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2/F Topy Comm. Bldg. Industria cor. Economia St.Bagumbayan

Quezon City Philippines 1100
Tel. No. 637-8317 to 20 ; Fax No. 637-8311

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GENERATOR ORIENTATION/TRAINING
DATE:
CUSTOMER:
LOCATION:

SUBJECTS

1. GENERATOR IDENTIFICATION AND FAMILIARIZATION

2. GENERATOR PRINCIPLE OF OPERATION
3. SYNCHRONIZATION PRINCIPLE
4. GENERATOR AND ATS SEQUENCE OF OPERATION
5. TROUBLESHOOTING AND MAINTENANCE
6. PROTECTION AND SAFETY
7. QUESTION AND ANSWER

OBJECTIVE

A technically controlled self-confidence and knowledge in handling situation pertaining to urgent responses and
manipulating operations of the Emergency Systems with total safety and environment considerations.

Training performed by:

Power Systems, Inc.

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1. GENERATOR IDENTIFICATION AND FAMILIARIZATION.

Generator Set is composed of 3 Major Parts. Each parts have their own model, brand and serial numbers.
A Generator Set is an assembly of Engine, Main Alternator and the Controller.

BRAND MODEL SER. NO. SPECS RATING

ENGINE Cummins KTA50-G9
ALTERNATOR Stamford HC4 400/230,3P,60Hz
CONTROLLER TGCM 4 X 240

GENSET PSITECH CS-KTA50-G9 GEN 150432 400/230,3P,60hz.

CONTROLLER

RADIATOR
ALTERNATOR
ENGINE

2. PRINCIPLE OF OPERATION.

ENGINE:
The Engine used in transport trucks are similar to the engine used in Generator Sets. It is powered by batteries for
starting and operating the controller and other accessories. The main purpose of the engine is to drive the Main Alternator
according to the designed rotation and speed (RPM).
The Governor or the Speed Controller is being used to achieve and maintain desired speed (1800 RPM).

MAIN ALTERNATOR:
The Main Alternator itself is actually the called the Generator because it is the one producing power through the
principle of induction. It is the reversed operation of a typical induction motor. The Alternator Rotor is being driven by
the engine and at the same time energizing the Rotor Winding causing induction to the Stator Winding then the Stator
release power.
The AVR(Automatic Voltage Regulator) is being used to achieve and maintain desired Voltage.
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CONTROLLER:
The controller is the commander. It is the key to operate and protect the Genset. As designed typically,
the Controller regardless of brand can manipulate the desired operation of the Genset and at the same time
protects the whole unit from undesired operation. From the controller we can Start or Stop the Genset either in
Manual or Automatic operation. Upon detecting any out of range setting or undersigned unit performance either
at the Engine or the Alternator, the controller will send warning or shutdown the unit. Some can even log events
and send status to BMS.

3. SYNCHRONIZATION PRINCIPLE.
To acquire more reserved power and distribute loads to all Gensets we are doing the Synchronization. This
is by paralleling desired numbers of Gensets to get its total power as one source. Using a Synchronizer
Controller the operation of the Gensets are dependent to the designed parameters of the Synchronizer. Typically
the system is designed as to take equal loads at all time and shed slave Genset/s when load drops smaller than
required.
Requirements to perform Synchronization are Gensets of same Phase, Voltage, Speed/Frequency. Some
Gensets of different KW capacity can also be paralleled but requires more controls.

4. GENSET AND ATS (Automatic Transfer Switch) SEQUENCE OF OPERATION

The connections between the Genset and the ATS are the “Power Cables” where the rated power of the
Genset is being supplied to the load by ATS transferring, and the “Auto/Remote Start” where the command of
Genset starting is being delivered by the ATS.

Transfer from Normal to Emergency as below sequence;

a. Upon Normal Power failure, the ATS will send command to the Genset to start by either a “Relay Dry
Contact” or AMF(Auto Mains Failure).
b. Genset starts after pre-set delay
c. Upon stabilizing power the Genset will “Close” the GCB then power sent to the ATS Emergency side.
d. Upon receiving power from Genset, the ATS will commence transfer from Normal to Emergency
position after pre-set delay from the ATS controller thus giving power to the load.

Transfer from Emergency to Normal as below sequence;

e. Upon Normal Power resume.
f. ATS Transfer from Emergency to Normal will commence after pre-set delay at ATS controller at the
same time opening the signal to Genset start.
g. Upon receiving the signal from the ATS, the Genset will “Open the GCB” after pre-set delay.
h. After opening the GCB, the “Cooldown” process will follow allowing the Genset to run at no load
ideally at 3-5 Minutes before shutting down.
i. As the Genset shuts down, the Genset is again ready for Auto operation in case of power failure.
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5. TROUBLESHOOTING AND MAINTENANCE

GENSET: (In case it won’t start)
a. Check for Batteries, Battery Charger, Engine Oil Level, Coolant Level, Fuel & Separators, Air &
Fuel Filters controller and ATS.
b. Check for Alarms that the controller may display.
c. Visually check for loose wiring particularly the battery terminals for corrosions.

ATS: (In case it won’t transfer)

d. Check for Batteries and charger if equipped..
e. Check ATS controller and Alarms.
f. Visually check for loose wiring particularly the battery terminals for corrosions.
g. If either Normal or Emergency power present at the ATS but not transferring put operation to Manual
then operate the transfer manually but observing protection.
For Manual operation of Breaker type ATS, make sure to put both Breakers to OFF or Open position
before ON or Closing one Breaker to avoid short circuit in case the Mechanical Interlock is not working.

6. PROTECTION AND SAFETY

OCCUPATIONAL SAFETY AND HEALTH STANDARDS.

1081 : General Provisions: 1081.01 : Every employer as defined in 1002:

(1) Shall at his own expense furnish his workers with protective equipment for the eyes, face, hands and feet, protective
shields and barriers whenever necessary by reason of the hazardous nature of the process or environment, chemical or
radiological or other mechanical irritants or hazards capable of causing injury or impairment in the function of any part
of the body through absorption, inhalation or physical contact.

7. QUESTION & ANSWER

8. OTHERS:
TYPICAL ENGINE OIL REQUIREMENT: 15W40
A single grade oil like 15W or SAE 40 oil has a high viscosity when cold and a lower viscosity when
hot. The first number 15W is the viscosity of the oil at cold temperature, and the second number 40 is the
viscosity at 100 °C.
The 15W40 designation means that the oil is a multigrade oil. It has the when viscosity of 15W cold and the
viscosity of SAE 40 when hot. This means that one type of oil works in all temperatures.

TYPICAL FUEL REQUIREMENT : DIESEL #2

COOLANT ADDITIVES REQUIREMENT: (DEPENDS ON BRAND). For Cummins they use DCA60L at 1 Part per
Liter of Water.
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TEST
____________________________________________________________________________
NAME:
_____________________________________________________________________________

1. What are the 3 major components of a Generator Set?

_______________________
_______________________
_______________________

2. The speed or RPM of a Generator Set Engine is being controlled by what?

AVR ______________
Battery Charger______________
Governor _______________

3. The Frequency is determined and measured by the Speed Controller/Governor only.

TRUE_____________ FALSE_____________ (Check the answer)

4. RPM means “Rated Power Measurement”.

TRUE_____________ FALSE_____________ (Check the answer)

5. What is the KVA of a 500KW Genset?

Answer: _________________KVA

6. What is the (L-N) Line to Neutral Voltage of a 415 (L-L) Line to 3 phase Line system?
Answer: _________________V

7. The Genset during running will stop when batteries experience low charge.
TRUE_____________ FALSE_____________ (Check the answer)

8. What are the 3 main considerations in Synchronizing or paralleling 2 or more Gensets?

_______________________
_______________________
_______________________

9. What is the old international cable color code for below phases;
Line1/Phase R_______________________
Line2/Phase S_______________________
Line3/Phase T_______________________

10. Give at least 1 reason why a Genset will not start and why.
____________________________________________________________________________________
____________________________________________________________________________________
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