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Operation & Maintenance Manual for WP4CD

Series Marine Diesel Gen-set

Weichai Heavy Machinery Co., Ltd.


Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Foreword
Weichai Heavy Machinery Co., Ltd. is China’s appointed manufacturer of various types
of stationary gen-set and marine gen-set.

The manual provides instructions on the installation, operation, maintenance and trouble
shooting of marine gen-set according to the characteristics of WP4CD Series marine diesel
gen-set for user’s safe and reliable operation. Please refer to the Operation Manuals for diesel
engine, power alternator and various special parts in instrument boxes when using this manual,
and operate, service and maintain it in accordance with corresponding requirements.

Along with technical development and product improvement, changes will be made on
this manual accordingly. This manual is subject to revisions and changes from time to time.
Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Contents
CHAPTER I CODE REPRESENTING METHOD .............................................................. - 1 -
CHAPTER II WORKING CONDITIONS ........................................................................... - 1 -
I. RELIABLE WORKING CONDITIONS........................................................................... - 1 -
II. WORKING CONDITIONS FOR GEN-SET TO OUTPUT RATED POWER ............... - 2 -
CHAPTER III TECHNICAL SPECIFICATIONS AND MAIN PARAMETERS ................ - 2 -
I. MAIN TECHNICAL SPECIFICATIONS ......................................................................... - 2 -
II. MAIN ELECTRICAL PERFORMANCE INDICATORS ............................................... - 2 -
III. GEN-SET PROTECTION PARAMETERS ................................................................... - 3 -
IV.OVERALL DIMENSIONS OF GEN-SET ................................................................... - 4 -
V. GEN-SET OUTLINE DRAWING.................................................................................... - 4 -
CHAPTER IV OVERVIEW OF MAIN STRUCTURES ..................................................... - 6 -
I. DIESEL ENGINE .......................................................................................................... - 6 -
II. ALTERNATOR ................................................................................................................. - 7 -
III. INSTRUMENT BOX ...................................................................................................... - 8 -
IV. SOLID BASE FRAME ................................................................................................... - 8 -
CHAPTER V STORAGE AND INSTALLATION ............................................................... - 8 -
I. STORAGE ......................................................................................................................... - 8 -
II. UNPACKING ACCEPTANCE ........................................................................................ - 8 -
III. LIFTING & HANDLING ....................................................................................... - 9 -
IV. INSTALLATION ............................................................................................................. - 9 -
1. Installation of gen-set external pipes ................................................................................. - 9 -
2. Installation of vent-pipe .................................................................................................. - 10 -
3. Installation of fuel pipes ...................................................................................................- 11 -
4. Installation of cooling pipes ............................................................................................ - 12 -
5.Installation of starting system ....................................................................................... - 13 -
6. Other requirements .......................................................................................................... - 13 -
CHAPTER VI ELECTRICAL SYSTEM OF GEN-SET .................................................... - 14 -
I. INSTRUMENT BOX ...................................................................................................... - 14 -
1. Local ordinary instrument box ........................................................................................ - 14 -
2. Local self-starting instrument box................................................................................... - 18 -
Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

3. New style local ordinary instrument box ........................................................................ - 22 -


4. New style local self-starting instrument box ................................................................... - 26 -
5. Onboard instrument ......................................................................................................... - 30 -
6. Accelerator servo mechanism.......................................................................................... - 33 -
II. ALTERNATOR ............................................................................................................... - 35 -
CHAPTER VII OPERATION ............................................................................................. - 36 -
I. PREPARATION ............................................................................................................... - 36 -
II. COMMISSIONING........................................................................................................ - 36 -
CHAPTER VIII PARALLEL OPERATION ....................................................................... - 38 -
I. CONDITIONS FOR PARALLEL OPERATION ............................................................ - 38 -
II. METHODS ..................................................................................................................... - 38 -
III. LOAD TRANSFER IN PARALLEL ............................................................................ - 39 -
IV. DISCONNECTION OF PARALLEL GEN-SET ..................................................... - 39 -
CHAPTER IX PRECAUTIONS ......................................................................................... - 40 -
CHAPTER X ANALYSIS OF COMMON FAULTS AND TROUBLESHOOTING ........ - 41 -
CHAPTER XI RULES FOR SAFE OPERATION ............................................................. - 42 -
CHAPTER XII SERVICING AND MAINTENANCE ...................................................... - 42 -
ANNEX I: LIST OF TOOLS DELIVERED WITH GEN-SET (EX-FACTORY STANDARD
CONFIGURATION) ........................................................................................................... - 45 -
ANNEX II: LIST OF SPARE PARTS DELIVERED WITH ALTERNATOR UNIT
(EX-FACTORY STANDARD CONFIGURATION) .......................................................... - 46 -
Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Chapter I Code Representing Method

CCF × ×

Factory design code, represented in capital letters


ranging from A to Z

Code of navigation zone applicable to gen-set , W for


unlimited navigation zone and Y for limited navigation zone

Gen-set classification code, J for basic type, Z for


automatic type and Z for emergency type

Gen-set rated power code representing in kW

Current classification code, J for AC and Z for DC

Marine diesel gen-set code

Chapter II Working Conditions

I. Reliable working conditions

Gen-set can operate reliably under following conditions:

Table 2-1 Working Conditions

1 Ambient temperature 45C


Outboard water 32C (Outboard water temperature of gen-set in limited navigating zone
2
temperature and under corresponding conditions shall be 25C.)
3 Relative air humidity 60%
4 Absolute atmosphere 100kPa
5 Transverse inclination 15°(22.5° for emergency gen-set and inland vessel)
Longitudinal
6 7.5° (10° for emergency gen-set and inland vessel)
inclination
7 Rolling 22.5°
8 Pitching 10°
9 Able to bear the vibration and shock generated during normal sailing.
10 Having salt fog, mould, oil mist, condensing fog, damp air.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

II. Working conditions for gen-set to output rated power

Gen-set should be able to continuously output rated power under following working
conditions:

a For gen-set in unlimited navigating zone: ambient temperature 45C, primary cooling
water temperature 32C, relative humidity 60%;

b For gen-set in limited navigating zone and under corresponding conditions: ambient
temperature 40C, primary cooling water temperature 25℃, relative humidity 60%.

Chapter III Technical Specifications and Main Parameters

I. Main technical specifications

Table 3-1 Main technical specifications

Serial No. Items Contents


1 Mode of gen-set CCFJ50J-W* CCFJ64J-W* CCFJ75J-W*

2 Diesel engine mode WP4CD66E200 WP4CD100E200

3 Rated power(kW) 50 64 75

4 Rated voltage (V) 400/230


5 Rated frequency (Hz) 50Hz
6 Rated current (A) 90 115 135

7 Rated power factor 0.8 (lagging)


8 Rated speed (r/min) 1500r/min
9 Starting mode Electric motor
10 Speed regulating mode Electric speed regulation/mechanical speed regulation
11 Exciting mode Brushless self-excitation
12 Voltage regulating mode Automatic
13 Wiring mode Three-phase four-wire Y-connection
14 Cooling method Opening type bi-circulating water cooling
15 Remarks 60 Hz diesel gen-set can be used as required by the customer

II. Main electrical performance indicators

Table 3-2 Main electrical performance indicators

Serial Items Electrical indicators

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

No.
Steady-state voltage regulation
1 ±2.5% (for emergency gen-set ±3.5%)
factor
2 Transient voltage regulation factor -15% transient voltage regulation factor +20%
3 Voltage stabilization time 1.5s
4 Voltage fluctuation ratio ±1%
5 No-load voltage setting range ≥±5% rated voltage
Electronic speed regulation 3%/(mechanical speed
6 Steady-state speed regulation factor
regulation 5%)
7 Transient speed regulation factor ±10%
8 Stabilization time 5S
9 Speed fluctuation ratio ±0.5%
110% rated load operating for 1 hour is allowed by gen-set continuously running for each 12
10
hours
Two gen-sets can maintain long-term stable parallel operation. It can maintain stable operation
and steadily transfer active power and reactive power when the load varies within 20%-100% of
11 total rated power against rated power factors; the active power sharing unbalance is not greater
than 15% of alternator’s rated power and reactive power sharing unbalance is greater than 10% of
alternator’s rated reactive power.

III. Gen-set protection parameters

Table 3-3 Gen-set protection parameters

Serial
Alarm description Alarm value Remarks
No.
1 Speed is high 110% rated speed Alarming
2 Oil pressure is low 0.15±0.02Mpa Alarming
3 Water temperature is high 95+3C Alarming
4 Oil temperature is high 120+3C Alarming
5 Speed is too high 115% rated speed Alarming and shutdown
6 Oil pressure is too low 0.12±0.02Mpa Alarming and shutdown
7 Storage battery voltage is low <19V Alarming
Alarming, and fuel leakage
8 Fuel leakage alarm (optional)
alarm apparatus required

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

IV.Overall dimensions of gen-set

Table 3-4 Overall dimensions of gen-set

Gen-set Model L*W*H (mm) Weight (kg)


CCFJ40J-WF 1700×904×1212 1070
CCFJ40J-WJ 1700×904×1212 945
CCFJ40J-W* CCFJ40J-WV 1700×904×1212 950
CCFJ40J-WR 1700×904×1212 928
CCFJ40J-WZ 1700×904×1212 955
CCFJ50J-WF 1700×904×1212 1070
CCFJ50J-WJ 1700×904×1212 945
CCFJ50J-W* CCFJ50J-WV 1700×904×1212 950
CCFJ50J-WR 1700×904×1212 928
CCFJ50J-WZ 1700×904×1212 1005
CCFJ64J-WF 1700×915×1212 1170
CCFJ64J-WJ 1700×915×1212 1052
CCFJ64J-W* CCFJ64J-WV 1700×915×1212 1105
CCFJ64J-WR 1700×915×1212 1093
CCFJ64J-WZ 1700×915×1212 1135
CCFJ75J-WF 1700×915×1212 1200
CCFJ75J-WJ 1700×915×1212 1096
CCFJ75J-W* CCFJ75J-WV 1700×915×1212 1125
CCFJ75J-WR 1700×915×1212 1149
CCFJ75J-WZ 1700×915×1212 1140

Note: “*”in “W*” represents the alternator to be used for the diesel gen-set. “*” can be
replaced by F, J, V, R, Z, among which, F represents LD alternator, J represents Marathon
alternator, V represents Stanford alternator, R represents Kangfu alternator (formerly known
as Sanbo alternator) and Z represents Wuxi Siemens alternator.

V. Gen-set outline drawing

Outline drawing examples of CCFJ50J-W*/CCFJ64J- W*/ CCFJ75J- W*marine diesel


gen-set (standard configuration: equipped with ordinary instrument box) are as shown in
Figure 3-1, Figure 3-2, Figure 3-3, Figure3-4 and Figure 3-5 (relevant drawings of other
configurations can also be provided according to customer’s requirements):

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 3-1 Front view Figure 3-2 Left view

Figure 3-3 Rear view Figure 3-4 Right view

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 3-5 Top view

Chapter IV Overview of main structures

I. Diesel engine

Diesel engine is the power source of gen-set and this unit adopts Weichai WP4CD series
alternator (please refer to Operation and Maintenance Manual for WP4CD Series Gas
Alternator for detailed structure principles). Main technical specifications of the diesel engine
are shown in Table 4-1:

Table 4-1 Main technical specifications of diesel engine

Serial Model
WP4CD66E200 WP4CD100E200
No. Items
In-line, four-stroke, water cooling, direct
1 Model
injection, pressurization, intercooling
2 Number of cylinders 4
3 Cylinder diameter/stroke mm/mm 105/130
Rotation of crankshaft (towards the end of
4 Anticlockwise
flywheel)
5 Declared speed r/min 1500
6 Declared power kW 60 90
7 Piston total displacement L 4.5
8 Compression ratio 18:1
9 Start-up mode Electrical starting
10 Electric motor starting power kW 6

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

11 Starting battery capacity Ah 100Ah*2


2
12 Starting cable mm 50(mm2)
Fuel consumption under rated conditions
13 200±5%
g/kW.h
14 Fuel type Domestic 0# or -10# light diesel oil (GB252)
15 Fuel system Mechanical /electrical pump
16 Engine oil grade CF or above
17 Maximum oil volume of oil pan L 10
18 Inlet air flow under rated condition kg/h 429
19 Exhaust back pressure kPa ≤6
20 Exhaust flow under rated conditions 303
21 Exhaust temperature before turbine C ≤700
22 Exhaust temperature after turbine C 550+3(T-25) T --intake temperature
(standard configuration) sea water pump flow
23 316
L/min
24 (standard configuration) sea water pump lift 15

Note: this table mainly describes relevant parameters of WP4CD Series 1500r/min
marine diesel engine. For this series, 1800r/min diesel engine can be used for 40-75kW/60Hz
and below gen-set if required by the customer.

II. Alternator

Alternator is a kind of equipment which is able to convert mechanical energy into


electric energy. Please refer to alternator manual for detailed structure principles. Main
technical specifications are shown in Table 4-2:

Table 4-2 Main technical specifications

Serial No. Item Value Remarks


1 Rated voltage V 400
2 Rated frequency 50
3 Rated power factor cosφ 0.8 (legging)
4 Rated current A I=1.804P
5 Insulation grade F/H
6 Protection level IP23
7 Exciting mode Brushless self-excitation
8 Outgoing line Three-phase Y-connection
9 Bearing type Rolling bearing

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

10 Radio interference level Level N


11 Anti-condensation heater 220V
In the left (seeing from diesel engine to
12 Stuffing box outlet direction
alternator)
Steady-state short circuit
13 3-5times rated current, duration 5s
current
14 Over-current features 1.5 times rated current, last for 2 min
15 Cooling method Self-ventilation

Note: alternators operating at other voltage levels and with 1800r/min speed
(corresponding rated frequency 60 Hz) may be selected as required by the customer.

III. Instrument box

Please refer to “Instrument box” in “Chapter VI Electric System of Alternator Unit” for
detailed structure functions.

IV. Solid base frame

The common chassisshall be made from bent steel plate.

Chapter V Storage and Installation


I. Storage

Storage yard shall be well ventilated with no acid gas, alkaline gas and other corrosive
gases and protected from the sun and rain. The factory guarantees that gen-set can be stored
for half a year after delivery, in case of more than half a year, proper treatment measures shall
be taken, such as alternator winding insulation measurement, moisture removal as the case
may be.

II. Unpacking acceptance

Unpacking method: remove connections between packing case housing and the bottom
of packing case and use lifting tools to open the case. Note: a person shall be assigned to
support the packing case housing with hand during lifting to protect exposed parts of gen-set
from being damaged by packing case housing. Generally, gen-set shall undergo unpacking
acceptance after arriving in delivery destination. Acceptance method and personnel shall be in
accordance with contract specifications. As the basis of acceptance, “packing list” shall be put
in same document pocket with other documents to be provided with the unit.

Basic acceptance items are:

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Appearance inspection: check whether exposed parts are damaged by visual inspection
or whether there is collision, deformation and other abnormal phenomena and make records;

 Check accompanying documents according to the list of accompanying documents


and make records;

 Check the spare parts according to the “list of accompanying spare parts” and make
records;

 Check accompanying tools according to the “list of accompanying tools” and make
records.

 In case that gen-set has any damages in appearance and accompanying spare parts,
attachment, documents and tools are inconsistent with the list. The consigner and
carrier shall be informed within 24 hours by fax or telephone after acceptance for
claims.

III. Lifting & handling

Steel wire rope shall have enough strength, and carrying capacity of lifting tools shall
meet safety specifications. Each steel wire rope shall be in the same length to avoid tilting
during lifting.

Steel wire rope shall be attached onto the lifting position of gen-set packing case base.

When bare machine is lifted, steel wire rope shall be attached onto the lifting position of
the common chassisof the generating unit. Contact between steel wire rope and other gen-set
components shall be prohibited, if not, separate them with a board. Cover lifting shall be
stopped if contact parts are small or non-bearing parts, and try again after changing the length
of rope or adding support to change force bearing point. Please contact us for any questions.

IV. Installation

1. Installation of gen-set external pipes

Installation of various gen-set pipes shall abide by following rules:

 External pipes and gen-set shall be connected by flexible hose.

 Sharp turn shall be avoided on the pipe line, and bend & tee shall be avoided in most
cases.

 For the convenience of maintenance, valves shall be installed in proper position.

 Pipes shall be reliably secured on the support. Measures should be taken to relieve

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

stress generated by expansion and contraction of pipelines.

 After the completion of gen-set installation, oil supply and water supply can only be
allowed after pipes are totally cleaned. Test run shall be carried out for checking
whether various pipes meet relevant requirements, pipeline pressure drop is too large,
pump drive capability is enough and cooling water flow meets operating
requirements. Otherwise, pipes in larger size shall be used.

2. Installation of vent-pipe

(1) Installation of vent-pipe shall abide by following rules:

a. Vent-pipe dead-weight shall be reliably supported, and it is strictly prohibited to use


supercharger to bear vent-pipe weight. Generally, fixed support shall be located 1m away
from expansion joint to prevent stress generated by vent-pipe gravity, thermal expansion or
transversal displacement from being transferred to supercharger. Diesel supercharger shall be
provided with precise bearing and impeller and has high speed. In case that supercharger
exhaust flange bears too much bending moment, supercharger shaft will be deformed and
normal operation of supercharger is disturbed with noise which finally leads to the damage of
supercharger.

b. External vent-pipe shall be made from steel tube without too many turns and shall be
fixed tightly on ship body with no vibrations. Its weight shall not be applied on diesel
expansion pipe. Exhaust back pressure of diesel engine shall be not greater than 6kPa after the
completion of exhaust system installation. Otherwise, diesel engine performance will be
affected. As diesel vent-pipe surface temperature is high during operation, vent-pipe shall be
kept away from flammable objects to avoid worker scald. Thermal insulation apparatus shall
be mounted on the surface of external exhaust pipes.

c. Exhaust silencer shall be installed on the end of vent-pipe to reduce influence of


exhaust noise.

d. There is vapor generated in the process of diesel oil burning, therefore, condensate
water drain valve shall be installed on vent-pipe to discharge condensate water in vent-pipe.
Condensate water drain valve shall be located as low as possible on the pipe close to diesel
engine.

(2) Diffuser pipe and vent-pipe diameter

The size of the bellow expansion joint provided by the manufacturer is not exactly the
same as the diameter of vent-pipe. Sometimes, a 500-800mm long diffuser pipe with
increasing diameter is needed, which is also used as a connector to reduce airflow resistance.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Diffuser pipe can be made from 3-5mm sheet steel.

(3) Exhaust silencer

Exhaust noise is generated when diesel combustion emission is discharged from exhaust
valve to vent-pipe, which always causes exhaust gas vibration and pressure wave. Pressure
wave is the mixture of many waves of different lengths and amplitudes. These wave lengths
(frequency) and amplitudes (loudness) are all within the recognizable range of human ear.

Exhaust silencer can consume and absorb the energy of pressure wave to reduce pressure
wave amplitude of exhaust gas discharged from exhaust silencer. Most diesel exhaust silencer
reduces acoustics energy by reflecting the pressure wave. Generally, increase of silencer
dimension will improve noise reduction effect. If there is limitation on silencer dimension,
increase of silencer decay degree will result in increase of exhaust resistance. Therefore,
proper silencer shall be selected according to the resistance of exhaust system.

Exhaust silencer is not covered in standard supply scope. The user can purchase in the
market or order from us.

3. Installation of fuel pipes

Installation of fuel pipes shall abide by following rules:

a. Volume of fuel tank for everyday use can keep gen-set continuously running for at
least 8h.

b. Oil tank shall be made aluminum sheet, phosphatization steel plate, and reinforced
plastic plate instead of galvanized steel plate.

c. Contact between oil return pipe and high temperature components (such as vent-pipe,
turbocharger, exhaust gas return pipe) of diesel engine shall be avoided during installation.
Throttling area is not allowed in oil return pipe. Return pipe shall not contact with sharp edges,
be bended with sharp corners or distorted. Improper installation of return pipe will lead to fuel
leakage on alternator. Fuel return pipe shall be connected to fuel tank with returned oil
flowing along with the tank wall to reduce eddying flow. The return oil of WP4CD series
diesel engine is internal return oil passed through cylinder head (Figure 5-1). Oil injector
mounting hole in cylinder head can ensure that return oil can be fully sealed.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Injector oil O-ring sealing


return hole oil return

Seal ring

Internal oil return through


cylinder head

Figure 5-1 Oil return method

d. Diesel engine inlet and outlet fuel pipe shall be equipped with stop valve for the
convenience of maintenance.

4. Installation of cooling pipes

Proper installation of cooling system plays an important part in diesel engine service life
and performance. Please read the operating principles and installation precautions of cooling
system to ensure the design and installation of gen-set external pipes meet following
requirements:

(1) Diameter of inlet and outlet pipes shall meet relevant requirements of gen-set.
Large diameter pipes shall be used when too many lengthy pipelines are required. Excessive
resistance of pipeline system will lead to insufficient flow of cooling water; therefore, the
diesel engine is lack of sufficient cooling water which causes abnormal operation of the diesel
engine. Elbows and tees shall be minimized.

(2) Pump suction pipe shall be as short as possible to guarantee that pump water inlet
pressure is greater than atmospheric pressure (i.e. positive pressure). Negative pressure will
cause pump gas etching and insufficient cooling water flow which cause abnormal operation
of pump.

(3) Pipeline system must be equipped with exhaust apparatus to discharge air in pipeline.

(4) Purchase a new pump when the lift of the pump supplied with the unit can not satisfy
pipeline lift requirement.

(5) Preservative must be added to cooling water in closed cooling system. Filter screen
shall be mounted on water suction pipe mouth in open type cooling system to protect
intercooler and oil/water cooler from being blocked by dirts.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Box-type fresh water Fresh water filler


heat exchanger

Diesel engine effluent


Thermostat

Small circulation

Sea water inlet

Sea water outlet

Diesel engine

Intercooler
Fresh water
pump
Diesel engine intake

Figure 5-2 Circulating cooling system diagram

5.Installation of starting system

Sectional area of cables (multi-core copper flexible cable) between starting engine and the
battery shall be not less than 70mm² and the length shall not exceed 1.5m. Our standard
marine diesel gen-sets are all equipped with starting battery cable.

6. Other requirements

a. A 1m maintenance space shall be reserved around gen-set.

b. Foundation of gen-set shall be firm and has no deformation during installation and
operation of gen-set. During installation, level gauge shall be used to measure the levelness of
foundation installation surface which should be leveled up with flat gasket to ensure that the
gen-set can be placed horizontally. Gen-set shall be fixed with foundation bolt and its classis
undersurface shall be in good contact with the ground during installation, in case of gaps, use
thin iron sheet to level them up to guarantee the concentricity of diesel engine and alternator
axial lead.

c. Diesel vent-pipe shall extend outboard to facilitate ventilation, and vent-pipe bending

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

angle shall be not less than 90° without too many bends. Inner diameter of external vent-pipe
shall not be less that the inner diameter stipulated in Diesel Engine Operation and
Maintenance Manual. Vent-pipe shall not be too long and satisfy fire protection requirements.
Vent-pipe and the diesel engine shall be in flexible connection instead of rigid coupling. Water
drain valve shall be installed at the lowest position of vent-pipe in order to guarantee the
smooth discharge of condensate water in vent-pipe. For other requirements, follow the Diesel
Engine Operation and Maintenance Manual.

d. The cabin shall be equipped with intake channel and exhaust channel. There shall be no
obstacles obviously hindering the airflow.

e. If ambient environment of gen-set in the winter is lower than 0C, anti-freezing solution
shall be added into gen-set cooling system.

f. Fuel tank separate from gen-set shall be 0.5m above the ground.

g. Sectional area of gen-set major loop connecting cable shall meet relevant current
requirements.

h. Gen-set must be equipped with ground lead and reliably grounded.

Chapter VI Electrical system of Gen-set

I. Instrument box

Please refer to Operation Manual for Diesel Engine Monitoring and Control Instrument
delivered with gen-set for main operation and maintenance instructions for instrument box.
Brief introduction to several common instrument boxes is hereunder provided. We can also
produce special instrument boxes according to customer’s special requirements.

1. Local ordinary instrument box

Local ordinary instrument box of WP4CD Series marine diesel gen-set is a


microcomputer-controlled full-automatic electronic measurement and control system for the
diesel engine and alternator which precisely detects and displays diesel engine speed, oil
pressure, water temperature, oil temperature, pressure and other parameters, and monitors all
detected parameters to send out audible alarm, visual alarm, remote alarm and other signals in
real time. In addition, it is provided with starting and stopping functions. So it will send out
shutdown signal when the parameter exceeds shutdown limit. Meanwhile, remote displayer or
diesel engine remote display instrument can also be used to realize remote monitoring and

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

control of diesel operating parameters. There are several indicators on instrument box which
can display the operating status and functional status of gen-set in real time. Instrument box is
characterized by advanced design, high measurement precision, reliable operation, small size,
digital display, precise and clear display, and easy installation.

Figure 6-1 Standard ordinary local instrument panel

6-1 Local ordinary instrument panel

(1) Operating function

Table 6-1 Local ordinary instrument function

Serial
Name Function description
No.
1 Power switch Turn on this switch to power on the instrument box.
Local/remote
2 Selection of diesel control position.
control
Instrument box will send out signals to start the diesel engine by pressing this
3 Starting
button.
When the switch is in “rated” position, diesel engine runs in high speed;
4 Idling/rated
When the switch is in “idling” position, diesel engine runs in low speed.
Instrument box will send out shutdown signal to shutdown the diesel engine
5 Shutdown
forcefully by pressing this button.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

When diesel engine shutdown and emergency shutdown functions are used,
this button has self-locking function. Press this button to close fuel magnetic
Emergency
6 valve and shut down the diesel engine forcefully. Press this button again after
shutdown
the diesel engine is completely stopped to open fuel magnetic valve for next
starting.
Speed fine
7 Diesel speed fine adjustment
adjustment
Press this button when there is no rotation, various channels of instrument box
will simulate external changing conditions to carry out self-inspection items
8 Self-inspection one by one. Instrument box will send out audible and visual alarm signal when
alarm setting value is reached, and instrument box will send out automatic
stopping signal when stopping setting value is reached.
Press this button when there is alarm signal, and the audible alarm will be
9 Silencer
turned off and alarm light keeps shining and stop blinking.
Press this button, and speed display window shows the accumulative running
10 Timekeeping
time of diesel engine. Speed will be displayed after 5 sec.
11 Reset Press this button to reset instrument box

Please refer to accompanying document Operation Manual for Diesel Engine


Monitoring and Control Instrument for more function descriptions and usage information.

(2) Local ordinary instrument box alarm protection function

Table 6-2 Local ordinary instrument box alarm protection function

Serial
Alarm description Alarm value Remarks
No.
110% rated
1 Speed is high Audible and visual alarm
speed
2 Oil pressure is low 0.15±0.02Mpa Audible and visual alarm
Water temperature is
3 95+3C Audible and visual alarm
high
4 Oil temperature is high 120+3C Audible and visual alarm
115% rated
5 Speed is too high Audible and visual alarm and shutdown
speed
6 Oil pressure is too low 0.120.02Mpa Audible and visual alarm and shutdown
7 Battery voltage is low <19V Audible and visual alarm
Fuel leakage alarm Audible and visual alarm; fuel leakage alarm
8
(optional) apparatus is required

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

(3) Local ordinary instrument wiring diagram

Microcomputer self-starting controller


Stop Stop when
Alarm Alarm Alarm when Alarm Battery Stop when
when oil undervolta Fuel when oil water Stop Successful Rated
when speed when oil water speed is
pressure temperatur indication starting speed
pressure is temperature temperatur ge leakage high
is high low is high e is high is low e is high

Relay board

Alarm Alarm Alarm when Alarm Battery Fuel Stop when Stop Stop when Stop Successful Rated
when speed when oil water when oil undervolta speed is when oil water
pressure is temperature temperatur leakage indication starting speed
is high low is high e is high ge high pressure temperatur
is low e is high

Shunt passive alarm contact, contact to central control room

Figure 6-2 a) Local ordinary instrument wiring diagram

Wiring diagram
Control position signal output

Remote starting
Diesel operation signal output

Remote high/low speed control

Remote emergency
Comprehensive alarm output

Remote shutdown
Fuel leakage alarm input
Outage magnetic valve
pneumatic starting
Double output during
Power supply-
Power supply+
Onboard alternator
Excitation voltage
Starting motor

Figure 6-2 b) Local ordinary instrument wiring diagram

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

2. Local self-starting instrument box

Local self-starting instrument box (hereinafter referred to as instrument box) of WP4CD


Series marine diesel gen-set is a microcomputer-controlled full-automatic electronic
measurement and control system. The whole system has functions of distribution panel loss of
power status monitoring, automatic starting of diesel engine, automatic monitoring and
measurement of working conditions, output of diesel alternator automatic switching on and
tripping signals, automatic stop, limit protection and other basic monitoring and control
functions. Control of speed-up and speed-down, preheating of cooling water and lubricating
oil and electronic speed regulating control can also be configured for the diesel engine on the
basis of basic functional configuration. Meanwhile, remote display or diesel remote display
instrument can also be configured to perform remote monitoring and control of diesel
operating parameters. There are various indicators on instrument box which displays gen-set
operating status and functional status in real time. In addition, many ways are available for the
communication between instrument box and cabin distribution panel to realize remote control
of the operation, remote monitoring and measurement, remote RS485 communication so as to
form a highly automatic marine diesel generating station.

Figure 6-3 shows standard local self-starting instrument box operation panel

Figure 6-3 Self-starting instrument panel

(1) Operation function

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Table 6-3 lists the operation functions of local self-starting instrument

Table 6-3 Operation functions of local self-starting instrument

Serial
Name Function description
No.
1 Power switch Turn on this switch to power on the instrument box.
Local operation can be performed when the switch is in “manual”
Manual/ position.
2 automatic Gen-set is in standby status when the switch is in “automatic” position
switching to automatically supply power for startup or stop power supply for
shutdown according to instructions from switch panel.
Self-starting instrument box will send out signals to start the diesel
3 Starting
engine by pressing this button.
When the switch is in “rated” position, diesel engine runs in high
speed;
4 Idling/rated
When the switch is on “idling” position, diesel engine runs in low
speed.
5 Shutdown Press this button to stop the diesel engine forcefully.
Operator can manually shut down the diesel engine in emergency
cases by pressing this button. Actuator can be controlled manually to
Emergency
6 cut down the fuel pipe by this button so as to shut down the diesel
shutdown
engine and open the main switch of gen-set forcefully.

Speed up/speed
7 Diesel engine speed fine adjustment
down
Voltage fine
8 Alternator voltage fine adjustment
adjustment
When gen-set is in standby status, open this switch and the heater
9 Heating switch works after being charged. When diesel engine is started or in
operation, the heater will be automatically switched off and stop work.
Press this button when there is no rotation, self-starting instrument
box will simulate external changing conditions to carry out
self-inspection items one by one. Audible and visual alarm signal will
10 Self-inspection
be sent out when alarm setting value is reached and automatic
stopping signal will be sent out when stopping setting value is
reached.
Instrument box can send out audile and visual alarm signals when
11 Silencer
diesel engine working condition is out of limit or the diesel engine

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

fails to start for three times, and relevant alarm indicators on the panel
twinkles; meanwhile digital display window corresponding to digital
displayer twinkles. Press “Silencer” button, and audible alarm will be
turned off and alarm light keeps shining and stop blinking until the
operation returns to normal conditions.
Press this button, and speed display window shows the accumulative
12 Timekeeping
running time of diesel engine. Speed will be displayed after 5 sec.
In case that diesel engine fails to start for three times and stops
because limit protection is triggered, it represents that the diesel
engine is faulty and needs to be repaired. In case that gen-set is to be
13 Reset
started after troubleshooting, press “reset” button to notify the
instrument box that the fault is eliminated. At this time, controller will
cancel alarm signal and put gen-set into operation again.

Please refer to accompanying document Operation Manual for Diesel Engine


Monitoring and Control Instrument for more function descriptions and usage information.

(2) Alarm protection function

Table 6-4 Self-starting instrument alarm function

Serial Alarm description Alarm value Remarks


No.
1 Speed is high 110% rated Audible and visual alarm
speed
2 Oil pressure is low 0.15 ± Audible and visual alarm
0.02Mpa
3 Water temperature is 95+3C Audible and visual alarm
high
4 Oil temperature is high 120+3C Audible and visual alarm
5 Speed is high 115% rated Audible and visual alarm and shutdown
speed
6 Oil pressure is low 0.12 ± Audible and visual alarm and shutdown
0.02Mpa
7 Battery voltage is low <19V Audible and visual alarm
8 Starting fails three Audible and visual alarm
times
9 Fuel leakage alarm Audible and visual alarm, and fuel leakage alarm
(optional) apparatus is required

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

(3) Local self-starting instrument box wiring diagram

Microcomputer self-starting controller


Alarm when Alarm when Alarm when Alarm when
Water Oil water oil Fuel Failure Battery
Oil speed is high oil pressure is temperature
Speed temperature temperature pressure low is high
temperature
is high leakage starting undervoltage

Remote control 10-core aviation plug

Remote control 5-core aviation plug

Water Oil Oil


Speed
sensor
temperature temperature
sensor sensor
pressure
sensor
Relay board

Alarm Alarm Alarm Alarm when Alarm when


Fuel Failure Battery
when oil when oil water oil
when speed temperature
pressure is pressure is temperature is leakage starting undervoltage
is high low low high
is high

Figure 6-4 a) local self-starting instrument box wiring diagram

Figure 6-4 b) local self-starting instrument box wiring diagram

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 6-4 c) local self-starting instrument box wiring diagram

3. New style local ordinary instrument box

On the basis of original WP4CD marine diesel gen-set local ordinary instrument panel,
our company has launched new style local ordinary instrument box by optimizing instrument
box components and parts, its functions and redesigning appearance. New instrument box has
more beautiful appearance, firm installation, reasonable functional design, beautiful wiring
layout and convenient plug connectors. Instrument box is a microcomputer-controlled
full-automatic electronic measurement and control system of diesel engine and gen-set which
precisely detects and displays diesel engine speed, oil pressure, water temperature, oil
temperature, water pressure and other parameters and monitors all detected parameters
according to user’s settings and sends out audible alarm, visual alarm, remote alarm and other
signals. If there is a stop setting, it will send out shutdown signal when the parameter exceeds
shutdown value. Meanwhile, remote displayer or diesel engine remote control display
instrument can also be provided to realize remote monitoring and control of diesel engine
operating parameters. There are several indicators on instrument box which can display the
operating status and functional status of gen-set in real time. Diesel engine instrument box
also has diesel engine running time accumulation function. It can also provide extended
alarms, diesel engine operating parameter and computer data communication functions
according to user’s special requirements.

Figure 6-5 standard new style ordinary local instrument panel

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 6-5 New style local ordinary instrument panel

(1) Operation function

Table 6-5 New style local ordinary instrument function

Serial
Name Function description
No.
1 Power switch Turn on this switch to power on instrument box.
Local/ remote
2 Selection of diesel engine control position.
control
Instrument box will send out signals to start the diesel engine by pressing this
3 Starting
button.
When the switch is in “rated” position, diesel engine runs in high speed;
4 Idling/rated
When the switch is in “idling” position, diesel engine runs in low speed.
Instrument box will send out shutdown signal to shutdown the diesel engine
5 Shutdown
forcefully by pressing this button.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

When diesel shutdown and emergency shutdown functions are used, this button
Emergency has self-locking function. Press this button to close fuel magnetic valve and
6
shutdown close the diesel engine forcefully. Press this button again after the diesel is
completely stopped to open fuel magnetic valve for next starting.
Speed fine
7 Diesel speed fine adjustment
adjustment
Press this button when there is no rotation, various channels of instrument box
will simulate external changing conditions to carry out self-inspection items
8 Self-inspection one by one. Instrument box will send out audible and visual alarm signal when
alarm setting value is reached and instrument box will send out automatic
stopping signal when stopping setting value is reached.
Press this button when there is alarm signal, and the audible alarm will be
9 Silencer
turned off and alarm light keeps shining and stop blinking.
Press this button, and speed display window displays the diesel accumulative
10 Timekeeping
running time. Speed will be displayed after 5 sec.
11 reset Press this button to reset the instrument box.

Please refer to accompanying document Operation Manual for Diesel Engine Monitoring
and Control Instrument for more function descriptions and usage information.

(2)New style local ordinary instrument box alarm protection function

Table 6-6 new style local ordinary instrument alarm protection function

Serial
Alarm descriptions Alarm value Remarks
No.
110% rated
1 Speed is high Audible and visual alarming
speed
0.15 ±
2 Oil pressure is low Audible and visual alarming
0.02Mpa
Water temperature is
3 95+3℃ Audible and visual alarming
high
4 Oil temperature is high 120+3℃ Audible and visual alarming
115% rated
5 Speed is too high Audible and visual alarming and shutdown
speed
Oil pressure is too 0.12 ±
6 Audible and visual alarming and shutdown
low 0.02Mpa
Storage battery voltage
7 <19V Audible and visual alarming
is low

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

8 Water pressure is low 0.01MPa Audible and visual alarming


Fuel leakage alarm Audible and visual alarm, and fuel leakage alarm
9
(optional) apparatus is required
10 Main power source fails Audible and visual alarming
Auxiliary power source
11 Audible and visual alarming
fails

(3) New style local ordinary instrument wiring diagram

Figure 6-6 a) New style local ordinary instrument wiring diagram

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 6-6 b) New style local ordinary instrument wiring diagram

4. New style local self-starting instrument box

On the basis of original WP4CD marine diesel gen-set local ordinary instrument panel,
our company has launched new style local ordinary instrument box by optimizing instrument
box components and parts, its functions and redesigning appearance. New instrument box has
more beautiful appearance, firm installation, reasonable functional design, beautiful wiring
layout and convenient plug connectors. Marine diesel alternator new style local self-starting
instrument box (hereinafter referred to as instrument box) is a full-automatic alternator
working condition electronic monitoring and control system, which is controlled by a control
system consisting of GEC16W monitoring display module and GEC8000-K1 safety
protection module. GEC16W monitoring display module has a large LCD which has CAN
communication interface and displays alternator speed, oil pressure, water temperature, oil
temperature and other parameters. Meanwhile, it can also detect battery voltage, alternator
accumulative operating time and other parameters; monitor and display all detected
parameters in real time. When there is alarm signal detected in control box, it will send out
audible and visual alarm signals; when fault shutdown signal is detected (for example
over-speed shutdown), control box will output shutdown control signal automatically to stop
the alternator. Control box system can be used to perform automatic starting and automatic
shutdown operations. Meanwhile, remote displayer or diesel engine remote control display
instrument can be used to perform remote monitoring and control of diesel engine remote
display instrument.

Figure 6-7 shows the new style local self-starting instrument box operation panel

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 6-7 new style local self-starting instrument panel

(1) Operation function

Table 6-7 shows the operation functions of new style local self-starting instrument

Table 6-7 Operation functions of new style local self-starting instrument

Serial
Name Function description
No.
1 Power switch Open this switch to power on the instrument.

Local/remote/automatic
2 Selection of “remote”, “local” and “automatic” control mode
control

Alternator oil/water heater control switch. Such change-over


3 Heating switch switch shall be in “off” position during normal condition;
change-over switch shall be in “on” position when oil water

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

heater indicator light is on.


When the switch is in “rated” position, diesel engine runs in
high speed;
4 Idling/rated
When the switch is in “idling” position, diesel engine runs in
low speed.
Starting of standby device This button can be used for emergency start when GEC 16W
5
module fails.
This button shall be used by operator for the emergency
stopping of diesel engine. Actuator is manually controlled by
6 Emergency shutdown
using of this button for disconnecting fuel pipe, stopping
diesel engine and open the main switch of gen-set forcefully.
7 Starting Used to control the starting of alternator under local mode.

8 Shutdown Used to control the stop of alternator under local mode.


To change displayed content (parameters of alternator) on the
main page, select parameter number on the parameter
9 Scrolling up/down
selection page, and set the digitals on the parameter editing
page.
To switch to parameter selection setting page from the main
page, return to the main page from parameter selection setting
10 Page switching
page, and return to parameter selection setting page under
parameter modification status.
To enter into corresponding submenu from parameter
11 Confirmation selection setting page, and write the modified parameter
under parameter modification status.
Press the two buttons when alternator stops running, and the
system will enter self-check procedure and displays user’s
Self-check in double predefined alternator parameters successively, such as
12
MODE combination number of flywheel tooth, rated speed, over-speed alarm
value, etc. The system will return to initial state automatically
after completion of self-check procedure.
Instrument box can send out audile and visual alarm signals
when diesel engine working condition is out of limit or the
diesel engine fails to start for three times, and relevant alarm
indicators on the panel twinkles; meanwhile digital display
13 Silencer
window corresponding to digital displayer twinkles. Press
“Silencer” button, and audible alarm will be turned off and
alarm light keeps shining and stop blinking until the
operation returns to normal conditions.
In case that diesel engine fails to start for three times and
stops because limit protection is triggered, it represents that
14 Reset
the diesel engine is faulty and needs to be repaired. In case
that gen-set is to be started after troubleshooting, press

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

“reset” button to notify the instrument box that the fault is


eliminated. At this time, controller will cancel alarm signal
and put gen-set into operation again.

Please refer to accompanying document Operation Manual for Diesel Engine Monitoring
and Control Instrument for more function descriptions and usage information.

(2) Alarm protection function

Table 6-8 New style self-starting instrument alarm function

Serial
Alarm description Alarm value Remarks
No.
110% rated
1 Speed is high Audible and visual alarming
speed
0.15±
2 Oil pressure is low Audible and visual alarming
0.02Mpa
3 Water temperature is high 95+3℃ Audible and visual alarming
4 Oil temperature is high 120+3℃ Audible and visual alarming
115% rated
5 Speed is too high Audible and visual alarm and shutdown
speed
0.12±
6 Oil pressure is too low Audible and visual alarming and shutdown
0.02Mpa
Storage battery voltage is
7 <19V Audible and visual alarming
low
Starting fails for three
8 Audible and visual alarming
times
Fuel leakage alarm Audible and visual alarming, and fuel leakage
9
(optional) alarm apparatus is required
Water level/oil level is low Audible and visual alarm, and level switch is
10
(optional) required

(3) New style local self-starting instrument box wiring diagram

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 6-8 a)new style local self-starting instrument box wiring diagram

Figure 6-8 b) new style local self-starting instrument box wiring diagram

5. Onboard instrument

Diesel engine monitoring and control instrument (hereinafter referred to as monitoring


and control instrument) shall be mounted on diesel engine body, so it is called onboard
instrument and is a microcomputer-controlled full-automatic electronic measurement and
control system of diesel engine and alternator which precisely detects and displays diesel
engine speed, oil pressure, water temperature, oil temperature, pressure and other parameters,
monitors all detected parameters and sends out audible alarm, visual alarm, remote control
alarm and other signals in real time according to user’s settings. If there is a stop setting, it
will send out shutdown signal when the parameter exceeds shutdown value. Meanwhile,
remote displayer or remote control display instrument can also be used to realize remote
monitoring and control of diesel engine operating parameters. Compared with local
instrument, onboard instrument is simpler in structures and functions.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Figure 6-9 onboard instrument panels

6-9 onboard instrument panel

(1) Operating function

Table 6-9 onboard instrument function

Serial
Name Function description
No.
1 Power switch Turn on this switch to power on the onboard instrument.
When “local/remote” control change-over switch is in “remote” position, the
monitoring and control instrument shall be in remote control state; therefore,
Local/ remote remote control instrument can be used to start the diesel engine remotely. When
2
control “local/remote” change-over switch is in “local” position, monitoring and
control instrument shall be in local status; therefore, the diesel engine can be
controlled locally.
Onboard instrument will send out signals to start the diesel engine by pressing
3 Starting
this button.
Onboard instrument will send out shutdown signal to shut down the diesel
4 Shutdown
engine forcefully by pressing this button.
Press this button when there is no rotation, various channels of onboard
5 Self-inspection instrument will simulate external changing conditions to carry out
self-inspection items one by one. Onboard instrument will send out audible and

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

visual alarm signal when alarm setting value is reached and instrument will
send out automatic stopping signal when stopping setting value is reached.
Press this button when there is alarm signal, and the audible alarm will be
6 Silencer
turned off and alarm light keeps shining and stop blinking.
Press this button, speed display window displays the diesel accumulative
7 Timekeeping
running time. Speed will be displayed after 5 sec.
8 Reset Press this button to reset onboard instrument.

Please refer to accompanying document Operation Manual for Diesel Engine


Monitoring and Control Instrument for more function descriptions and usage information.

(2) Onboard instrument alarm protection function

Table 6-10 Onboard instrument alarm protection function

Serial
Alarm description Alarm value Remarks
No.
1 Speed is high 110% Rated speed Alarming
2 Oil pressure is low 0.15±0.02Mpa Alarming
3 Water temperature is high 95+3℃ Alarming
4 Oil temperature is high 120+3℃ Alarming
5 Speed is too high 115% rated speed Alarming and shutdown
6 Oil pressure is too low 0.12±0.02Mpa Alarming and shutdown
7 Storage battery voltage is low <19V Alarming
Audible and visual alarming, and fuel
8 Fuel leakage alarm (optional)
leakage alarm apparatus is required

(3) Onboard instrument wiring diagram

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Power
supply-

Power
supply+

Battery
charging+

Excitation+

Starting+

Shutdown+

Shutdown-

Alarm+
Comprehensive
alarm

Fuel leakage
(input)

Fuel leakage
(input)

Figure 6-10 Onboard instrument wiring diagram

6. Accelerator servo mechanism

A set of accelerator servo mechanism shall be equipped for mechanically regulated marine
diesel gen-set to control diesel engine speed. Generally, WP4CD Series marine diesel gen-set
adopts A-300B6 type servo mechanism. Hereinafter provide a simple introduction of such
servo mechanism.

(1) Main technical data

Voltage: DC 24V Power: 40W Current: 3A

Boundary dimension: 235×220×95mm weight: 5kg

(1) Motor wiring diagram

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

a)Reducer 0.75WHJ type worm speed reducer

b)Torque regulating scope 1-100KG-CM

c)Speed ratio: 1:42135

d)Input speed: 3000 r/min

(3) Typical application wiring diagram (reference)

High speed limit


switch

Low speed limit


switch

Notes:
KMA1, KMA2, KMA3 adopts Schneider
CJX2-Z/25A auxiliary equipment
Contact 2-open, 1-close A-300B3 type servo
mechanism
Buttons SA1, SA2, SA3 adopts LA18.
Indicator AD11

(4) Precautions (the product shall be in power-driven status during delivery)

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

1)Hand wheel shall rotate in clockwise direction from left to right during electric or
manual operation.

2)Hand wheel shall be pulled back during manual operation and make spindle nose turn
right by 60.

3)Hand wheel shall be pulled back during electric operation and make spindle nose turn
left by 60.

Please refer to Operation Manual for Servo Mechanism for more information about the
operation of servo mechanism.

II. Alternator

1. WP4CD Series marine diesel gen-set adopts five kinds of alternators: Marathon
alternator, Stanford alternator, Siemens alternator, Kangfu alternator (formerly known as
Sanbo alternator) and Landian alternator. WP4CD Series marine diesel gen-set is mainly
configured with above-mentioned five alternators. Please refer to relevant alternator
operation manual supplied with the unit for relevant alternator descriptions and wiring
principles.

2.Special configuration for marine alternator

Working environment of marine gen-set is very bad. Moisture on water surface, salt fog
on the sea, oil mist in the cabin and large day and night temperature difference has a bad
influence on alternator insulating material. Therefore, following special configurations are
added to marine alternator.

(1) Air filter

Some dust, oil mist can be removed by installing air filter on alternator air inlet to
prevent moist air during shutdown.

(2) Anti-condensation heater

220V electric heater shall be mounted on the end of alternator stator winding. Electric
heater shall heat alternator winding to remove moist air and prevent water condensation on
the winding.

(3) Winding temperature sensor, alarm and protection

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Alternator’s external circuit or improper operation will lead to the sharp rise of winding
temperature which will exceed the alternator’s temperature rise limit. In order to prevent
motor winding damage, temperature sensor shall be embedded on motor winding.
Temperature sensors are divided into two kinds: one is PTC thermistor, the other is PT100,
which together with detection, alarm and trip circuit, can provide protection for the alternator.

Chapter VII Operation

I. Preparation

1.Clean the dust and other dirt on gen-set surface.

2.Check whether various fasteners and connectors are loose and various revolving
components are flexible.

3.Check whether all electrical connection parts are in good contact and correct wiring.

4.Add corresponding fuel into fuel tank to remove the air left in fuel system according to
fuel specifications stipulated in Diesel Engine Operation and Maintenance Manual.

5.Check whether diesel lubricating oil meets requirements according to lubricating oil
specifications stipulated in Diesel Engine Operation and Maintenance Manual. In case
of replenishment, lubricating oil in corresponding grade shall be added.

6.Check whether the stored cooling water meets requirements.

7.Check whether battery voltage is within specified ranges (generally it is 23-28V)

8.Check the status of following switches:

(1) Gen-set power distribution system air isolation switch shall be in normal tripping
position;

(2) Starting switch shall be in off position;

(3) Electron speed regulator “rated/idling” switch shall be in idling position.

II. Commissioning

1.Gen-set starting

1)Press “start” button to start the gen-set (pay attention to readings of various

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

instruments)

2)Observe whether various parts are in normal operation (engine oil pressure shall
be greater than 0.15Mpa)

3) Gen-set shall be in idling status (generally 600-750 r/min), idling engine heating
shall last for 5-10 min;

2.Engine heating

The diesel engine shall operate for 5-10min in idling status after the starting of gen-set
meanwhile observing diesel oil pressure, oil temperature, cooling water temperature and
diesel operating conditions, in case of abnormalities, shut down the unit for inspection.

3.Acceleration and voltage buildup

High/low speed switch of electronic speed regulator mounted on gen-set shall be


switched to high speed position when diesel engine speed reaches rated speed, the diesel
engine will accelerate the speed automatically. Regulate speed fine adjustment potentiometer
to make diesel engine speed reach rated speed; at this time, alternator voltage shall be built
up.

Regulate voltage setting resistor to make it reach rated value; then turn the voltage
change-over switch mounted on onboard detection device to check whether three-phase
voltage is in balance, no current value is shown, and alternator indicator light turns on.

4.Test run

1)During normal operation of the unit, connect the load and observe whether
various parts are in reliable operation and indicating device is in normal operation;

2)About 25% rated load shall be connected during test run, and check whether
various parameter indicators and whether any abnormal noise arising from
alternators or diesel engine;

3)Load shall be added gradually under normal operation and the load for first test
run shall be not greater than 80% rated load.

4)Observe the water temperature, oil temperature, oil pressure and other diesel
engine parameters and voltage, current and other electrical parameters.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

5)Record various parameters during operation.

Notes: sharp increase and decrease of load shall be prohibited during initial operation.

5.Shutdown

Reduce the load gradually, turn off main switch and open load disconnector. The diesel
engine will operate at the speed reduced to idling value for 2~5 min; then the alternator will
be stopped and various switches shall be turned off to separate these units. Then the
commissioning is finished.

Chapter VIII Parallel operation

Parallel operation of gen-set can increase power supply reliability and stability, in
addition, number of parallel gen-sets shall be determined according to load level in places
subject to large load fluctuation for economic operation.

I. Conditions for parallel operation

Gen-set shall meet following conditions during parallel operation:

(1) Voltage of gen-set to be connected shall be the same as that of operating unit;

(2) Frequency of gen-set to be connected shall be the same as that of operating unit;

(3) Phase position of gen-set to be connected shall be the same as that of operating unit;

(4) Phase sequence of gen-set to be connected shall be the same as that of operating unit;

II. Methods

Common parallel connection methods include light extinction method, light rotation
method and synchronizing device method. Currently, the most commonly used method is
synchronizing device method. And synchronizing device method can be divided into
quasi-synchronizing parallel method and automatic self synchronizing parallel method.
Hereinafter provide the introduction of quasi-synchronizing parallel method.

On implementation model, quasi-synchronizing parallel operation is divided into manual


quasi-synchronizing parallel method and automatic quasi-synchronizing parallel method.
Hereinafter provide the introduction of manual quasi-synchronizing parallel method.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Gen-set to be connected in parallel shall be involved in synchronizing operation after


meeting the four parallel conditions stipulated in this Chapter. Operating steps are as follows:

(1) Check whether phase sequences of two parallel gen-sets are consistent with each
other before parallel operation and use phase sequence indicating device to check
alternator stator winding leading-out terminal marks.

(2) Start the gen-set and adjust the speed and voltage of two gen-sets into rated value,
meanwhile, their phase sequences shall be consistent (the adjustment of gen-set
steady-state speed regulation factor and steady-state voltage regulation factor shall be
completed before delivery). One gen-set shall be switched on firstly (it can operate
without load or be used to supply power);

(3) Regulate regulating resistor of gen-set to be connectedconnected to make the voltage


be consistent with that of the already connected unit;

(4) Manual quasi-synchronizing operation: observe the rotation of synchronizing


indicating finger, then make corresponding regulation upon frequency of gen-set to be
connected until synchronizing indicating finger reaches synchronizing balance line in
clockwise rotation and send out switch-on order immediately to make put gen-set into
parallel operation. After parallel operation, regulate the speed of one gen-set to achieve
power sharing balance. All input signals of combined type synchronoscope shall be
turned off after parallel operation to take the synchronoscope out of service.

III. Load transfer in parallel

Load transfer shall be done after units are put into parallel operation. There are load
transfer method, one is active load transfer between two gen-sets which is achieved by
regulating accelerator to change diesel engine oil supply. Active load increases along with oil
supply; the other is transfer of reactive load,which can be accomplished by using regulating
differential resistor and voltage regulation resistor on regulation panel to regulate reactive
power between two gen-sets.

IV. Disconnection of parallel gen-set

When load of two gen-sets in parallel operation is less than the 50% of rated load and
one unit needs to be disconnected, all the load (or most part) of the unit to be disconnected
shall be transferred to the other unit by adjusting speed before turning off load switch to
disconnect the unit.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Chapter IX Precautions

1.Personnel who are unfamiliar with gen-set operating specification are prohibited to
operate on the unit.

2.Gen-set output current shall not exceed the rated current stipulated on alternator
nameplate. Please refer to power correction method stipulated in diesel engine Operation
Manual to correct gen-set output power when gen-set working condition does not
conform to working conditions stipulated in this manual.

3.During initial operation, maximum power of the unit shall not exceed 90% of rated
power which help extend service life. When gen-set is started in emergency status, initial
load shall not exceed 50% of rated power.

4.Check water temperature, engine oil pressure changes regularly to meet specifications
stipulated in diesel engine operation and maintenance manual.

5.Check battery voltage regularly to ensure it is in good condition.

6.During operation of gen-set, pay attention to cooling water level in box cooler and
replenish if necessary.

7.Repair it in a timely manner in case that there is oil leakage, water leakage and air
leakage in various pipes.

8.Do not use silicon rectifier to replace battery

9.Water in cooling system shall be discharged or anti-freezing agent shall be added when
gen-set ambient temperature is low with possibility of freezing to prevent frost crack of
unit body and water drainage shall be done after the unit has stopped for half an hour.

10.During operation of gen-set, loading process shall be stable to avoid gen-set from
being damaged by impact load.

11.Gen-set shall be in horizontal position during lifting.

12.As gen-set can be exposed in moisture air, salt mist, oil mist and mould environment,
the user shall start it up regularly to guarantee that gen-set is in good working condition
to prevent gen-set from being corroded or damaged.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

13.Pay attention to keep gen-set clean and make it in good working conditions.

14.Gen-set is heavy equipment. For the sake of human body and equipment safety, it shall
be operated with care. Operation against rules and drunk operation are prohibited.

15.In case that there are any failures and factory assistance is required, the user should
provide the detailed information for quick solution.

Chapter X Analysis of common faults and troubleshooting

1.Analysis of common faults

Table 10-1 Analysis of common faults

Fault phenomena Analysis of causes Troubleshooting methods

Battery fault Check battery wiring, capacity and voltage.

Cannot be started
Check whether fuel oil circuit is blocked and
Fuel circuit is blocked.
discharge air in fuel oil circuit.
Electronic speed regulator Check electronic speed regulator.
Excitation circuit is open. Check the wiring of excitation circuit.

AC, DC transformation system is


Refer to alternator Operation Manual.
No voltage damaged.

Fuse is damaged. Replace fuse.

Excitation circuit is in bad contact. Check the wiring of excitation circuit.


Alternator voltage is
Rectifier diode has poor
unstable. Replace diode.
performance.

Alternator speed is Electron speed regulator does not Refer to electronic speed regulator Operation
unstable. work in optimum status Manual.

2.See Operation Manual for Three-phase Synchronous Alternator for synchronous


alternator fault and troubleshooting methods.

3.See Operation Manual for Diesel Engine Monitoring and Control Instrument for
gen-set instrument box fault troubleshooting methods.

4.See Operation Manual for Electronic Speed Regulator for electronic speed regulator

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

fault and troubleshooting methods.

Chapter XI Rules for Safe Operation

1.Operator shall be familiar with gen-set operations, operation method and positions of
all control mechanisms, manual valves and stop mechanism.

2.Open flame is forbidden in cabin with fuel oil and lubricating oil to avoid fire.

3.Proper fire fighting equipments shall be equipped in cabin or in nearby places.

4.Whole gen-set must be earthed reliably and meet applicable neutral earthing
requirements.

5.The equipment, barriers and dangerous goods not to be used for the unit shall not be
placed on the unit and the ground shall be dry and clean without oil contamination.

6.As there are noises generated during gen-set operation, it is recommended that worker
in noise environment shall wear proper safety devices, such as ear protector.

7.All power supply lines must be disconnected before any maintenance, especially DC
power supply circuit. Set a “during maintenance” warning plate and assign another
person to ensure the safety, especially for maintenance performed in narrow area.

Chapter XII Servicing and Maintenance

1.Please read relevant chapters of this Operation Manual carefully before maintenance and
servicing.

2.Generally, gen-set shall be inspected once a week. Operate for a short time with load
(best of all) to confirm that gen-set is in good status; meanwhile make records on relevant
conditions and parameters.

3.Basic maintenance specifications are as follows:

(1)Check the conditions of air filter, fuel filter elements, clean them in time and replace
them if necessary.

(2)Check cooling water or anti-freezing solution and replenish it in time.

(3)Check whether there is lubricating oil, fuel and cooling water leakage.

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

(4)Check whether oil in pump body is within specified limit and replenish it in time.

(5)Check the battery voltage and specific gravity of electrolyte.

(6)Check the conditions of various indicating devices and various switches on instrument
box.

(7)Check whether electric connection and mechanical joint is loose and fasten it if
necessary.

4.Routine inspection items

(1)Diesel maintenance

The purpose of correct maintenance is to guarantee the normal and reliable operation of
diesel engine and is an important step to extend diesel engine service life. The user shall
maintain the diesel engine regularly according to technical maintenance items stipulated in
this Chapter.

1)Maintenance frequency of WP4CD Series diesel engine

First inspection (P) after diesel engine runs for 30-50 hours

Level I maintenance (WD1) after diesel engine runs for each 250 hours

Level II maintenance (WD2) after diesel engine runs for each 500 hours

Level III (WD3) after diesel engine runs for each 1000hours

Level IV (WD4) after diesel engine runs for each 4000 hours

Note: Above-mentioned frequency shall be calculated assuming that the unit operate for
1500 hours annually, in case that diesel engine working time annually does not exceed 500
hours, diesel engine maintenance frequency shall be 0.5 times above-mentioned
maintenance frequency; in case that diesel working time annually exceeds 1500 hours, the
maintenance frequency shall be 1.5 times above-mentioned frequency.

Note: Lubricating oil of CE grade or lower is not allowed for WP4CD Series diesel engine.
Replace oil filter element during oil replacement.

3)Operations to be done during diesel engine inspection and maintenance

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Table 12-1 Operations during diesel engine maintenance

First Routine
Item WD1 WD2 WD3 WD4
inspection inspection
Replace diesel engine oil ▲ ▲ ▲ ▲ ▲ ▲
Check whether water pump leaks. ▲ ▲ ▲ ▲ ▲
Replace oil filter ▲ When replacing alternator oil
Check and regulate air valve gap. ▲ ▲ ▲ ▲ ▲
Replace fuel oil filter. ▲ ▲ ▲ ▲
Clean fuel oil pump coarse strainer. ▲ ▲ ▲ ▲
Check the capacity of cooling liquid
▲ ▲ ▲ ▲ ▲ ▲
and replenish if necessary.
Fasten cooling pipe clamp. ▲
Fasten air inlet pipe and flexible pipe. ▲ ▲ ▲ ▲ ▲
Clean air filter element. ▲ ▲ ▲
Check and fasten triangle belt. ▲ ▲ ▲ ▲ ▲ ▲
Check fuel oil injection pump in

special workshop.
Regulate idling speed. ▲

(2) Gen-set routine inspection items

Note: “1” in Table 12-2 represents inspection after operation for each 12 h or once a
week; “2” represents inspection after operation for each 100h or once a month; “3” represents
inspection after operation for each 200h or once a year.

Table 12-12 Inspection items during diesel engine-gen-set maintenance

Parts Inspection item Frequency

Check battery electrolyte level. 1


Starting
Use hydrometer to check the charging status. 2
part
Clean battery terminals and oil it again. 3

Use dry compressed air to purge the porthole and internals. 2

Replace bearing lubricating grease (if necessary). 3


Alternator
Check whether inner coupling bolt is loose. 2

Check whether there is barrier in ventilation area. 1

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

Check the conditions of alternator outgoing line insulation. 1

Check the working condition of air isolation switch. 3

Check whether alternator terminals are loose. 1

Check and fasten all bolts and nuts. 3

Check the status of damper. 3


Gen-set Clean whole gen-set. 3

Operate gen-set for 1h at 50% load (optimal condition) and record the starting
1
time of gen-set.

Annex I: List of Tools Delivered with Gen-set (Ex-factory Standard Configuration)

Serial No. Parts name Specification Quantity


1 TOOL LIT 1
2 WRENCH DOUBLE 10×12 1
3 WRENCH DOUBLE 13×15 1
4 WRENCH DOUBLE 14×17 1
5 WRENCH DOUBLE 19×22 1
6 WRENCH DOUBLE 24×27 1
7 SOCKET 1/2SQ TWELVE 1/2×13 1
8 SOCKET 1/2SQ TWELVE 1/2×14 1
9 SOCKET 1/2SQ TWELVE 1/2×15 1
10 SOCKET 1/2SQ TWELVE 1/2×17 1
11 SOCKET 1/2SQ TWELVE 1/2×19 1
12 SOCKET 1/2SQ TWELVE 1/2×22 1
13 SOCKET 1/2SQ TWELVE 1/2×24 1
14 SOCKET 1/2SQ TWELVE 1/2×27 1
15 HANDLESS LICING 1
16 EXETENSION BAR 1/2SQ 1/2×250 1
17 EXETENSION BAR 1/2SQ 1/2×125 1
18 HANDLE-BALL PEEN 1
19 MAGNETIC PROBING PEN 1
20 WRENCH-ADI 200mm 1

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Operation and Maintenance Manual for WP4CD Series Marine Diesel Alternator Unit

21 PLIER SHORT/JOINT 150mm 1


22 DRIVER(+-) 5×125 2
23 FEELER 1
24 L-WRENCH 5-12 1
25 U-JOINT1/2SQ DR2 1/2 1
26 RACHET HANDLE 1/2 1
27 FILTER WRENCH 1
28 JOINT-WRENCH 1/2×7mm 1
29 JOINT-WRENCH 1/2×14mm 1
30 JOINT-WRENCH 1/2×16mm 1

Annex II: List of Spare Parts Delivered with Alternator Unit (Ex-factory Standard

Configuration)

Serial No. Name Quantity Remarks

1 Narrow triangle belt 2

2 Screw filter 2

3 Fuel filter element 2

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