POWER

BY
KIRLOSKAR

We can achieve excellent performance from a Silent DG set,

if proper care is taken during its installation. (The following
suggestions shall help you to achieve optimum performance
from the D.G. Set.)

For Assistance

Please contact our customer care at C-266-267, Mayapuri Industrial Area, Phase-II,
New Delhi-110 064

Mobile No. 9871590738, 9871590740

Phone No. 011-28114072 (D), 28111510, 28113231, Fax No. 28113149
e-mail: [email protected], [email protected]

In case you are not satisfied, kindly register your complaint to

Jakson care No. - 8800447864

General Note:
1. Please always sign the report made by our Service Engineer.
2. Warranty is applicable for two years for engine & alternator only
subject to use of Kirloskar K-Oil Premium, Kirloskar genuine filters,
K cool super plus and services sourced through KOEL authorized
Service Dealer.
F Revalidation :- If Generator set kept without commissioning (not in
operation after delivery) for 6 months or more without preservation
then Engine revalidation must be carried out through Authroized
Kirloskar Dealer and Customer has to bear revalidation cost.
Disobedience of above instruction may lead to problem in
entertaining claim.

JAKSON & CO.

 INDEX
S. NO. DESCRIPTION PAGE NO.

1. SELECTION OF SITE 1

2. FOUNDATION DETAILS & 2-3

GUIDELINES
Ref. Drawing For Foundation of Gen Set

3. EARTHING SYSTEM 4

4. EXHAUST PIPING 5

5. FUEL PIPING 6

6. CABLING 7

7. BATTERY CHARGING PROCEDURE 8

8. SUMP CAPACITY 9

9. CHECK UP BEFORE STARTING 10

THE DG SET.

10 SUMP CAPACITY (NEPAL) 11

11 ROUTINE MAINTAINANCE OF SDG SET 12

12. PRE-COMMISSIONING CHECK 13

13. ROUTINE CHECK POINTS 14

14. DO'S & DON'T'S 15

15. TROUBLE SHOOTING - ENGINE 16-20

16. TROUBLE SHOOTING - ALTERNATOR 21-22

17. TROUBLE SHOOTING GUIDE FOR 23

MANUAL PANEL
18. TROUBLE SHOOTING GUIDE FOR 24-25
AMF PANEL
19. SAMPLE WARRANTY CERTIFICATE (NEPAL) 26
20 SAMPLE WARRANTY CERTIFICATE (DOMESTIC) 27
21. REVALIDATION POLICY GENSET 28-29
22 WARRANTY TERMS AND CONDITION 30
FOR BATTERY

JAKSON & CO.

 1

SELECTION OF SITE
Ø Proper space should be there for placement and opening of doors of the
Silent DG set.
Ø There should be atleast 1.5 meter free space around the DG set for
proper operation and maintenance.
Ø There should be cross ventilation of air to ensure proper cooling of DG
set. Exhaust gases and hot air discharge should not re-circulate inside
the acoustic enclosure (canopy).
Ø If Genset is to be installed in the room, please ensure proper cross
ventilation and surrounding space.
Ø There should be no restriction for fresh air suction and hot air discharge.
If 2 nos. DG sets are installed at the site, ensure that hot air outlet of the
one DG set does not become the fresh air intake of the 2nd DG set.
Ø If Genset is to be installed in the basement, please ensure ventilation
with respect to Air requirement and clear space for every maintenance.
Ø Distance between two SDG set should be minimum 1.5 meters.
Ø A low height shelter for the Silent DG Set should be avoided. It should
not obstruct the hot air outlet, shelter height minimum 1.5 meter or
equal to height of genset
Ø It is preferable to install the DG set in an open area. No shade (roof) is
required over it. However, if the AMF Panel is outside the Acoustic
Enclosure, then a shelter is recommended for the AMF Panel.
Ø For Roof Top Installation, ensure that the civil structure is capable to
bear the static and dynamic load of DG set. The load of the Silent DG set
should be borne by Columns and Beams of the building.
Ø Proper space should be there for Earthing.
Ø If there are no space constraints, the DG set should be placed near the
distribution panel.
Ø The DG set should be located away from polluted surroundings such as
corrosive fumes, cement dust, fibres, cotton and toxic chemicals to
avoid overheating of the D.G. Set.
Ø There should be sufficient space around the Genset to avoid resonance
and echo effect which contributes to abnormal sound from Genset.
Ø The space should be open without any obstacles.

JAKSON & CO.

 2

FOUNDATION DETAILS AND GUIDELINES

A. Ground base Foundation (RCC/PCC)

Ø The foundation should be water leveled and at least 300mm above the
ground level to maintain cleanliness and avoid flooding.
Ø The length and width of the foundation should be at least 600mm to
800 mm more than that of the DG set size i.e. 300mm on each side.
Check the foundation level diagonally as well as across the length and
width.
Ø Please refer to the foundation drawing attached herewith (page-3).
Ø A rigid foundation ensures the least vibration. Sand Filling should be
there around the foundation. 18mm rubber matting must be used over
the foundation to minimize the vibration effect and noise leakage.
Ø Ensure that the foundation to support 1.5times of the total wet weight
of the single generator and 2 times of the total weight for the multiple
generators.
Ø Please refer to the dimension of DG set for deciding the foundation
length, width and depth.
Note: Please ensure that the foundation should not be made over any
basement, water tank or Sewer Line.
B. Roof top Installation
Ø A rooftop installation requires proper planning and the structural
design considerations for dynamic loading.
Ø The weight of Silent DG set should be on Column and Beam through
proper foundation.
Ø The RCC foundation should be on the Beam or supported on two
Beams.
Ø ISMC Channel or MS “I” Section may also be used to cater the load of the
DG set with the canopy. Load of ISMC Channel or MS “I” Section should
be on the column of the building.
Ø M.S. Sheet is to be provided at the bottom of the base frame of the Silent
DG set for roof top installation.

JAKSON & CO.

 NOT TO SCALE IF IN DOUBT ASK

JAKSON & CO.

LENGTH OF DG SET +600 MM

50
50

DG SET

WIDTH OF DG SET + 600 MM

3

TABLE FOR BAR' S SIZE

TOP VIEW
S.NO RATING OF SLENT DG SET SIZE OF BAR
1 UP TO 82.5 KVA 10MM DIA
2 100 KVA TO 200 KVA 12MM DIA
3 250 KVA TO 750KVA 16MM DIA
BARS @ 150 C/C BOTH WAY. (PL. REFER TABLE)

200 FFL
RCC 1:2:4 THERMOCOL
450 SAND
SOLD&
SERVICED
JAKSON & CO.
C-266,267,IND, AREA,PHASE-2,MAYAPURI, -NEW DELHI - 64
FRONT VIEW PCC
TITLE FOUNDATION DRAWING OF SOUND PROOF GEN SET

PART NAME FOUNDATION DRAWING

DIMENSION MARKED AS ( ) TO BE DECIDED BY STRUCTURAL CONSULTANT/ CLIENT.
DRAWN BY DRG. NO. RF-7-06
CHECKED BY DATE 7/02/06
*THIS IS ONLY A REFERENCE DRAWING. KINDLY CONSULT YOUR CIVIL ENGR / CONSULTANT
FOR MAKING FOUNDATION APPROVED BY KIRLOSKAR ENGINE
 4

EARTHING SYSTEM
Ø An Earthing system is required for the protection of equipment and human
being, as per Indian electricity Rules 1956.

Ø Separate earth should be used for Genset body and neutral earthing.

Ø 2 Nos. earthing pits are required for 1 phase DG set and 3 phase upto 30 kVA
1 each for neutral & body.

Ø 3 Nos. earthing pits are required for 40-125 kVA DG set 1 for neutral & 2
for body.

Ø 4 Nos. earthing pits are required for 160 kVA & above DG set, 2 each for
neutral & body.

Ø The min. distance between 2 earthing pits should be 2.0 meters.

Ø An earth pit cover should be provided.

Ø A watering pipe of 25mm with a funnel should be provided for each pit,
wherever depth of the earthing pit is not at water level.

Ø Earthing system should be checked with megger and resistance between

earth pits and terminal should be less then 1Ω B/W 2 earth pits

Ø The earthing plate/pipe and strip size should be above 100 mega Ω when
Genset is not connected

Details of Earthing Strip

SDG Set Rating Recommended Earth Strip/Cable
5-75 KVA 8SWG-Copper
82.5-180 KVA 25X3 mm Copper / 25X6 mm GI
200-380 KVA 32X3 mm Copper / 25X6 mm GI 2 runs
400-500KVA 25X6 mm Copper 2 runs / 50x6 mm GI 2 runs
600-1010KVA 50X6 mm Copper/50x6 mm GI 2 runs
TYPICAL EARTH PIT / STATION ARRANGEMENT

JAKSON & CO.

 5

Exhaust Piping
The exhaust system must be designed to keep the resistance to hot gases
(back pressure) as low as possible and load of the extended exhaust pipe / silencer
should not be on the engine manifold
The following may please be noted.
1. There should not be any load or stress on the expansion bellow.
2. There should be proper support for the exhaust pipe.
3. Exhaust Pipes should be extended through proper flanges only.
4. Short bend should be avoided.
5. Always use proper size MS pipe ( G.I. Pipe and bend should not be
used in exhaust piping)
6. At the time of Genset Installation , Please ensure proper alignment of exhaust
silencer with respect to expansion bellow
Exhaust pipe load should not come on Expansion bellow and it should not touch
the roof body.
As per statutory regulations, exhaust pipe has to be extended above the
surrounding stack as below.
H= h + 0.2 x kva
Where H = Minimum height of exhaust stack, h= height of building
Exhaust Pipe Details
Engine Model Minimum exhaust
(Air Cooled) pipe OD (mm)
EA10 G1 /EA16 G1 50
HA294 G1/HA394TCI G1/HA394TCI G2/HA494TCI G1 63
HA694TCI G1 76

Engine Model Minimum exhaust

(Water Cooled) pipe OD (mm)
2R1040 G1 63
3R1040T G1/3R1040TA G1 76
4R810TA G1/4R1040TA G1 75
4K1080TA G2 /6R1080TA G1/6K1080TA G2 101
6SL-Series 138
DV-Series 150
Note-
1. If the extension of exhaust pipe is more than 5 meters above Genset,
increase pipe diameter by 13mm for every 3 meters.
2. If no.of bends are more than 4, increase the diameter of exhaust pipe and bend
by 13mm for addition of each bend.
3 Joining of Exhaust pipe for the both bank is not recommended. In case of
necessity common pipe diameter should be at least 10% higher and refer proper
procedure (Use of NRV valve and angle between chimni and pipe should be
maintained) before joining two exhaust pipe.
4. Both the Exhaust pipe should not be connected opposite to each other. Angle
0 0
between pipe should be 30 to 45

JAKSON & CO.