柴油发电机组调试步骤 Debugging steps for diesel generator set

不管是任何型号的柴油发电机组安装完毕，投入运行之前，必须对机组进行全面检查，这样才能做到万无一失，那么到底应该怎样检查呢？

   一、柴油机的启封

　　为了防止柴油机锈蚀，产品出厂之时，其内外均已油封，因此，新机组安装完毕，符合安装要求后，必须启封才能启动，否责会造成飞车危险，应予重视。

   二、除去油封的方法步骤如下：

　　1、将柴油加热到45℃~56℃以上，用以洗擦除去外部防锈油。

　 2、将水加热90℃以上，然后从水套出水口不断地灌入，由汽缸体侧面的放水开关（或水泵进水口）流出，连续进行2--3小时，并间断地摇转曲轴，使活塞顶、气缸套表面及其他各处的防锈油溶解流出。

　　3、用清洁柴油清洗油底壳，并换入新机油。冷却及燃油系统、燃油喷射调速系统、水泵、启动传动系统均应按说明书要求进行清洁检查，并加足清洁冷却水，充足起动蓄电池，做好开机前的准备工作。

    三、机组试机前的检查

　　柴油机试机前的检查步骤如下：

　　1、检查机组表面是否清洁干净；地脚螺帽、飞轮螺钉及其他运动机件螺帽有无松动现象，发现问题及时紧固。

　　2、检查各部分间隙是否正确，尤其应仔细检查各进、排气门的间隙几减压机构间隙是否符合要求。

   3、将各气缸置于减压位置，转动曲轴检听各缸机件运转声音有无异常声响，曲轴转动是否自如，同时将机油泵入个摩擦面，然后，关上减压机构，摇动曲轴，检查气缸是否漏气，如果摇动曲轴时，感觉很费力，表示压缩正常。

4、检查燃油供给系统的情况，步骤如下：

　　①检查燃油箱盖上的通气孔是否顺畅，若孔中有污物应清除干净。加入的柴油是否符合要求的牌号，油量是否充足，并打开油路开关。

　　②打开减压机构摇转曲轴，每个气缸应有清脆的喷油声音，表示喷油良好。若听到喷油声不来油，可能油路中有空气，此时可旋松柴油滤清器和喷油泵的放气螺钉，以排除油路中的空气。

　　③检查油管及接头处有无漏油现象，发现问题及时处理解决。

 5、检查水冷却系统的情况，步骤如下：

　　①检查水箱内的冷却水量是否充足，若水量不足，应加足清洁的软水。

　　②检查接头水管有无漏水现象，发现问题及时处理解决。

　　③检查冷却水泵的叶轮转动是否灵活，传动带松紧是否适当。检查传动带松紧，在转动带中部用手推压，传动带被压下10~15mm为宜。

6、检查润滑系统的情况，步骤如下：

　　①检查机油管及管接头处有无漏油现象，发现问题及时处理解决。

　　②检查油底壳的机油量，将曲轴箱旁的量油尺抽出，观察机油面的高度是否符合规矩的要求，否则应添加机油，对柴油机，冬季加8号或11号柴油机机油，夏季加14号机油。在检查是，如发现油面高度在规矩高度以上时，应认真分析机油增多的原因，通常有三个方面的原因。

　　　　a.加机油时，加的过多。

　　　　b.柴油漏入曲轴箱，将机油冲稀。

　　　　c.冷却水漏入机油中。

　　③需要人工加油的油孔，均应加注机油做用油枪加注润滑脂。

7、检查起动系统情况，步骤如下：

　　　　a.先查起动蓄电池电液比重是否在1.240~1.280范围内，若比重小于1.180表明蓄电池电量不足。

　　　　b.检查电源电线是否正确。

　　　　c.检查蓄电池接线柱上有无积污或氧化现象，应将其打磨干净。

　　　　d.检查起动电动机及电磁操纵机构等电气触电接触是否良好。

四、交流发电机安装检查步骤如下：

　　1、交流发电机与柴油发电机耦合，要求联轴器的平行度和同心度均小于0.05mm。实际使用时要求可略底些，约在0.1mm以内，过大回影响轴承的正常运转，导致破坏，耦合好要用定位销固定。安装前要复测耦合情况。

　　2、滑动轴承的发电机在耦合时，发电机中心的高度要调整得你柴油机中心略地些，这样柴油机上的飞轮的重量就不会转移到发电机轴承上，否则发电机轴承将额外承受飞轮的重量，不利于滑动轴承油膜的形成，导致发热，甚至烧毁轴承。这类发电机的联轴器上也不能带任何重物。

　　3、安装发电机时，要保证冷却空气入口处畅通无阻，并要僻避免排出的热空气再进入发电机。如果通风盖上有百叶窗，则窗口应朝下，以满足保护等级的要求。

　　4、单轴承发电机的机械耦合要特别注意定子转子之间的气隙要均匀。

　　5、按原理图或接线图，选择合适的电力电缆，用铜接头来接线，铜接头与汇流排，汇流排与汇流排固紧后，其接头处局部间隙不大于0.05mm，导线间的距离不大于10mm，还需加装必要的接地线。

　　6、发电机出线盒内接线端头上打有U、V、W、N印记，不表示实际的相序取决于旋转方向。合格证上印有UVW表示顺时针旋转时的实际相序，VUW即表示逆时针旋转时的实际相序。

　　7、如果在供电系统中的各台柴油发电机的中性点互相连接，或发电机中性点和变压器及其负荷中性点连接时，发电机组运行时在中性线会出线3倍频率的中线电流。因此，必须对运行中可能出现的各种负载情况下，发电机的中线电流进行测定。为使发电机运行不致过热，其中线电流不得超过发电机额定电流底的50%。中线电力过大，在中线上应加装中线电抗器加以限制。

Before any type of diesel generator set is installed and put into operation, a comprehensive inspection of the unit must be carried out to ensure that everything is foolproof. So, how should the inspection be carried out?

1、 Unsealing of diesel engine

In order to prevent corrosion of the diesel engine, both the inside and outside of the product are sealed with oil when it leaves the factory. Therefore, after the installation of the new unit is completed and meets the installation requirements, it must be unsealed before starting. Failure to take responsibility may cause a risk of runaway and should be taken seriously.

2、 The steps for removing the oil seal are as follows:

1. Heat the diesel to above 45 ℃~56 ℃ for cleaning and removing external rust proof oil.

2. Heat the water to above 90 ℃, then continuously pour it in from the water jacket outlet, and let it flow out through the water discharge switch (or water pump inlet) on the side of the cylinder block for 2-3 hours, while intermittently shaking the crankshaft to dissolve the rust proof oil on the piston top, cylinder liner surface, and other areas.

3. Clean the oil pan with clean diesel and replace with new engine oil. The cooling and fuel system, fuel injection speed control system, water pump, and starting transmission system should be cleaned and inspected according to the instructions, and sufficient clean cooling water should be added. The starting battery should be adequately charged, and preparations should be made before starting up.

3、 Inspection before unit test run

The inspection steps before the diesel engine test are as follows:

1. Check if the surface of the unit is clean and tidy; Check for looseness in the anchor nuts, flywheel screws, and other moving parts nuts, and tighten them promptly if any problems are found.

2. Check whether the gaps between each part are correct, especially carefully inspect whether the gaps between the intake and exhaust valves and the pressure reducing mechanism meet the requirements.

3. Place each cylinder in the depressurization position, rotate the crankshaft to check for any abnormal sounds from the operation of the cylinder components and whether the crankshaft rotates freely. At the same time, pump the oil pump into the friction surface, then close the depressurization mechanism, shake the crankshaft, and check for air leakage in the cylinder. If it feels difficult to shake the crankshaft, it indicates normal compression.

4. Check the condition of the fuel supply system, the steps are as follows:

① Check if the vent hole on the fuel tank cap is smooth, and if there is any dirt in the hole, it should be cleaned thoroughly. Whether the added diesel meets the required grade, whether the fuel volume is sufficient, and turn on the oil circuit switch.

② Turn on the pressure reducing mechanism and rotate the crankshaft. Each cylinder should have a clear fuel injection sound, indicating good fuel injection. If you hear the sound of fuel injection and there is no oil coming, there may be air in the oil circuit. At this time, you can loosen the air release screws of the diesel filter and fuel injection pump to eliminate the air in the oil circuit.

③ Check for oil leakage at the tubing and joints, and promptly address and resolve any issues found.

5. Check the condition of the water cooling system, the steps are as follows:

① Check if the cooling water in the water tank is sufficient. If the water is insufficient, add enough clean soft water.

② Check if there is any leakage in the joint water pipe, and promptly address and solve any problems found.

③ Check whether the impeller of the cooling water pump rotates flexibly and whether the tension of the drive belt is appropriate. Check the tightness of the drive belt, and push it down by hand in the middle of the rotating belt. It is advisable to press down the drive belt by 10-15mm.

6. Check the condition of the lubrication system, the steps are as follows:

① Check for oil leaks at the oil pipes and pipe joints, and promptly address and resolve any issues found.

② Check the oil level in the oil pan, pull out the dipstick next to the crankcase, and observe whether the height of the oil level meets the requirements of the regulations. Otherwise, add engine oil. For diesel engines, add No. 8 or No. 11 engine oil in winter and No. 14 engine oil in summer. When checking, if the oil level is found to be above the standard height, the reasons for the increase in oil should be carefully analyzed. There are usually three reasons for this.

a. When adding oil, add too much.

b. Diesel leaks into the crankcase, diluting the engine oil.

c. Cooling water leaks into the engine oil.

③ Oil holes that require manual refueling should be filled with engine oil and lubricated with grease using an oil gun.

7. Check the starting system condition, the steps are as follows:

a. First, check if the specific gravity of the starting battery's electric fluid is within the range of 1.240~1.280. If the specific gravity is less than 1.180, it indicates that the battery is low.

b. Check if the power cord is correct.

c. Check for dirt or oxidation on the battery terminals and polish them clean.

d. Check whether the electrical contact of the starter motor and electromagnetic control mechanism is good.

4、 The installation and inspection steps for the AC generator are as follows:

1. The coupling between the AC generator and the diesel generator requires that the parallelism and concentricity of the coupling be less than 0.05mm. In actual use, it is required to be slightly lower, within about 0.1mm. If it is too large, it will affect the normal operation of the bearing and cause damage. If the coupling is good, it should be fixed with positioning pins. Before installation, it is necessary to retest the coupling situation.

2. When the sliding bearing generator is coupled, the height of the generator center should be adjusted slightly to the center of the diesel engine, so that the weight of the flywheel on the diesel engine will not be transferred to the generator bearing. Otherwise, the generator bearing will bear the additional weight of the flywheel, which is not conducive to the formation of the sliding bearing oil film, resulting in heating and even burning of the bearing. The coupling of this type of generator should not carry any heavy objects.

3. When installing the generator, it is necessary to ensure that the cooling air inlet is unobstructed and to avoid the hot air discharged from entering the generator again. If there are louvers on the ventilation cover, the window should face downwards to meet the protection level requirements.

4. Special attention should be paid to the uniform air gap between the stator and rotor in the mechanical coupling of a single bearing generator.

5. According to the schematic or wiring diagram, select the appropriate power cable and use copper connectors for wiring. The copper connectors should be connected to the busbar, and after the busbar is tightened, the local gap at the joint should not exceed 0.05mm, and the distance between the wires should not exceed 10mm. Necessary grounding wires should also be installed.

6. The markings of U, V, W, and N on the wiring terminals inside the generator outlet box do not indicate that the actual phase sequence depends on the direction of rotation. The certificate of conformity is printed with UVW indicating the actual phase sequence when rotating clockwise, and VUW indicating the actual phase sequence when rotating counterclockwise.

7. If the neutral points of each diesel generator in the power supply system are connected to each other, or if the neutral points of the generator are connected to the neutral points of the transformer and its load, the generator set will output a neutral current of three times the frequency on the neutral line during operation. Therefore, it is necessary to measure the neutral current of the generator under various load conditions that may occur during operation. In order to prevent the generator from overheating during operation, the line current should not exceed 50% of the rated current of the generator. The neutral power is too high, and a neutral reactor should be installed on the neutral line to limit it.