Any reference to trademarked product names used within this publication is owned by their respective companies.

Transcription

1 Ravenstor Road Wirksworth Derbyshire DE4 4FY ENGLAND Sales Tel: +44 (0) Sales Fax: +44 (0) Website: Installation Guide Compact Welf-Air Build No: WAC90B, WAC90H, WAC120H Publication: Harrington Generators International Limited All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act Applications for the copyright holder s written permission to reproduce any part of this publication should be addressed to Harrington Generators International Limited at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. Harrington Generators International Limited reserves the right to change the contents of this document without prior notice.

2 Change Control Date Iss Author Mod Reason for change Nov Dec Apr 14 C MC Mar 16 D MC WM Inclusion of WAC120H Jan 18 E MC Aligned format to Added GA and WDs

3 Harrington Generators International Contents Contents 1.0 INSTALLATION General Cabin Exhaust Outlet Inlet Ventilation Hot Air Outlet Cabin Distribution Board Access and Clearance CONTACT DRAWINGS General Arrangement WIRING WAC90H WAC120H Remote Start Timer DKG Remote Start Leads INSTALLATION CHECKLIST MANUFACTURER S SERVICE AND USER GUIDE LINKS Kubota Engine Operator s Manuals Sincro SK160 User Manual DKG114 Datasheet...10 Compact Welf-Air

4 Harrington Generators International Compact Welf-Air

5 Harrington Generators International Compact Welf-Air 1500 RPM Diesel Generator Compact Welf-Air

6 Harrington Generators International Installation Guide 1.0 Installation Installation of the generator is to be made by qualifi ed personnel in accordance with the appropriate regulations e.g., Electricity Safety, Quality and Continuity Regulations 2002 (S.I. 2002/2665), and the following Electrical Safety regulations: I.E.E Regulations 17th Edition (BS 7671:2008) Health and Safety Executive Publications GS27 Protection Against Electric Shock Health and Safety Executive Publications GS24 Electricity On Construction Sites Health and Safety Executive Publications PM53 Emergency Private Generation 1.1 General The Welf-Air Compact range of generators has been designed by HGI to perform exceptionally well in the confi nes of a small cabin. New type mounts are used in the set, so that vibration is kept to a minimum, when placed on a cabin fl oor. Two silencers, special sound insulation, water cooled engines and careful canopy design keep noise level to an absolute minimum. The integral base mounted tank gives many hours of continuous operation, is easy to refi ll and has a low fuel shutdown to stop air entering the fuel system. The access door is a lift-off type to save space. The keyless stop/ start means no lost keys. The Welf-Air Compact has long service intervals and its service items are on the outward facing side, thus making servicing easy and economic. Hot air exits the top quarter of the end panel opposite the air inlet panel. The set is designed to be pushed up to the right and against a cabin wall, which should have a louvre panel cut into it. Other louvres need to be made in the cabin to allow cool air to enter the generator compartment. ( An alternative left hand air out version is also available). The generators exhaust exits vertically. An extension tube, brackets and heat wrap are supplied. It is important that the heat wrap is fi tted so that operatives do not burn themselves. The generator is designed to be easy to install. Do not hesitate to contact HGI for further advice and help. These instructions apply to all variants of this type machine. These instructions explain the installation of Welf- Air Compact generators. Read completely before installing. The generators are designed to be installed into a pre-prepared cabin. Louvres, air escapes, brackets and exhaust outlet should be pre-fi tted to the cabin in accordance with the drawings attached. A fi tting kit is supplied. This usually includes: m approx exhaust extension plus 2 brackets plus heat wrap brackets for fi tting the skid channel to the Cabin fl oor. 3. A length of 63 Amp rated cable with 63 Amp plug to connect the generator. 4. Engine and alternator service books and laminated maintenance/user sheets designed to be left with the generator. A rectangular hole (vent) should be cut into the cabin wall to allow the hot air from the generator to escape. The size of hole should be a minimum of 550 mm wide x 300 mm high. It should be positioned 1425 mm up from the cabin generator compartment fl oor. All measurements are made internally. When you look into the cabins generator compartment, the generator is positioned up against the right hand cabin wall. The hot air escape should be cut into the right hand wall. The skids that are welded to the underside of the generator are not fi nished identically back or front. The rear skid fi xing can be bolted directly to the fl oor using the fi xing brackets. The front fi xing uses a bolt fi xed through the holes in the skid tubes. The fl oor must be a solid, fl at surface. All models have the hot air outlet on the right hand side of the set and should be pushed up to the right hand cabin wall, to within 25mm of the cabin wall. The foam seal (supplied fi tted to the generator) around the hot air exit will squash and act as an air seal. It does not need to be perfectly air tight. 1.2 Cabin Exhaust Outlet The cabin manufacturer should weld a short (100 mm) piece of 1½ inch outside diameter tube through the cabin wall near the roof inside the generator storage area. This will accept the 1½ inch ID fl exible tube supplied by HGI from the generator. The welded exit pipe can be cut at an angle outside to stop rain getting in. Using the fl exible pipe and clamps supplied, connect the fl exible pipe to the generator exhaust stack and to Compact Welf-Air

7 Installation Guide Harrington Generators International the cabins exhaust outlet. Use the heat wrap to keep the pipe cool to the touch. Care must be taken to make a gas tight seal when connecting the exhaust. A 63 Amp BS4343 socket is fi tted on the generator. This single socket supplies all the generators power for the cabin. The additional sockets are for auxiliary use for lights, tools or other suitable loads. In brief the following is the preferred sequence of events:- 1. Prepare the cabin, including hot air exits, inlet louvres, skid brackets and exhaust exit. 2. Fork truck the generator into place. 3. Push the set against the skid brackets and push against the hot air outlet cut into the cabin. 4. Bolt front skids down. 5. Clamp fl exible to exhaust and cabin exhaust outlet. Cover with wrap. 6. Connect cabin to the 63 Amp socket. Test generator. 1.3 Inlet Ventilation Adequate sized louvre panels should be built into the cabin doors and cabin walls for generator ventilation purposes. It is recommended that the typical free inlet should provide at least 0.08m 2 Care must be taken to ensure that the machine does not circulate its own exhaust fumes, the machine must be able to take in cold air in order to perform correctly. Weather ingress Animals, pests and vermin Health & Safety considerations Vandalism 1.5 Cabin Distribution Board The cabin AC distribution system should include all required protection MCBs and for out going circuits and a RCD earth leakage unit. 1.6 Access and Clearance The generator needs to occupy a clear space within the cabin compartment. Water pipes, pumps, tanks, waste pipes and other items should be mounted away from the generator. The cold air inlet must be kept clear. Suggested Clearances for access: Left Hand Side - 200mm Right Hand Side - 25mm Behind - 100mm In Front - 100mm Above - 500mm 2.0 Contact If you are in any doubt or have any concerns about the safe installation of the generator then please consult with your service depot or contact HGI: Technical Helpline: General Enquiries: Check with HGI Ltd if in doubt. 1.4 Hot Air Outlet If at all possible, fi nish the interior of the cabins hot air outlet with fl at fl ush metal, so that the generators foam seal has a suitable surface to seal against. It is recommended that high level ventilation performed by a grill or fan be installed to keep the generator cool. Typically this is 50% of the inlet area, see drawings for dimensions. The outside fi nish is the responsibility of the cabin manufacturer but should take into account: Compact Welf-Air

8 Harrington Generators International Drawings F F Drawings E E 3.1 General Arrangement Lockable Lift-off Rear Panel Hot Air Outlet Exhaust Outlet Lift-off Maintenance Door Lockable Hinged Service Door Fan Belt Access Plate Control Panel D D Output Socket 18.0 C C B off - B 12.0 Holes For insert & fabrication specifications refer to PD Material Finish C A A Checked 3D veiws are for illustration only. A B C Title Drg No. Compact Welf-air General Arrangement /00 D RW DAC R.W DAC Compact Welf-Air

9 Wiring Harrington Generators International 4.0 Wiring 4.1 WAC90H Compact Welf-Air

10 Harrington Generators International Wiring 4.2 WAC120H Compact Welf-Air

11 Wiring Harrington Generators International 4.3 Remote Start Timer DKG Compact Welf-Air

12 Harrington Generators International Wiring 4.3 Remote Start Leads Compact Welf-Air

13 Other Harrington Generators International 5.0 Installation Checklist # Description 1 Check the generator is bolted down to the fl oor. 2 Check the generator is pushed up to the right hand wall of the cabin and the air outlet connection is made to the air outlet grille with the foam sealing strip making a good seal. 3 Check there is adequate clearance around the generator and in front of the service door. 4 5 Check the exhaust extension is securely fi tted and that there is a gas tight seal around the joins. Check that the pipe clamps are fi tted and tight. If alternative method used check the air outlet duct is secure with the foam seal contact with the generator forming a good seal. 6 Check there is an adequate fresh inlet air supply through a louvre in the door or wall. 7 Check there is a high level ventilation grille or fan to keep the generator compartment cool. 8 Check all pieces of equipment are electrically cross bonded to earth. 9 Check all fuel connections to the fuel tank ( if supplied ) are sound. 10 Check all cables and fuel pipes are adequately supported and protected Compact Welf-Air

14 Harrington Generators International Manufacturer s Service and User Guides 6.0 Manufacturer s Service and User Guide Links Every effort is made to ensure that the manufacturer s user and service guides contained in this manual are the latest available at the time of publication. If in doubt about the recency of the documents then please contact the manufacturer or visit their website for the latest information. 6.1 Kubota Engine Operator s Manuals Sincro SK160 User Manual - If you are still unsure then please contact HGI Technical Helpline: +44 (0) or Compact Welf-Air

15 Manufacturer s Service and User Guides Harrington Generators International 6.3 DKG114 Datasheet TYPICAL CONNECTIONS DKG-114 MANUAL AND REMOTE START UNIT Total DC Current Output Rating: 10A-DC. Max. Current for each Terminal: 10A-RMS. Operating temp: -30 C (-22 F) to 70 C (158 F). Storage temp: -40 C (-40 F) to 80 C (176 F). Maximum humidity: 95% non-condensing. IP Protection: IP65 from front panel, IP30 from the rear. Dimensions: 72 x 72 x 43mm (WxHxD) Mounting: Front panel mounted with rear retaining steel spring. Panel cut-out dimensions: 68 x 68mm. Weight: 180 g (approx.) Charge excitation current: 12V-DC. Cranking dropouts: survives 0V for 100ms. Genset low frequency limit: 30Hz. Genset high frequency limit: 57Hz. Frequency error delay: 3 sec. Preheat timer: 10 or 30 sec selectable. Number of starts: 3 Start duration: 6 sec. Wait between starts: 10 sec. Cooldown duration: 2 min. Stop duration: 30 sec. Alarm duration: 1 minute. Protection delay: 10 sec. Case Material: Flame Retardant High Temperature ABS (UL94-V0, 110 C) Conformity (EU directives) -73/23/EEC and 93/68/EEC -89/336/EEC, 92/31/EEC and 93/68/EEC Norms of reference: EN (safety requirements) EN (EMC requirements) EN (EMC requirements) INPUTS AND OUTPUTS FUEL: Fuel solenoid control.(10 START: Engine starter solenoid control. (10 AUXILIARY: Positive output relay activated by any alarm condition (or optionally stop solenoid or preheat output). (10 LOW OIL PRESSURE SWITCH: negative closing switch input for low oil pressure protection. HIGH TEMP SWITCH: negative closing switch input for engine high temperature protection. DC SUPPLY: 12 or 24 volts DC, (+) and (-) terminals. REMOTE START/SPARE FAULT: If the battery positive voltage is applied to this input the genset will start. If the positive voltage is removed, it will stop. A battery negative connection will generate a SPARE ALARM. CHARGE: This terminal will be connected to the charge alternator D+ terminal. It will supply the excitation current and monitor the charge alternator status. G: Generator phase voltage. NEUTRAL: Generator neutral terminal. APPLICATIONS - Manual gensets, - Automatic gensets with voltage relay - Diesel pumps - Marine gensets - Marine auxiliary gensets - Marine diesel engines The unit fits into a standard 72x72mm panel meter opening and offers a very cost effective and space saving solution for the basic genset control. Thanks to the completely sealed structure, IP65 protection degree is achieved from the front panel. The unit works on both 12 Volt and 24 Volt gensets. DESCRIPTION FEATURES The DATAKOM model DKG-114 is a low cost, microprocessor controlled generator control unit designed to start and stop the genset both manually and remotely. The manual control is made using the pushbuttons on the front panel. The remote control is made via the remote start input signal. In the STOP position, the DC supply is removed from the module, thus zero power consumption is achieved. The unit powers up when the RUN button is pressed or battery+ is applied to the REMOTE START input. This will also energize the fuel solenoid relay. The engine is automatically started 3 times until operation. Once the engine is running, the device monitors the internal protections and external fault inputs. Only the first occurring alarm will be displayed, disabling further alarms. If the STOP button is pressed or the REMOTE START signal is removed, the engine will be stopped. The unit offers jumper selectable operating parameters, which lets it to be used in a large variety of applications. The jumper options select the operating voltage of the unit, the auxiliary relay function, the engine running signal type and the cooldown cycle. Both manual and remote controlled engine starting and stopping, Automatic shutdown on fault condition, Optional cooldown cycle on remote start operation, Optional energize to stop or preheat output, Survives cranking dropouts, High current relay outputs, Selectable engine running signal (from genset voltage or charge alternator), Delayed overspeed and underspeed alarm, Sealed front panel, IP65 protection. Plug-in connection system for easy replacement, Low cost, Small dimensions, Standard panel dimensions, (72x72mm) TECHNICAL SPECIFICATIONS Alternator voltage: 277V-AC (Ph-N) Alternator frequency: 0-200Hz. DC Supply Range: 9 to 33 V-DC. 4 to 33 V-DC while cranking Current consumption: 0 ma-dc in OFF mode 250 ma-dc max. (Relay outputs open) Compact Welf-Air

16 Important: This manual contains important safety information. If you lose this manual please contact HGI Limited with the Serial Number of your generator and we will send you a replacement free of charge.