pump enables control over the oil pressure.
When replacing or reinstalling parts, measure the gap between the end surface and cover of the oil
pump gear. If necessary, make adjustments with a gasket made of pergamyn paper. After it is
assembled, turn the driving shaft by hand. The shaft should be turned freely. Otherwise re-align
reaming for the stop pin on the oil pump cover.
5.2 Engine oil filter
The lubricating system has an oil filter to remove foreign matters in the
circulating engine oil and avoid damaging shaft or part matching surfaces.
The filter performance has direct effect on the performance and useful life
of the engine. There is a by-pass valve on the head of the full-flow oil
filter to provide insurance when the oil passage is blocked by dirt or the
filter core is blocked.
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5.3 Engine oil cooler
The oil cooler for the Camda gas engines is of the water-cooled type.
The oil cooler is in a cylinder shape. There is a core inside composed of radiating fins and distance
pieces. Water flows in the tube of the core; oil flows in the interlayer between the core and the
shell.
Clean the oil cooler periodically. When re-assembling the filter, keep the sealing ring balanced and
at the right position. Replace the aged or sticky sealing ring. Otherwise, the oil and the water may
mix up to cause engine failure. When maintaining the cooler, check whether there is any missing
solder or damage to the cooler core. If necessary, make up the solder or cover the apertures at both
ends of some pipes and then continue the use. If the cooling copper pipe is damaged seriously,
replace the whole core.
When using the engine in a cold area or in winter, drain the cooling water in the engine after it
stops or use antifreezer to prevent the cooler from frost cracking.
5.4 Oil pan
For all Camda gas engines, the wet oil pan is applied for storing engine oil. When the engine is
working, the working status of the lubricating system is monitored by the oil thermometer,
pressure gauge and dipstick. Oil drain taps are provided on one side of the oil pan and on the
ground respectively to drain the sump oil under different conditions.
Oil pan
44
Engine oil drain outlet
45
5.5 Lubricating system flow chart
Piston cooling, connecting rod and overhead mechanism
1. Main oil passage 6. Camshaft follower
2. Piston cooling oil passage (outside) 7. Rocker (air exhaust)
3. Camshaft oil passage 8. Oil supply pipe for main bearing
4. Piston cooling nozzle (outside) 9. Oil supply up to connecting rod
5. Metering hole 10. Piston cooling nozzle (outside)
46
Turbo rear gear train
1. from main oil passage 5. oil supply up to upper output housing
2. oil supply up to antithrust bearing 6. Turbo oil supply pipe
3. Camshaft oil passage 7. Turbo oil return
4. Idler wheel
47
Full-flow oil filter base
1. Oil supply up to oil filter base 9. Piston cooling oil passage (outside)
2. Engine oil back to oil pan 10. Piston cooling nozzle (outside)
3. Oil supply up to filter 11. Main oil passage
4. Oil pressure adjuster 12. Piston cooling control valve
5. Engine oil filter (centrally installed)
6. Control device oil passage 13. Piston cooling nozzle (centrally
7. Filter by-pass valve installed)
8. Piston cooling control valve (outside)
48
Chapter 6 Cooling System

The cooling system of the Camda gas engines are the forced liquid or positive circulation liquid
cooling system, by which the coolant circulation is completed by the dedicated cooling water
pump on the engine. The circulation cooling is closed.
The so-called closed circulation indicates that the engine cooling system contains a complete
closed circulation loop.
The closed water-cooled engine drives the cooling pump to produce a circulation power which
enables the coolant in the cylinder and cylinder head pipe to continuously circulate and dissipate
heat, and the engine cooling pump and radiator (or heat exchanger) form a closed power
circulation cooling system. The most common cooling system is the radiator and the cooling fan
directly driven by the engine. The alternative is the heat exchanger, far-placed radiator or
far-placed heat exchanger.
Correct design and installation of the cooling system is essential to the performance and useful life
of the engine:
(1) The whole cooling system should be designed and installed to keep the temperature of the
water radiator upper tank no higher than the limit specified on the performance data sheet for the
particular engine.
(2) The cooling system should be able to exhaust surplus air within the time specified on the
engine performance data sheet. Once the empty cooling system is filled up with cooling water for
the first time, no additional cooling water will be required.
(3) Expansion space equivalent to approximately 5% of the gross capacity of the cooling system
should be provided in the water radiator upper tank (or expansion water tank).
(4) A venting system should be provided in the cooling system, which enables the cooling system
to be filled up with cooling water at the specified minimum speed within the longest water filling
time specified on the engine performance data sheet.
(5) When the engine with the water radiator is running at a high idle speed or the filling cover of
the cooling system is removed and the cooling water temperature is 82-88°C, the pressure at the
water inlet of the water pump should be higher than the atmospheric pressure, i.e. a positive
pressure.
49
6.1 Water pump
The water pump of the Camda gas engine is of the centrifugal type and installed on the front part
of the engine. When installing the water pump impeller, check the axial gap between the impeller
and water pump bell, which can be adjusted with a washer.
When the engine is running for 400-500h, fill an appropriate of grease with an oil gun from the
through-type forced filling oil cup of the water pump.
After the engine working at a low temperature stops, open the drain valve on the water pump
immediately to drain the water left in the pump to prevent it from frost cracking.
Cooling water pump
6.2 Radiator
The radiator, or commonly known as water tank, is used to dissipate heat by the coolant of the
engine. Use radiators of the same model but with different cooling areas based on the rated power
and operation compliance of the engine.
The radiator is composed of the tube-and-fin radiating core, upper and lower water sinks, air
director and supports. Water radiators require regular maintenance to ensure the heat exchange
between coolant and air. Generally, every 500h of running of the engine, clean the outside and
inside of the radiator. To get rid of the deposits and settled impurities, drain the water in the
radiator, then fill clean water with a certain pressure into the radiator core until the outflow water
50
is clean.
After the radiator is used for a period of time, repair any leak with solder. Before starting the
engine, inject the coolant into the empty cooling system at an appropriate speed. After filling it up,
stop and waiting for two minutes to allow the air in the system come out and fill the coolant again,
so as to prevent false fill-up and overheated engine.
After the engine working at a low temperature stops, open the drain valve immediately to drain the
water left in the radiator to prevent it from frost cracking.
When installing the radiator, mount rubber shockproof pads provided or special-purpose vibration
absorber between the mounting supports and the common base bearing surface to mitigate the
vibration from the engine to the water tank.
6.3 Fan
The piercing riveting fan used in the Camda gas engine serves to create forced blowing for cooling
the air-cooled cooling water tank. Use fans of different specifications based on the model and
rated power of the engine.
Check regularly whether the fan is firmly mounted and whether there is any visible deformation of
the blades. If any, make a replacement immediately. Adjust regularly the tightness of the triangular
rubber belt. Too tight belt may results in excessive wear of the bearing; too loose belt may reduce
the air volume of the fan and affect the cooling performance. Inject an appropriate amount of
grease regularly into the through-type forced filling oil cup.
6.4 Thermostat
The thermostat is used in the Camda gas engine to adjust the operating temperature of the engine
coolant. When the engine starts working, the coolant temperature going through the thermostat is
lower than its starting temperature. When the outlet valve of the thermostat closes, all the coolant
in the engine flows back to the inlet of the water pump for further circulation so as to heighten the
water temperature in the engine. When the coolant temperature going through the thermostat
reaches about 70℃, the outlet valve of the thermostat opens and some coolant in the engine flows
to the radiator through the outlet valve, and the remaining coolant still flows back to the water
51
pump inlet. When the coolant temperature going through the thermostat reaches about 85℃, the
outlet valve of the thermostat opens fully, the by-pass valve closes fully, and the coolant in the
engine flows to the radiator through the outlet valve. When the outlet valve closes, the air is
exhausted through the hole on the outlet valve of the
thermostat.
When disassembling or assembling the thermostat, make
sure that it will not get damaged. When checking whether
the thermostat is working properly, heat the thermostat
slowly in water, observe and find whether the temperatures
are within the specified range when the outlet valve of the
thermostat opens or fully opens.
Thermostat
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6.5 Cooling system flow chart
Thermostat housing
1. Flow to low-temperature inter-cooler radiator
radiator 4. Inter-cooler coolant supply
2. Flow from low-temperature 5. Inter-cooler coolant backflow
inter-cooler radiator 6. Inter-cooler core air outlet
3. To low-temperature inter-cooler 7. Coolant back to radiator
53
Chapter 7 Air Intake and Exhaust System
7.1 Air intake system
The air intake system of the gas engine works to mix the fresh air and qualified inflammable gas
clarified and purified and direct the gas mixture into the cylinder to supply the air and fuel
required for the engine to work.
The gas supply system comprises the air filter, mixer, relief valve and the gas pressure stabilizer
mounted outside the engine. Make sure that the direction of the relief valve is not reverse.
The control valve at the mixer outlet is connected with the speed governor to control the intake air
volume and adjust the working status of the engine.
The main parts of the engine air intake system are described below.
7.1.1 Relief valve
The relief valve is a main part of the pressure stabilization system. As shown in figure 5-1, it
comprises the spring 6, diaphragm set 4, upper housing 5, lower housing 1, lever set 2 and valve
set 3. After the pre-load position of the spring 6 is set to a position, if the intake pressure P1 rises,
the opening of the valve set 3 will increase, thus the outlet gas pressure P2 will increase as well.
At this time, the gas pressure at the bottom of the diaphragm set rises to push the diaphragm set to
move up. The upward movement of the diaphragm set drives the lever set to move, as the result,
the opening of the valve set decreases and the outlet gas pressure drops. When the intake gas
pressure is reduced, the valve set opening is reduced as well as the outlet gas pressure. Then, the
diaphragm set moves down under the force of the spring to increase the opening of the valve set
and the outlet gas pressure.
According to the above working principle, the pressure after the relief valve can remain
unchanged regardless of the increase or decrease of the source gas pressure to ensure a steady
intake pressure throughout the working process of the gas engine.
Increased spring pre-load of the spring diaphragm set means increased opening of the valve set,
and heightened gas pressure after the relief valve. Decreased spring pre-load means decreased
opening of the valve set, and reduced gas pressure after the relief valve.
When installed the relief valve, orient its upper arrow to the airflow direction.
54
Relief valve
55
7.1.2 Mixer
The Venturi mixer (with national patents) developed by Camda is characterized by accurate
controlled fuel/air ratio, uniform mixing and high reliability, particularly suitable for such fuel
gases as natural gas, biogas, coalbed methane and casing head gas.
The Venturi mixer is a key part of the gas supply system and should be given special protection.
Users must ensure that the source gas pressure is 2-20 Kpa (a pressure indicator is required at the
intake). Moreover, for the sake of safety, provide an individual valve at the inlet of each gas
engine to ensure that the gas can be shut off when the engine is not working due to emergency. To
prevent impurities and hard particles away from the AVR and engine that may affect their useful
lives, a screen is required to be installed at the inlet of the proportioner. The proportioner is an
imported part comprising the mixer body and butterfly valve. If the butterfly valve shaft cannot
turn freely after the proportioner is used for a long time, perform maintenance of them.
Air flows through the Venturi tube at the center of the mixer. The gas surrounds the Venturi tube in
a round cavity and enters into the air flow through the small holes.
7.1.3 Air filter
The air filter serves to filter dust in the air to mitigate wear of the cylinder housing and parts of the
piston set and extend the useful life of the engine.
When the filter is working, the air enters into the internal cavity through the filter intake. When the
air flows by, it drives the blades to rotate. Impurities under the centrifugal force are thrown into
the internal wall of the filter and settled at the dust exhaust mouth. The air then enters into the
central passage through the micropores on the central paper core and to the mixer.
Remove the settled dust regularly by shaking the dust exhaust month to allow the impurities to
flow out.
Every 500h of running, remove the dust in the dust collector. Every 500h, take out the filter core
and knock gently its end or blow compressed air of a pressure of no more than 490kpa(5kgf／cm2)
outward from the internal cavity of the filter core, or brush gently the surface with dirt.
Never use oil or water for cleaning. Otherwise the filter core may be easily blocked by dust to
result in insufficient air intake for the engine and lowered output power. Replace the core if it is
found damaged or too dirty to be cleaned. Pay special attention to the proper use and maintenance
of the air filter. Once the paper core is broken, its sealing surface cannot properly installed to
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cause short circuit and thus serious damages to the cylinder, piston and piston ring, and worsen
operation economy, etc.
7.1.4 Inlet pipe
The inlet pipe is made from cast aluminum and shared by cylinders 4 and 6. When installing the
pipe, ensure that the adjoining plane between the inlet pipe and the cylinder head is airtight. No
impurities are allowed in the inlet pipe. Otherwise, they will damaged the parts if being suctioned
into the cylinder.
7.2 Air intake system flow chart
Central-installed inter-cooler
1. To turbocharger inlet
2. Turbocharger
3. Turbocharger air to the inter-cooler
4. Air inlet to cylinder
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7.3 Air exhaust system
7.2.1Exhaust pipe
The exhaust pipe is made from heat resistance cast iron. Each cylinder shares one exhaust pipe.
Follow strictly the external connection requirements for the exhaust pipe.
Exhaust manifold
1. Exhaust manifold 6. Flat washer
2. Exhaust manifold bolt 7. Lock plate
3. Exhaust manifold 8. Space bush
4. Exhaust manifold bolt 9. Exhaust manifold
5. Exhaust manifold sealing pad
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7.2.2 Silencer
The silencer is made by welding the silencer body, silencer, exhaust pipe and central partition
together. There are many pores on a section of the exhaust pipe inside the silencer body, which is
divided into two parts by the central partition. When it is working, the waste gas exhausted from
the cylinder enters into the exhaust pipe from the flange end, flows to the internal cavity of the
silencer body through the pores on the right side of the exhaust pipe, and then back to the exhaust
pipe through the pores on the left side of the exhaust pipe. At last, it is exhausted into the
atmosphere through the outlet.
Exhaust pipe
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Chapter 8 Operation Instructions for the Control

System
8.1 Cautions
Unless necessary, do not cut off the terminal of the current transformer (CT)!
Read the operation manual provided by the manufacturer when operating components of the
system!
Do not commission or repair the system without receiving professional training or understanding
the drawings!
Ensure that the ground terminal is well connected.
Comply with the operation regulations!
Remain concentrated and alert.
Be aware of the consequences of your operations!
Do not neglect any details or abnormal conditions.
8.2 Overview
Parameters of the system can be viewed through the human-machine interface (HMI) on the remote
control panel and local control panel, and can be set. Operating and protection parameters can be set
and revised under different management authorities. The system mainly comprises:
(1) Remote control panel
The generator set master control panel is installed in the control room. It processes all the
operation data of the generator set and conducts sequence control, logic control and PID control
according to the operation instructions and data. It comprises a PAC, a special controller and a
human-machine interface (HMI).
1. PAC. The high-performance logic controller processes and calculates various analog quantity
parameters connected by the sensor, responds to all the external hard operation instructions (hard
wiring) and soft operation instructions (HMI), and gives corresponding instructions according to
logic. Collect alternating-current and protection parameters through the Ethernet.
2. The generator set controller collects the alternating-current parameters (including current,
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voltage and power) of the fuel gas generator set and the power network, and control the start,
parallel operation and load distribution.
3. The HMI enables users to check the generator set's operation parameter and status, set operation
and protection parameters and view failures and records.
4. D.C. power supply provides 24V DC current for the whole control system and recharges the
storage battery.
5. Generator differential protector
6. Ethernet switch
7. Damp heater
(2) Local control pane
It is the auxiliary control panel installed beside the generators. It comprises the basic voltage and
speed adjusting module of the generator set, concentration point of all generator set data and the
middle connecting point between the remote control panel and the generator set. Data is connected
to the remote control panel through the Ethernet.
1. Remote data collection module (Advantech 5000 serial). All analog quantity parameters of the
engine and outside are input into the module and transmitted to PAC through Ethernet after being
processed. Control instructions given by PAC to the accessory devices of the generator set are also
transmitted through the Ethernet to the remote output module.
2. Voltage adjustment panel
3. Digital speed adjustment panel
(3) The whole system provides four operation authorities: operator, engineer, administrator and
debugger. The debugger authority is only given to our debuggers.
(4) The operation system interface provides the simplified Chinese and English editions for users.
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8.3 Outer appearance of the control system
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8.4 Operation Procedure
(1) Human-machine interface (HMI)
The human-machine interface, or touch display, enables users to monitor operation data of devices
and operate devices in the automatic system. It follows the WYSWYG principle and is
user-friendly
Main console
燃气发电机组
Fuel gas generator set
Initial page of the HMI, where users can choose the operation language.
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Overview
甲烷含量 Methane content

目标功率 Target power
节气阀 Throttle
缸套水温 Cylinder sleeve water temperature
缸套水压 Cylinder sleeve water pressure
中冷水压 Inter-cooler water pressure
中冷水温 Inter-cooler water temperature
机油压力 Engine oil pressure
机油温度 Engine oil temperature
负载比例 Load percentage
保养时间 Service time
首页整体并网交流引擎空燃比故障登录记录
Home page Overall Grid connection Communication Engine Air-fuel ratio
Failure Log in Record
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Home page Overall Grid connection Communication Engine Air-fuel ratio Failure
Log in Record
手动停止自动
Manual Stop Automatic
运行选择并网选择
Operation Grid Connection
1#散热 2#散热 3#散热 4#散热中冷水泵
1#Cooling 2#Cooling 3#Cooling 4#Cooling Inter-cooler water pump
进风风机预润滑泵加油泵后冷水泵风闸选择
Intake air blower Pre-lubrication pump Oil-feed pump Post-cooling water pump
Airbrake selection
The "Manual" position of “Operation selection” and “Grid connection selection” indicates that the
operation switch is turn off on the control panel, the “Automatic” position needs remote signal. The
"Start, Stop" button on the local control panel (on HMI) is equal to the “Start/Stop” operation switch on
the remote control panel. However, operations on the remote control panel have the priority. If a device
is started on the remote control panel, it cannot be stopped on the local control panel; if it is started on
the local control panel, it can be started on the remote control panel.
After the generator set is started, all power network and valve operation selections will fail. Operations
will only become effective two seconds after the "Start, Stop", "Grid Connection, Disconnection"
switches are turned on.
Before the generator set is started, all pump and valve selection switches must be in the “Automatic”
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position, otherwise, the generator set cannot be started as it will fail to pass the safety inspection. The
program can only enter the generator set start program after receiving the valve and pump starting
signals.
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Grid connection page
The voltage adjustment button is only effective before the generator set grid connection operation. After
the grid connection, the LED turns from yellow into red. The time that the switch is turned on and off
and the power is displayed.

发电电压发电频率发电功率
Power generating voltage Power generating frequency Power generating output
目标频率目标电压合闸次数功率因数
Target frequency Target voltage Valve closing time Power factor
电网电压电网频率发电电流电压差相角差频率差
Network voltage Network frequency Current Voltage difference Phase angle
difference Frequency difference
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A.C. current parameters
Log in Record
线电压相电流有功功率发电频率
Line voltage Phase current Active power Power generating frequency
无功功率功率因素视在功率合闸次数
Reactive power Power factor Apparent power Valve closing time
电度
Electric degree
额定功率负载比例
Rated power Load percentage
前轴承后轴承
Front bearing Rear bearing
Display the kilowatt-hour meter and its voltage and power.
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Engine page
Log in Record
机油压力缸套水压岐管压力中冷水压
Engine oil pressure Cylinder sleeve water pressure Manifold pressure Inter-cooler water
pressure
机油温度缸套温度岐管温度中冷水压
Engine oil temperature Cylinder sleeve temperature Manifold temperature Inter-cooler water
pressure
Show the engine oil pressure and various parameters of the engine network.
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Failure display
Log in Record
报警摘要总数日期时间点名称报警值报警限定节点名
Warning summary Total number Date Time Spot Warning value Limit Node
火花塞保养气门保养通讯超时急停-就地急停-内模块 1 丢失模块 2 丢失
市电末合闸
Spark plug maintenance Valve maintenance Communication overtime Emergency
shutdown-local Emergency shutdown-internal Module 1 Loss Module 2 Loss Mains
supply fails to switch on
描述分类时间名称优先级认可群组节点锁定范围高级
Description Classification Time Name Priority Approval Group Node Lock
Scope Advance
认可点认可屏幕认可全部消警复位
Accept spot Accept screen Accept all Cancel warning Reset
If the system shows failure information, solve the failure first and then tap "Failure Reset". Tap "Cancel
Warning" to stop the buzzer before the failure is solved.
When the page displays the warning information, the words turn red. After the user touches the display,
the words will turn yellow. After the failure is solved, the words will turn green.
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Log-in page
Log in Record
Log in to the set the generator set's operation and protection parameters. Choose the username and enter
the password according to the authority. Then tap “Enter” to enter the function selecting page.
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Basic settings
Log in Record
预润滑时启动时间稳定时间怠速时间并网时间过载比例停机后冷
Pre-lubrication time Start time Stable time Idle time Grid connection time Overload
percentage Post-shutdown cooling
后润滑时启动转速卸载空转进风后冷散热后冷并网比例
Post-lubrication time Start rotation speed Unload idling Post-ventilation cooling
Post-radiation cooling Grid connection percentage
The idle time is the time between the generator set is started and enters the high speed.
The unloading idle running time is the time that the generator set continues running after the grid is
disconnected.
The time limit for grid connection is the time permitted for network connection after the network
connection switch is turned on. If the breaker is not turned on within the time, the grid connection
will fail and the generator set will be turned off.
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Protection setting
Log in Record
正常保养小时火花塞保养小时气门保养小时
Normal maintenance Hour Spark plug maintenance Hour Valve maintenance Hour
已运行小时清零
Operating time Hour Reset
After maintenance, reset the system. Otherwise, information will remain in the system.
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Protection setting 1
Log in Record
主水压高主水压警主水压停主水温警主水温停辅水压警辅水压停
High main water pressure Warning main water pressure Shutdown main water pressure
Warning main water temperature Shutdown main water temperature Warning accessory
water pressure Shutdown accessory water pressure
辅水温警辅水温停高岐温警高岐温停低油压警低油压停高油温
Warning accessory water temperature Shutdown accessory water temperature Warning
manifold temperature Shutdown manifold temperature Warning low oil pressure
Shutdown low oil pressure Shutdown high oil temperature
高油温警高排温警高排温停缸温高警缸温高停机房温警报警延时
停机延时
Warning high oil temperature Warning high exhaust temperature Shutdown high exhaust
temperature Warning cylinder temperature Shutdown cylinder temperature Warning
machine room temperature Warning delay Shutdown delay
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The page shows the setting of the engine protection parameters.
The main water is the jacket water. The auxiliary water is the intercooler water, or low-temperature
water.
The high manifold temperature refers to high temperature of the intake manifold, or high MAP
temperature. If the auxiliary water temperature is low, while the MAP temperature is high, the
intercooler may be jammed or the heat cannot be dissipated effectively.
The delay time of all warnings is the same, so is that of the grid suspension.
Note that the protection setting has two pages. Tap "Next page" to enter the next page.
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Protection setting 2
逆功分闸逆功急停电流失衡电压失衡高频报警高频急停低频报警低频
急停
Reverse power disconnection Emergency reverse power shutdown Current unbalance
Voltage unbalance Warning high frequency Shutdown high frequency Warning low
frequency Shutdown low frequency
过流报警过流急停压高报警压高急停压低报警压低急停超速报警超速急停
Warning over current Shutdown over current Warning high voltage Shutdown high
voltage Warning low voltage Shutdown low voltage Warning high speed Shutdown
high speed
The page enables users to set the A.C. current protection parameters.
Current unbalance refers to the unbalance of the three-phase load current.
Voltage unbalance refers to the unbalance of the three-phase voltage
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Air-fuel ratio
燃气阀启动位置启动延时初始位置手动增速自动增速调速延时合闸增值

稳定时间怠速死区高速死区压力死区压力急停保护延时启前延时
Fuel gas valve Start position Start delay Initial position Manual accelerating Auto
accelerating Speed adjustment delay Switch-on increase Stable time Idle dead zone
High-speed dead zone Pressure dead zone Pressure shutdown Protection delay Prior-start
delay
总管压力稳压压力涡前压力理论压力实际压力压力差值空燃比例燃阀
实际空阀实际当前功率检查转速
Main header pressure Steady pressure Prior-turbo pressure Theoretical pressure Actual
pressure Pressure difference Air-fuel ratio Actual fuel gas valve Actual pneumatic valve
Current power Examine rotation speed
空气阀限值辅助调节电压最小差值燃阀单步增值燃阀脉冲问题调速
Pneumatic valve Restrict accessory adjustment Min voltage difference Fuel gas single-step
increase Fuel gas impulse problem Speed adjustment
启动位置手动增速风门系数甲烷含量
Start position Manual speed adjustment Ventilation door factor Methane content
燃气伺服复位燃气伺服使能伺服当前值伺服原点值伺服终点值
Reset fuel gas servo Enable fuel gas servo Current servo value Original servo value Final
servo value
空气伺服复位空气伺服使能
Reset air servo Enable air servo
功率设定功率设定值必须从左到右，由小到大填写 map 设定
Power setting The power values must be set from small ones to bigger ones from left to right
Map setting
The page enables users to adjust the air-fuel ratio and initiate the start grid according to the content of
methane. Users can judge whether to adjust operation of the grid according to the methane content.
Parameters on the page indicate the operating status of the grid.

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Speed adjustment
节气阀起始电压空载限制限制设定

Throttle Start voltage Idle limit Limit setting
调速输出执行器反馈节气阀悬冲间隔
Speed adjustment output Actuator feedback Throttle pulse interval
调速限制执行器开度功率处理
Speed adjustment limit Actuator openness Power processing
启动电压调速 p 负载 p 负载阀值
Start voltage Speed adjustment p Load p Load threshold value
初始电压调速 I 负载 I 额定转速
Initial voltage Speed adjustment I Load I Rated rotation speed
自动增速调速 D 负载 D 目标功率
Auto acceleration Speed adjustment D Load D Target power
手动增速取样时间取样时间功率上限功率下限
Manual acceleration Sampling time Sampling time Max power Min power
增加值怠速死区负载速度飞轮齿数
Increase Idle speed dead zone Load speed Flywheel gear number
切换转速高速死区负载死区启动转速
Switch rotation speed High speed dead zone Load dead zone Start rotation speed
基本设定负载 PID 死区 PID 延时怠速转速
Basic setting Load PID dead zone PID delay Idea rotation speed
This page shows parameters relating to engine rotation speed adjustment and limitation.
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Real-time trend
实时趋势图采样间隔样品总数群组编号

Read-time trend figure Sampling interval Total sample number Group number
点名称
Spot name
值最高显示工程单位
Value Highest Engineering unit
描述
Description
新的点改变值报警曲线图认可点认可群组
New spot Change Warning curve Accepted spot Accepted group
Users can choose necessary operating parameters and collect them at an interval of one minute. A text
will be created everyday and stored in the hard drive.
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(2) Preparation for starting the generator set
1. Check the coolant pressure and engine oil level.
2. Check the 230V AC power supply and 380VAC power supply.
3. Check the fuel gas pressure and temperature.
4. Check the pressure and gas volume of the starting and instrument gas.
5. Check whether the selection switches are in the right position and whether the water valve
selection switch, pre-lubrication valve, bearing lubrication pump and water pump selection
switches are in the "Automatic" level.
6. Check whether the manual water, oil and gas valves are opened.
7. Check if there is warning information on the touch display.
8. Enter the HMI “overall” page, check whether the generator set is prepared. Note that the
generator set can only be started after it is prepared.
(3) Start the generator set
Turn the “Start, Stop” switch on the remote control panel to the right (read LED) for more than 2
seconds, the generator set will enter the self-check program. First, three kingston valves will be
opened and the electric ball bearing lubricant pump set will enter the "Pre-lubrication" status. Start
the pre-lubrication motor to pre-lubricate the engine (the pre-lubrication LED on the meter panel
turns red and flicks). After the pre-lubrication completes, the motor will stop. Start the pneumatic
motor to drive the engine (the motor LED on the meter panel turns red and flicks). Start the
ignition system and main fuel valve is opened. When the rotation speed reaches the starting motor
escape speed (HMI setting), the generator set is started and enters the idle status. If the rotation
speed fails to reach the idle value within the starting protection time (internal setting), the
generator set is not started and the starting motor will be stopped and a warning will be made.
Cautions:
1. In the starting process, turn the "Start, Stop" switch to the left (Green LED) at any time for
more than 2 seconds, the starting program of the generator set will be stopped immediately.
2. Pay attention to the touch screen, rotation speed, pre-lubricant pump and starting motor and to
the countdown of the status. The main fuel valve's opening status can also be monitored.
3. In case of any abnormal conditions, press the emergency stop button.
4. The operation halt before the closure of the generator breaker and the grid connection will not
trigger the back cooling program.
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(4) Idle operation
After the generator set is started, it enters the idle status. During the period, various operating parts
of the generator set will be pre-heated and pre-lubricated. The time of the period can be set on the
HMI. In the idle speed status, the generator set is under protection.
Cautions:
1. In the idle speed operation period, turn the "Start, Stop" switch to the left (Green LED), the
starting program of the generator set will be stopped immediately.
2. The low oil pressure, high water temperature, high water pressure, low water pressure, high
rotation speed and high voltage protection is triggered in the idle speed rotation status.
3. Pay attention to the touch screen in the idle speed status. Parameters including the rotation
speed, oil pressure and water temperature can be monitored. The opening status of the main fuel
valve can be displayed. Pay attention to whether the rotation speed is stable and other parameters
remain in the normal range.
5. Users can monitor the countdown of the idle status on the generator monitoring page.
(5) High speed operation
After the idle operation ends, the generator set starts to accelerate to the rated speed and enters the
high speed status. The touch screen shows "Accelerating" in the generator set status column.
When the rotation speed of the generator set is close to the rate one (set in the HMI), the automatic
voltage stabilizer starts to work and the output voltage will be stabilized at the rated voltage.
When the generator set's voltage and frequency are stabilized at the rated status, the set enters the
status operation (stable high speed) status, users can slightly adjust the voltage and frequency on
the touch screen. In the stable operation status. all parameters should be in the normal range,
except those related to the load, and all protection measures are triggered.
Cautions:
1. In the high speed operation period, turn the "Start, Stop" switch to the left (Green LED), the
starting program of the generator set will be stopped immediately.
2. Pay attention to whether the voltage and frequency of the generator set are stable and whether
the differences in the voltage and frequency between the generator set and grid are normal.
3. Pay attention to whether various operation parameters of the engine are normal.
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(6) Parallel operation
After a period of stable operation (stable high speed) (set in the HMI), if the “Parallel,
Disconnection” operation switch on the remote control panel is turned on the right (red LED) for
more than 2 seconds, the generator set will automatically enter the parallel operation program. The
generator set is the first generator set. If the program detects no voltage signal on the bus line, it will
directly give the switch-on instruction; if it is not the first parallel operation generator set and the
program detects voltage signal on the bus line, it will automatically start the frequency, voltage and
phase angle tracking program and give the switch-on instruction in the synchronizing range.
Cautions:
1. After entering to parallel operation program, the generator set's voltage and frequency cannot be
adjusted manually.
2. The synchroscope on the touch screen shows whether the parallel operation is tracked.
3. Power is only supplied for the under-voltage tripper only when the generator set enters the stable
high speed status. Therefore, a minor sound in the parallel operation breaker is normal when the
generator set enters the stable high speed status.
4. There are many settings of the generator set parallel operation in the controller. These items are set
during commissioning. Users can only revise the parameters with instructions of Camda's
technicians.
5. Do not open the door of the low-voltage panel breaker cabinet during parallel operation to ensure
safety.
6. In case of any abnormal conditions during parallel operation, turn the “Parallel operation,
Disconnection” operation switch to the left (green LED) for more than 2 seconds or press the
emergency button.
7. If the parallel operation fails within the specified time (set in the HMI), the generator set will give
a parallel operation failure warning and stop.
(7) Loading
After the grid connection breaker closes, the power will be increased according to the target power.
When the power reaches the target one, it will fluctuate slightly.
Cautions:
1. During the loaded operation, turn the "Start, Stop" and "Grid connection, Disconnection" operation
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switches to the left (green LED) at any time for more than 2 seconds, the generator set will
immediately enter the unloading and disconnection program. If the "Start, Stop" switch is turned, the
generator set will first unload and disconnect before cold shut-down and the back cold program will
be implemented no matter how long the generator set has operated. If the "Grid connection,
Disconnection" switch is turned, the generator set will only unload and disconnect, and continue to
operate at a high speed.
(8) Unloading
If it is necessary to shut down the generator set for maintenance or other reasons, turn the "Start,
Stop" switch to the left (green LED) for more than 2 seconds, the generator set will immediately
enter the unloading and shutdown program. The system will automatically reduce the load (according
to the unloading rate). When the load is decreased to the min load, the grid connection breaker will
automatically open. After the generator set continues to operate under an idle load for a period (set in
the HMI), cut off the main fuel valve and the generator set stops and enters the "Prepared" status for
the next start instruction.
(9) Post lubrication
After the generator set is shut down, the pre-lubrication oil pump will be started immediately to
post-lubricate the generator set.
(10) Standby
After the shutdown, the generator set enters the "Prepared" (standby) status to wait for the next start
instruction. The protection systems for the generator set is stopped, with only the safety protection
system remaining open (fire and gas protection).
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8.5 Protection and Warning
While fulfilling the generator set operation and parallel operation, the control system provides
comprehensive protection and warning for the generator set and accessory devices as well as
engineering on the offshore drilling platform.
1. Safety protection system. Each generator set has an IR flame detector and a flammable gas alarm
to protect the generator set.
2. Generator set protection system. The control system provides comprehensive protection for the
entire generator set, including each operation link and platform. For critical links, the system also
provides multiple protection measures.
3. The failure protection system has three levels. The first level is warning. The control system can
give a warning and unloading signal. The second level is normal shutdown. The system will give a
warning, unload the valve and shut down the generator set. The third level is emergency shutdown. It
will shut down the generator set and give a warning at the same time.
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8.6 Failure Processing
Any failure, if not processed properly, may cause personal injury and equipment damage, or even
greater accidents. Therefore, failures must be processed by trained professionals.
Before processing a failure, press the emergency shutdown button!
In case of any failure to the generator set, follow the instructions on the human-machine interface
(HMI). Several simply failures are described hereinafter.
(1) Unable to start
1. Check if there is any information about the failure, parameters of the generator set on HMI are
normal, the generator set is prepared, pre-lubrication is normal and the motor control valve is
powered when it is started.
2. Check whether the fuel gas pressure and composition are normal and battery's voltage drop is
normal when it is started.
3. Check whether the main fuel valve is opened.
4. Check whether the spark plug is moistured and ignition parameters are normal.
(2) No-load operation failure
1. The generator set cannot enter the high speed operation status. Check whether PAC sends the
conversion signal and whether 2301D speed adjustment panel receives the signal.
2. The rotation speed is not instable. Check whether the gas pressure is normal, the air-fuel ratio can
be adjusted and the speed adjustment valve is stuck.
3. The pressure and speed cannot be adjusted manually. Check whether the generator set is in the
high-speed stable status. Check whether AGC-3 outputs pressure adjustment signal and whether the
generator set is well connected.
(3) Parallel operation failure
Check whether the pressure and speed can be adjusted manually, whether the synchroscope can work,
breaker is recharged, under-voltage tripper of the breaker is powered, rotation speed of the generator
set is stable, and the generator set's voltage and frequency are stable.
(4) Load failure
1. The active power is not well distributed. Check whether the rated power setting is normal, speed
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adjustment valve is opened, the output of the speed adjustment panel is normal, AGC-3 speed
adjustment signal is normal and the air filter is jammed.
2. The reactive power is not well distributed. Check whether the AGC-3 speed adjustment signal is
normal, setting of the pressure adjustment panel is normal and the voltage of the generator set is
abnormal.
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8.7 Appendix
(1) Settings of Generator Set Parameters
Settings of parameters
Serial
Parameter Scope Unit General setting
Number
1 High main water pressure 300-500 kPA 400
2 Warning main water pressure 150-300 kPA 180
3 Shutdown main water pressure 100-200 kPA 120
4 Warning main water temperature 70-90 ℃ 85
5 Shutdown main water temperature 80-100 ℃ 88
6 Warning high exhaust temperature 600-700 ℃ 650
7 Shutdown high exhaust temperature 600-700 ℃ 680
8 Warning high manifold temperature 40-70 ℃ 65
9 Shutdown high manifold temperature 40-70 ℃ 68
10 Warning accessory water pressure 150-300 kPA 180
11 Shutdown accessory water pressure 100-200 kPA 120
12 Warning accessory water temperature 40-80 ℃ 65
13 Shutdown accessory water temperature 40-80 ℃ 70
14 Warning high oil temperature 60-90 ℃ 85
15 Shutdown high oil temperature 60-90 ℃ 88
16 Warning low oil temperature 250-500 kPA 350
17 Shutdown low oil temperature 250-500 kPA 300
18 Warning delay 0-10 s 5
19 Shutdown delay 0-10 s 5
20 Generator room temperature warning 40-60 ℃ 48
21 High cylinder temperature warning 700-720 ℃ 700
22 High cylinder temperature shutdown 700-750 ℃ 720
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(2) Protection settings
Protection setting
Serial
Parameter Scope Unit General setting
Number
Emergency reverse
1 0-20 % 15
power shutdown
2 Current unbalance 0-20 % 15
3 Voltage unbalance 0-10 % 6
High frequency
4 90-110 % 105
warning
High frequency
5 90-110 % 108
emergency shutdown
Low frequency
6 80-100 % 95
warning
Low frequency
7 80-100 % 92
emergency shutdown
Over current
8 90-120 % 105
warning
Over current
9 90-129 % 110
emergency shutdown
High voltage
10 100-110 % 105
warning
High voltage
11 100-110 % 108
emergency shutdown
Low voltage
12 90-100 % 95
warning
Low voltage
13 90-100 % 92
emergency shutdown
14 Over speed warning 100-110 % 105
Over speed
15 100-110 % 108
emergency shutdown
Reverse power
16 0-20 % 8
disconnection
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Chapter 9 Use and Operation Procedures of

Generator Set
9.1 Selecting the fuel gas, engine oil and coolant
Before using our engine, select appropriate fuel gas, engine oil and coolant based on the particular
application environment and conditions. The useful life of the engine is largely dependent upon
the fuel gas, engine oil and coolant selected.
9.1.1 Fuel gas
The Venturi mixer (with national patents) developed by Camda used in our gas generator set is
characterized by accurate controlled fuel/air ratio, uniform mixing and high reliability, particularly
suitable for such fuel gases as natural gas and methane. The gas used is free of free water, crude
oil and lightweight oil after drying and dehydration processes.
Gas requirements: total sulfur content is not more than 200ppm, H2S content is not more than
100ppm. Relative humidity of gas at the inlet is less than 80%, and no water condensation is
allowed on the engine parts. The recommended gas temperature of the engine is at least 15℃
above the dew point temperature. Generally, humidity is not a problem for natural gas. The
maximum H2 allowed in the fuel gas is 12%vol, the maximum solid particle size in the gas is 5um,
the maximum concentration of particles between 1um and 5um is 10 mg/Nm³.
Air pressure requirements: 2 -20kPa, A pressure above this range must be reduced by a pressure
relief valve, otherwise will lead to improper working of and even damage to the engine. On the
other hand, gas pressure needs to be increased for systems with a pressure lower than the inlet
pressure in order to ensure proper working of the generator set. (The above data is for reference
only and subject to changes according to the actual working environment of the engine) .
9.1.2 Engine oil
The engine oil is used to lubricate and cool the moving parts and remove the impurities from the
parts and prevent them from rusting. Its quality not only affect the performance and useful life.
For this, it should be selected based on the operating environment temperature of the engine, so
that it can maintain good liquidity at the minimum environment temperature and proper kinematic
viscosity at its maximum temperature.
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A common standard for lubricating engine oil for gas engine has be available now. Other than ash,
the lubricant oil used for gas engine contains other key ingredients, including phosphor of a low
content, high anti oxidation and nitration agent (usually produced at a high temperature) and
quality corrosion inhibitor (especially with the existence of corrosive gas).
Generally, the engine oil used has a moderate content of ash, quality paraffin, stable anti oxidation
and nitration performance, and is able to protect the machine at a high temperature and reduce
carbon sink and residues. Therefore, it can keep the machine in a good condition and running for a
long time. Additionally, the low foaming rate, high demulsification and good anti-corrosion of the
oil can effectively protect the cylinders and gears, reduce wear of the piston ring, cylinder liner
and valve seat. It has the advantage of cleaning the engine and preventing sediments. In addition, a
number of additives in the engine oil can prevent wear of the piston and the cylinder surface.
A proper type of engine oil has these benefits:
a Efficiently preventing from corrosive gases
b Efficiently protecting cylinder head valve seat and conduits
c Protecting piston friction and cylinder liner surface
d Cleaning the engine
e Minimizing sediments
f Preventing foam and corrosion
g Good alkali resistance
h Extending the useful life of the engine oil and filter
i Long useful life
The recommended engine oil is Total NATERIA MJ40, with the following characteristics:
Typical
Method Unit NATERIA MJ40
characteristics
SAE class 40
Density at 15℃ ISO 3676 Kg/m3 891
Kinematic viscosity at
ISO 3104 mm2/s 148
40℃
Kinematic viscosity at ISO 3104 mm2/s 15.1
90
100℃
Viscosity index ISO 2909 - 104
Flash point OC ISO 2592 ℃ 250
Pour point ISO 3016 ℃ - 12
Sulfated ash content ISO 3987 % 0.82
BN ASTM D2896 mg KOH/g 8.8
Another recommended engine oil brand is Caltex:
SAE class 40
Kinematic viscosity at 40℃ mm2/s 125±5
Kinematic viscosity at 100℃ mm2/s 13±2
Total base number (TBN) mg KOH/g ≥4
Ash content % 0.1-0.6
It is recommended to change the engine oil every 500-800 hours, dependent upon the engine
oil test report.
When the engine oil tested achieves the following number, it should be replaced. The
reference data for replacing engine oil is as follows:
Lubricating oil consumption rate g/kWh 0.5
Kinematic viscosity at 40℃ +15% or -10% of fresh oil
Total base number (TBN) mg KOH/g Min. 3
Total acid number (TAN) mg KOH/g Max. increase 2.5
pH value Min. 4
Water % 0.1
ethylene glycol % 0.1
Oxidation reaction A/cm Max. 20
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Nitration reaction A/cm Max. 20
Iron Fe mg/kg ≤20
Copper Cu mg/kg ≤10
Lead Pb mg/kg ≤10
Tin Sn mg/kg ≤5
Aluminum Al mg/kg ≤10
Chromium Cr mg/kg ≤10
Silicon Si mg/kg ≤10
Sodium Na mg/kg Much higher than the fresh
oil
9.1.3 Coolant
During the assembling of the engine, pay attention that the quality of cooling water will affect
the thermal transfer. Any water treatment process is intended to protect the cooling system from
being eroded , and prevent from the entry of deposits and scale, which may weaken the continuous
water flow in the cooler.
It is recommended to use clean soft water as the coolant for directly cooling the engine in the
cooling system, for example, distilled water, deionized water, drinkable tap water, rainwater or
clarified river water. Well water or other ground water (hard water) can easily produce scale inside
the engine water jacket due to its high content of minerals, affecting the cooling effect and causing
faults. If only hard water is available restricted by conditions, do not use it directly until it has
been softened in the following ways:
(a) Boiling— boil the water and leave it for settling;
(b)Add a small amount of caustic soda, mix, settle and then use the above clear water.
The best way to avoid problems arising from erosion, oxidation, deposited sediments is to add
sufficient additives in the water of the cooling system, which can protect the metal surfaces in the
system by producing a rustproof layer on the metal surfaces to prevent erosion of the cooling
system.
Various antiseptic additives can be used for protecting the gas engine from erosion and rust.
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Additives Protection effect Problem caused
Phosphate Steel, iron, Unstable, worn fast, sediments (caused by hard water)
aluminum
Borate Iron, copper Aluminum eroded at a high temperature
Nitrogen (hydrogen Iron Quickly worn
dioxide)
Silicon (silica acid) Aluminum, iron, Membrane produced by fast wear, even green membrane,
neutral substances to affect heat exchange
Carboxyl-contained Aluminum,
acid neutral substances
Prevent the coolant from freezing to break related parts when using the engine at a temperature
below 0℃. To prevent water from freezing, it is better to use high-quality anti-freezer, even in hot
days, as such products will raise the melting point of water. Avoid water boiling and evaporating.
An anti-freezer product is a liquid lyotrope made from ethylene glycol. A sufficient amount can
not only mitigate the risks of freezing and evaporation, but also improve the non-corrosive
performance in cooling. Effective dosing is adding 2% calcium into 10% anti-freezer.
Use anti-freezing liquid with a suitable condensation point according to the ambient temperature
or add hot water before the engine starts. But drain the water after it stops.
Prevent fire when using the anti-freezing liquid as ethylene glycol and alcohol are inflammable.
Before using the anti-freezer for the engine, clean the dirt from its cooling system to prevent new
chemical sediments from producing and affect the cooling effect.
Use a cleaning solution to clean the cooling system if there is too much deposit and dirt. The
solution can be prepared with water, Na2CO3 and Na2SiO3, by adding 40g Na2CO3 and 10g
Na2SiO3 in to a liter of water. When cleaning the cooling system, inject the cleaning solution into
the cooling water jacket, start the engine until the outlet water temperature is above 6℃, stop the
engine after it runs for two hours and drain the solution. Cleanse the engine with clean fresh water
twice after the engine is cooled. Then drain the water and inject the cooling water and start the
engine again until the outlet water temperature reaches above 75℃. Stop the engine and drain the
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waste water and finally inject fresh coolant.
The mixed coolant comprises 50% ethylene glycol anti-freezer and 50% pure water. The
anti-freezer must conform to the standard ASTM D5345 or ASTM D4985 .
Propylene glycol can replace ethylene glycol, but its concentration can only be 50%.
Protection capacity of anti-freezer:
Ethylene glycol
Concentratio Anti-freezing Boiling prevention
n
50% -23℃(-9°F) 106℃(223°F)
60% -51℃(-60°F) 111℃(232°F)
Propylene glycol
Concentrati Anti-freezing Boiling prevention
on
50% -29℃(-20°F) 106℃(223°F)
Water characteristics requirements
Minimum requirements for acceptable water
Substance Maximum content
Chloride 40mg/L
Sulfate 100mg/L
Total calcium carbonate content 170mg/L
Total solids 340mg/L
pH value PH value from 5.5 to 9.0
Note: Water not meeting the requirements will cause the production of solid sediments in the
cooling system, thus resulting in excessively high temperature of the engine.
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9.2 Conditions for the location for installing and using the gas generator set
(1) Well ventilated, no more than 40℃ ambient temperature.
(2) Clean environment, no articles that will produce corrosive acidic or alkaline gas and steam
should be placed nearby.
(3) Preferably installed indoor or weatherproof conditions.
(4) If the generator set is installed in a special room, the foundation should be horizontal platform,
which is +200mm longer and +200mm wider than the generator set, 200mm above the ground.
Place the generator set directly on the platform, preferably with an elastic liner in between to
prevent vibration.
(5) If the generator set is used indoor, the hot air from the fan and the waste gas from the gas
generator should be channeled to outdoor. The exhaust pipes should not be too small in diameter,
without too many bends to ensure smooth air exhaust.
(6) Erect cable brackets indoor which are covered by flooring. All the connecting cables between
the generator set and the low-voltage distribution cabinet should be laid in the cable brackets.
(7) The generator set should be provided with grounding wire and grounded safely.
(8) Consult the civil engineering designer, fire control, electrical and plumbing technicians when
designing and constructing the generator room.
The generator set can be installed in the basement, on the ground or rooftop. Generally, there
should be sufficient space in the engine room for ventilation and sufficient working space around
the engine and the alternator.
General space requirements for a generator room:
Basic space of a generator room=area of all distances + area of the generator (see below for the
master layout plan)
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通风窗 Ventlight 1000*800

储气罐 Gas storage tank
燃气开关 Gas switch
储气间 Gas storage room
排风室 Exhaust air box
燃气熄火器 Fire arrester
蓄电池 Storage battery
发电机组 Generator set
柔性导风罩 Flexible air director
空气开关 Air switch
电缆沟 Cable trench
进风室 Air inlet chamber
观察窗 Observation window
低压配电柜 LV distribution cabinet
低压配电房 LV distribution room
灭火器 Extinguisher
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9.3 Floor requirements
The floor should be even. Generally, the concrete thickness of generator sets of 500KW or below
should be no lower than 250mm. If the generator set power exceeds 500kW, the required thickness
is between 300mm and 500mm.
Note: The floor must be solid, without another level under it !
Users can select the quality and dimensions of the base according to the actual situation.
The base thickness and floor load capacity can be calculated in the method described below:
The load on the floor depends on the weight of the whole generator (including fuel and water),
volume and the quantity of shockproof pads. If the base is directly fixed onto the floor,
the floor load =
Weight of the entire generator set
Dump rail's area
If there are shockproof pads, and the weight of the generator is evenly distributed on every pad,
the floor load =
Weight of the entire generator set
Shockproof pad's area x quantity
Therefore, the floor load can be reduced by increasing the quantity of shockproof pads.
If the weight is not evenly distributed, the maximum floor pressure will be produced on the pad
bearing the maximum weight (assuming all the pads are of the same size).
Max. floor pressure =
Weight of the shockproof pad with the largest load
Area of the shockproof pad
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9.4 Fixing and shockproof devices of generator set
9.4.1 Generally, shockproof pads have been installed on the rigid base of a generator and the
alternator and engine have been calibrated in the course of production. So just install the generator
set at the expected position and keep it horizontal. (see the figure below)
发动机 Engine
发电机 Generator
9.4.2 If no shockproof pads are provided, other shockproof devices must be in place when the
generator set is placed on the flat base. Rubber pads or steel balls together with rubber pads can be
used to eliminate shock to prevent damages to the machine and improper vibration.
9.4.3 If possible, compact the soil or refill concrete first under the concrete base, and then apply a
200mm shockproof layer of a mixture of cement, asphalt, cinder and water to effectively prevent
generator vibration and floor resonance.
The natural vibration frequency of the plate should be twice of the rotating speed of the engine. If
it is close to the rotating speed of the engine, resonance may occur in some part of the building.
9.4.4 Ventilation
The running of the engine and the alternator will distribute heat in the room and increase the room
temperature. Thus it is necessary to ventilate the room to effectively control the temperature rise in
the generator room and provide cool and fresh air to the generator.
9.4.5 Circulation
A good ventilation system requires sufficient air inflow and outflow and free circulation in the
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room. Therefore, there must be enough space in the generator room to allow free air circulation so
as to keep uniform air temperature in the room without flames.
Cautions:
1) Hot air from the generator set should be directed outdoor with an air director, which should be
sealed with the air outlet on wall to prevent backflow of hot air to reduce the cooling effect (as
shown in the figure).
引风罩 Air director

发电机 Generator
2) Cooling air must be drawn from outdoor at a temperature as low as possible. Arrange the air
intake (and air director) according to the particular structure of the generator room.
3) The temperature in the generator room should be no higher than 43°C. Otherwise, not only the
power of the generator set will be reduced but also the electric components may be damaged. If it
is possible that the temperature may be above 43°C, preferably use two exhaust fans to accelerate
ventilation in the room. The two fans are installed in the incoming and outgoing air directors, with
one blows in cooling air into the room and the other exhaust hot air from the room.
4) Required area of air outlet: the air outlet area must be 1.3 times or above of the radiation area of
the water tank. If a protection mesh is provided on the air outlet, enlarge the size of the air outlet
according to the area of the wire mesh. If an air deflector is provided at the air outlet, enlarge the
size of the air outlet according to the effective pass-through area of the air deflector.
5) Required area of air inlet: the air inlet area must be 1.3 times or above of the air outlet area. If a
protection mesh is provided on the air inlet, enlarge the size of the air inlet according to the
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effective pass-through area of the wire mesh; if an air deflector is provided on the air inlet, enlarge
the size of the air inlet according to the effective pass-through area of the air deflector.
9.4.6 Installing generator set in basement (see the figure)
发动机 Engine
散热器 Radiator
帆布罩 Canvas cover
导向筒 Guide pipe
出风口 Air outlet
地面 Ground
Note: the air inlet and outlet are of the same area. The R on the figure is no less than 150mm.
9.4.7 Air vent duct
1) The engine is located to the extent that the air vent duct is as short as possible and the number
of bends and blocks as small as possible.
2) Normally, the air vent duct goes out of the external wall and extents to the rooftop along the
external wall. There is a sleeve outside the wall opening to absorb vibration. And an expansion
joint is provided on the duct to compensate the difference in length as the result of expansion and
contraction. Generally, the air vent duct is not allowed to share an flue with other devices as one of
them will make an reaction to impair the operation of the other.
3) The exhausted air can directly enter into a special flue, which can serve as an outlet of the
radiator and achieve the soundproof purpose.
4) The silencer can be installed within the flue or the room. Its tail pipe extends to the outside. The
air vane guide should be installed within the flue to guide the air from the radiator upward and
reduce the flow resistance of the radiator fan.
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5) For engines on rooftop penthouse, individual outdoor shelter or trailer, the exhausted fume from
the air vent duct and the exhausted air from the radiator can flow on the shelter without any flue.
Sometime to achieve this purpose, the radiator is fixed horizontally and an electric motor is used
to drive a fan to exhaust the air vertically.
9.4.8 Installing air vent duct
1) The exposed part of the air vent duct should not contact with wood or other inflammable
matters. The vent pipe inside the building (including the silencer in the room) should be covered
with suitable thermal insulating materials to avoid burning people and reduce the temperature.
2) The air vent duct should be installed vertically or horizontally without tilting; there should be
no more than 3 bends; the vent pipe should be no more than 3000mm long.
Too many bends and too long vent pipe will affect the exhaust back pressure of the engine, and
thus the proper operation of the engine.
1)The gas exhausted from the generator is not only harmful but also hot. Pay attention to fire
protection and poisoning prevention !Do not orient the air outlet directly to cables or other
inflammables, or buildings such as plants and dorms!
2) The waste gas exhausted is toxic !
The waste gas from the engine contains carbon monoxide, which is a colorless, odorless, toxic gas,
and causes people to die unknowingly. Symptoms of carbon monoxide poisoning include:
1.Dizziness 5.arrhythmia
2.Sickness 6.muscle spasm
3.Headache 7.vomiting
4.Weakness and lethargy 8. trouble with thinking
9.4.9 Noise reduction
1) The level of noise is determined based on the size and sound pressure level of the generator
room. Reduce the generator noise with reference to noise standards for corresponding
environment. Too high standard will incur unnecessary overspending and is not recommended.
2) In many cases of installation, the generator noise can be reduced to the acceptable level by
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fixing the generator with elastic fixers, controlling air exhaust and intake and installing radiator
fans.
3) If the generator noise is still high after the above measures are taken, erect soundproof panels
around the room and the generator, install acoustic panels on the walls of the generator room, or
place the generator in a especially designed soundproof shelter to reduce the noise.
9.4.10 Connecting power lines
Power lines should be designed and installed in compliance with the relevant national or industrial
standards, and be erected by professionals.
1) AC power line
The current intensity of AC conductors installed on site between the output end of the generator
set and the first over-current protection device should be higher than 115% of the FLA.
The conductor between the output end of the generator set and the first over-current protection
device should be as short as possible (generally no more than 10m). The current carrying capacity
of conductor must conform to the relevant national or industrial standard.
Neutral line current intensity is permitted to be equivalent to or larger than the maximum
unbalanced single-phase load value. In case of an apparently non-linear load, select the neutral
line based on full load.
2) Grounding
An effective system should ensure that sudden power failure will not endanger personal life and
operators' health at any time. Requirements for good grounding: low resistance, avoiding lightning
stroke and short-circuit, a capacity of repeatedly driving high current, and a capability of fulfilling
all required functions during the installation.
System grounding: The neutral line of Camda generator set is not grounded during operation. If as
an individual power supply (with 4-pole switch), the neutral line should be connected to the
system ground wire by an electrician. If the neutral line of the generator is found to be connected
with the ground wire, a typical application is to connect it to the neutral point of a 3-pole switch,
in which case the neutral point of the generator should not be grounded on the side of the
generator. If the neutral line cannot be separately grounded, the grounding point of the neutral line
and the mains should be marked as required by the electric power standard.
Equipment grounding: A grounding terminal is provided on the base of the generator set. An
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on-line breaker can provide a grounding terminal. According to the electric power standard, a
dedicated grounding wire is required. The flexible conduit absorbing vibration is not allowed to be
used as a grounding wire.
Grounding resistance: grounding resistance is a main indicator of good grounding performance of
the ground electrode. To protect the safety of people and equipment, the national standard
provides the range of grounding resistance of various ground electrodes.
>100KVA low voltage generator set R<4 Ohm
<100KVA low voltage generator set R<4 Ohm
Electric equipment protection grounding R<4 Ohm
Null line iterative grounding R<4 Ohm
Grounding short circuit current Id>4000A R<2000/Id
Grounding short circuit current Id<500A 10 Ohm >R<120/Id
Control line: the DC and AC control lines to the switch and remote display should be separated
from the power transmission line. Use stranded wire and flexible conduit for the connection to the
generator set.
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9.5 Generator Operation Procedure
9.5.1 Pre-start preparations
Check and adjust the conditions of the engine and other parts of the generator set. The connection
and fixation of all components must be reliable and correct. The cooling water system and electric
start system of the engine are reliably connected, without leak or loosening. The switches can
operate smoothly. The lubricating system is in good condition as well as the gas supply system and
ignition system. Otherwise, repair and adjust them immediately before starting the machine.
All the gas engines provided by Camda have go through running-in process and can operate with
load straight away. The recommended load for operation for the first time is 80-90% of the rated
output power.
1） Remove the dust, water, oil and rust stains on the engine surface.
2） Check whether all mechanical connectors and fasteners are loosen, all moving parts can
turn freely, and there is any friction or jam; and check whether all wires are connected
firmly and correctly, contacts are reliable, and there is any loosening or coming-off.
3） Check whether the gas inlet pipe is clear.
4） Check whether the engine oil in the bottom case of gas engine oil is sufficient.
5） Check whether the cooler has been filled up with cooling water.
6） Turn on the switch of the gas inlet pipe.
9.5.2 Matching powers between engine and working machines
For selecting an engine, users should not only consider the rated power of the matched generator
or other working machines but also the load factor of the working machines. For example, are they
working intermittently or continuously? What are their loads? If the operation economy of the
working machine is considered, such consideration should be extended to the match between the
load working characteristics and the engine characteristics. Proper rated power of the engine and
match between the engine and the working machines are prerequisites for reliability, long useful
life and economical operation of the engine. Otherwise, the engine may be overloaded and
unnecessary faults caused, or its power cannot be fully utilized if under-loaded, which is not only
uneconomical but also likely to cause problems such as engine oil flees.
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The Camda generator set can be working stably and continuously at 50%-90% of the rated
power.
9.5.3Starting the generator set
1) Check whether the pressure indicator on the gas pipe is working properly. Turn on the gas
supply valve, adjust the gas pressure to 0.8-1.0Kpa. Turn on the power, keep the idle/rated switch
of the speed governor on one side, and press the start button to start the engine. Once the oil
temperature, water temperature and oil pressure have achieved the required levels respectively,
turn the idle/rated switch to the rated position to allow the engine to run at its operating speed.
2) Turn on the draining valve at the bottom of the surge tank to drain the sewer and exhaust the air
from the tank. Turn off the draining valve.
3) If the engine cannot be started after three attempts, turn off the gas switch and start the engine
again to exhaust the residual gas from the exhaust system. Before the re-start, check and
troubleshoot all problems.
4) Maintain the rotating speed at about 1500rpm or 1800rpm after the gas generator set is started.
Pay close attention to the reading of the engine oil pressure. If there is no indication of the
pressure, stop the set immediately and check.
5) At this moment, if the engine is working properly, turn off the air switch and then increase the
load gradually. Note that the air switch has a voltage-loss protection device. Never close the
switch before the voltage of the generator reaches the rated pressure (to close it, pull down the
switch handle and close the switch upward).
6) For new engines or those not working for more than 5, turn the crankshaft for 3-5 times before
starting them.
7) For standby engines for emergency use, to enable them to start quickly in emergency, start them
at intervals of 3-5 days during the standby stage.
9.5.4 Check during operation
1) When the engine is working properly, the voltage should be about 400V or 440V-480V, the
current should be no higher than the generator's rated current, the frequency should be about 50Hz
or 60Hz, the water temperature of the gas engine should be no higher than 95℃, the engine oil
temperature no higher than 110℃, and the engine oil pressure within the range of 0.4-0.6MPa. Pay
attention to their changes when the generator set is running. If any specified value is exceeded,
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remove some load or stop and check.
2) Check from time to time all pipes of the gas engine. Make repairs immediately if there is any
damage or leakage.
3) Observe the color of the exhausted air from the gas engine. The exhausted gas is colorless when
the gas engine is running under full load.
4) Allow no water, oil, metal or other impurities to enter into the engine.
5) If the engine is not working normally and required to be powered off or stopped, press the
"ESD"button or pull the "Stop"handle.
6) During the operation of the engine, take records frequently of relevant readings, ambient
temperature, running time and stop time, reasons for stop, and results of inspections or provisional
servicing, etc.
Standard parameters for gas engine during operation:
Normal oil pressure: 4bar—6bar
Normal water temperature: 75℃- 95℃
Normal battery voltage: 24V - 30V
Normal frequency: 50HZ (1500 rpm) Or 60HZ(1800rpm)
Normal line voltage: 400V Or 440V-480V
Normal phase voltage: 230V Or 254V-277V
9.5.5 Idle operation after start
When all are prepared, turn on the gas valve, connect to the starting power supply, press the button
to start the engine. Once the engine is started, pay attention to the engine oil pressure meter and
make sure the pressure is normal. The engine should be operating at an idle speed for a period of
time. During this time, observe the operation of every part of the engine to find whether it is
working properly and there is any abnormal sound, and deal with and solve problems if any. The
idle operation also works to raise the engine temperature, especially in winter. This is necessary
and helpful for the use of the engine.
9.5.6 Normal load output
After ensuring the engine temperature has reached a certain level through observation of the water
temperature during the idle operation, operate the electronic control "throttle" to accelerate the
engine to the rated operating speed, adjust the pressure and frequency of the engine to the rated
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values, then close the switch to output load. To ensure a load is available outside when the switch
is closed, it is recommended to set the no-load speed (frequency) to a little bit high before the
closing. As the load is changing, adapt the "oil volume" control switch, that is, the potentiometer
of the electronic speed governor to meet the required output and ensure stable voltage and
frequency.
9.5.7 Applying the engine in high altitude areas
Due to the difference in applying the engine between high altitude areas and plains, there are some
changes to the performance and application of the engine. Users in the high altitude areas may
refer to the followings in using the engine:
The low air pressure, thin air, low oxygen content and low ambient temperature in high altitude
areas may disable the engine, particularly the naturally aspirated engine, to generate the specified
rated power due to insufficient air input.
Considering the tendency of ignition delay under the high altitude condition, to improve the
operation economy of the engine, increase the ignition advance angle properly.
As the result of higher altitude, reduced power and increased exhaust temperature, users should
take into account the engine's working capacity in high altitude areas in selecting an engine to
avoid overloading the engine.
With the elevation of altitude, the ambient temperature drops compared to that in plains, at about
0.6℃ per 1000m rise in altitude. Together with thin air in high altitude areas, the engine start
performance is worse than in plains. Users should take support measures suitable for
low-temperature start.
9.5.8 Stop steps
1) Before stopping the engine, reduce the load gradually, turn the speed switch to the low-speed
position for idle operation for 10 minutes, then turn off the gas valve to stop the engine and power
it off. Try not to stop the engine suddenly under full load to prevent accidents such as overheating.
2) When the ambient temperature is below 5℃, drain all the water remaining in the water cooler,
circulating water pump, engine oil cooler and engine body in the gas engine cooling system, and
prevent it from freezing. It is unnecessary to drain the water if anti-freezer liquid has been used.
3) If the engine will be stored for a long time, after the last stop, drain the used engine oil from the
engine body and inject the sealing oil instead, and seal the engine after it is running for 2 minutes.
4) Clean the entire set and prepare for the next start and operation.
107
Special Notice
During the production process, major components of the fuel gas generator set may be improved
or modified. Changes that do not affect the product performance are not explained. Therefore, the
description in this manual may differ slightly from the product.
We hope that users can notify us of any problems and give us suggestion so that we can continue
to improve the product quality and offer better services.
108

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Operation Manual of Gas Generator Set

Operation Manual of Gas Generator Set

8.4 Operation Procedure................................................................................................................................ 63

relevant manuals. You are welcomed to provide us your valuable advice.

control panel, which will be described further in this document.

engine oil. Never mix up different types of engine oil.

covered by the warranty.

the gas valve and then start the set.

for a prolonged time.

must be exhausted before the set is started.

from being damaged and protect operators.

Chapter 1 Safety Rules and Precautions of Gas

1.1 —Safety introduction - danger classes

grievous bodily harm.

Notice it indicates information directly or indirectly related to person safety or equipment

1.2 Safety rules

Fuel gas and oil gas are inflammable and explosive.

connected with the engine.

Air exhausted from the engine is fatal.

ventilation system is clear.

Turning parts will cause grievous bodily harm or death.

prevent the generator from unintentional start.

may short circuit electric connections to cause personal shock or burn.

prevent the generator from unintentional start.

Electric shock may result in personal injury or death.

protective cover of electric equipment needs to be opened;

then apply rubber insulating pads on them.

shoes, or wet on skin.

electric circuit without authorization.

☆ Comply with relevant national standards or applicable local protection regulations.

☆ All electric installation operations must be performed by qualified electricians.

misoperation to cause accidents on people and equipment.

Responses to be made when an alarm is heard.

measures to prevent them from being opened accidentally.

☆ Call the fire brigade.

☆ Do not re-enter related areas.

☆ Wait until the fire brigade comes.

☆ Warn others of the danger.

operate the equipment.

understood the related safety regulations and observe such regulations.

☆ Wearing Personal Protection Equipment (PSA)！

when staying beside the engine.

do harm to not only himself but also others.

wear proper personal protection kits.

☆ Assembling operation during maintenance and servicing:

☆ Put up safety shoes, protection suit and gloves!

☆ On site or inaccessible points during installation:

There is a risk of serious injuries to your head caused

by falling, tilting or flying objects, swinging weights

☆ Put up helmet and safety shoes！

☆ High-temperature surfaces and media (engine oil,

cooling water): The surface temperature on the surface

of the engine or pipe can be as high as 150 °C.

☆ Put up thermal insulating gloves and protection suit! JAP

a high temperature and have pressure.

☆ Put up goggles, protection suit and thermal insulating gloves！

☆ Put up mask, goggles, protection suit and gloves！

☆ Put up acid or chemical resistance gloves and

protection suit, goggles and safety shoes. Pay

attention to the manufacturer's instruction！

☆ Working at heights (above 1.2 m): Even falling from

a low height may result in serious injury. To work

aloft (above 1.2m) when fall-arrest system (for

example, guardrail, working platform...) is