Manually Testing Diesel Generator HT Cooling Water Set Points (Alarm and Shutdown)
Important Notes:
- Safety First: Ensure all safety precautions are followed before performing this procedure. Refer to the manufacturer’s manual for specific safety instructions related to your generator model.
- Qualified Personnel: Ideally, a qualified technician familiar with the generator and its control system should perform this test.
- Alternatives: Consult the manufacturer’s manual to see if there are alternative methods for testing the set points, such as using diagnostic software or built-in testing functions.
Procedure:
- Preparation:
- Generator Off and Secured: Ensure the generator is completely off and disconnected from any electrical load. Lock out or tag out any switches to prevent accidental startup.
- Identify Components: Locate the HT cooling water temperature sensor, the high-temperature alarm indicator (light or buzzer), and the engine shutdown mechanism (usually a relay or contactor). Refer to the generator manual or electrical schematics for guidance.
- Tools: Gather necessary tools, which might include a reliable thermometer with a range exceeding the expected high-temperature set point, a heat source (optional), safety glasses, gloves, and rags.
- Temperature Monitoring:
- Start the engine and allow it to run for a short period to reach normal operating temperature. Monitor the coolant temperature using the generator’s built-in gauge or your separate thermometer at the designated point (refer to the manual).
- Alarm Test:
- Gradual Increase (Preferred Method): If feasible, gradually increase the coolant temperature using a controlled heat source (e.g., heat lamp) directed towards the cooling system. This allows for observing the alarm activation at the designated set point.
- Manual Intervention (Alternative): If a controlled heat source isn’t available, you might carefully simulate a temperature rise by briefly disconnecting the sensor or simulating a high resistance with a resistor (consult a qualified electrician for safe implementation).
- Monitor the instrument panel or alarm indicator. Once the coolant temperature reaches the alarm set point as specified in the manual, the high-temperature alarm should activate (usually a visual or audible signal).
- Record the observed temperature at which the alarm activates.
- Shutdown Test (Use Caution):
- Important: Proceed with extreme caution as this test involves stopping the engine. Ensure no critical loads depend on the generator’s operation during this test.
- Gradual Increase (Preferred Method): If using a controlled heat source, continue raising the coolant temperature slightly above the alarm set point. Observe if the engine shuts down automatically as programmed.
- Manual Intervention (Alternative): If using manual intervention, keep the sensor disconnected or resistance simulated for a very brief period (seconds) just beyond the alarm set point. The engine control system should trigger a shutdown.
- Record the observed temperature at which the engine shuts down.
- System Reset and Verification:
- Once the alarm and shutdown functions have been tested, allow the engine to cool down naturally.
- Reconnect the sensor (if disconnected) or restore normal operation if a resistor was used.
- Verify that the engine starts and runs normally after the cooling system temperature has returned to a safe range.
- Documentation:
- Document the observed alarm and shutdown set points during the test and compare them to the manufacturer’s specifications.
- Document any discrepancies or malfunctions for further investigation or repairs.
Important Reminders:
- Exercise caution during the test, especially during the shutdown simulation.
- Consider alternative testing methods recommended by the manufacturer if available.
- If unsure about any step, consult a qualified technician for safe and proper execution of the procedure.