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TECHNICAL TRAINING HANDBOOK
(LEVEL I)
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FORMATION TECHNICO-COMMERCIALE (NIVEAU I)
1
CONTENTS
Introduction
First part : basic principles
•Magnetic fields
•Creation of one sinusoid
•Frequency formula
•Number of phases
•Three phases alternators
•Three phases sinusoides
•A few formula to remember
•Intensity
•Power factor cos 
•Active power / Apparent power
•Electric power / mechanic power
•Mechanic power
•Various types of power
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Page 14 to 15
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Page 21 to 22
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Page 24 to 25
Page 26
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CONTENTS
Second part : the engine
•Various types of engine
•Diesel engine
•Air circuit
•Cooling circuit
•Water cooling circuit
•Various water cooling systems
•Gasoil supply circuit
•Various types of intake
•Pre-heating
•Suspensions
•Speed regulation
•Electronic speed regulation
•Diesel engine lubrification
•Engine securities
•Engine output
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Page 34 to 36
Page 37 to 39
Page 40 to 44
Page 45
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Page 47 to 48
Page 49 to 51
Page 52 to 53
Page 54
Page 55
3
CONTENTS
3rd Part : the alternator
•Exploded view
•Voltage regulator
•6 threads alternators coupling
•12 threads alternators coupling
•Electrical connections
•Alternator protection
Page 57
Page 58
Page 59
4th Part : control command
•Introduction
•Various types of panels
•Manual panel
•Automatic panel
•ATS
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Page 62 to 63
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Page 68 to 69
Page 70
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CONTENTS
5th Part : Various notions
•Installation
•Noise
Page 72 to 76
Page 77 to 78
Questions
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WHAT IS A GENERATING SET ?
+
ENGINE
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+
ALTERNATOR
FORMATION TECHNICO-COMMERCIALE (NIVEAU I)
CONTROL COMMAND
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PRESTATIONS DE SDMO INDUSTRIES
ENTRIES
AIR
INSTALLATION
EXHAUST
ENGINE
EXHAUST
AIR
WATER
Ventilation
Cooling
FUEL
Speed regulation
PETROL
GAZOIL
GAZ
FRAME POSITION
CONNECTION
Customer
Installator
ALTERNATOR
CONTROL
OUTPUT
LOAD
S
P
E
E
D
Ventilation
FREQUENCY
Voltage regulation
VOLTAGE
Manufacturer
Manufacturer
Engine safeties
Alternator safeties
Amps
KW
Circuit breaker control
or ATS
cos phi
normal/standby
Manufacturer
S.D.M.O.
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Customer
MAGNETIC FIELDS
 The magnetic field created by the rotating

magnet cuts the coils leading to induced
current.

 The flux direction changes (alternates) once per
rotation thus creating ALTERNATIVE POWER.
The number of times this is happening per second is called
FREQUENCY.
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MAIN FUNCTIONS
In case of mains failure
The generating set is an element of assistance
replacing the faulty mains and ensuring
operating of vital functions of one company,
one store or one hospital…
When there is no network
It is used as the unique energy production
source on one construction site, within one
works or in the desert…
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CREATION OF ONE SINUSOIDE
Rotor rotation degrees
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FREQUENCY FORMULA
Unlike the continuous current (supplied by a battery), the ALTERNATIVE current reverses its polarities + and – 50 times /
second, thus obtaining a frequency of 50 Hz (or 60 times in 60 Hz).
Formula to remember :
F
Frequency (Hz) = Number of poles pairs (P) x rotation speed (rp/s.)
If number of poles = 4 (2 pairs)
Then :
Engine speed = 1500 rp/mn
F =
2 x 1500
n
P
=
=
If number of poles = 2 (1 pair)
Then :
Engine speed = 3000 rp/mn
50 Hz
60 sec.
F =
1 x 3000
=
60 sec.
The frequency is constant. The number of poles is constant.
A genset must operate with a constant speed
 Importance of the frequency stability.
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50 Hz
SHAPE OF ONE SINUSOÏDE
Positive maximum voltage
Negative maximum voltage
1 period
50 ou 60 per second
1 Hz = one period / second
50 Hz = 50 periods / second
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NUMBER OF PHASES
We can distinguish alternators according to the number of phases :
SINGLE PHASE ALTERNATORS :
Fitted with coils so that the output voltage is obtained
in two terminal points.
THREE PHASES ALTERNATORS :
Fitted with 3 independent groups of coils un-phased
by 120° between each others.
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THREE PHASES ALTERNATORS
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THREE PHASES SINUSOIDES
1 period
Dephased
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A FEW FORMULAS TO REMEMBER
VOLTAGE:
Potential difference between two
threads. It is measured with a
voltmeter.
INTENSITY :
Current passing through one
receiver within a given time period.
It is measured with an anmeter in
series.
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Schéma Chute d’eau
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INTENSITY
Contrary to the voltage that must remain stable, intensity varies depending on the requested load.
Intensity, in the case of some electrical engines supply, may at the start-up of these engines, become during
some milliseconds from 6 to 8 times superior to the nominal intensity.
I (Amp.)
ID
I D = Release intensity
I N = Nominal intensity
IN
t
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POWER FACTOR 
In some cases of utilization (supply of electric engines), the current is « late » compared to the voltage. This
« delay » is called the power factor « cos ” and its value is very important for the gensets dimensions.
The power factor cos  of one electric engine is very different between the starting phase and the nominal
phase.
U
i

U

Cos  d = can reach 0,2
Cos  n = 0,8 up to 0,9
0
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/2


2 /3
2

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ACTIVE POWER / APPARENT POWER
Electrical equipments supplied by the generating set (the « consumers ») do not give back the entire power supplied.
One distinguishes then the active power from the apparent power.
a) SINGLE PHASED
Active power = Apparent power x Power factor Cos 
kWe = kVA x cos 
P(kW) = V x I x cos 
S (kVA) = V x I
« V » = Voltage between phase and neutral.
b) THREE PHASED
Active power = Apparent power x Power factor Cos x 3
P (kW) = U x I x cos  x 3
S (kVA) = U x I x 3
« U » = Voltage between phase
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ACTIVE POWER / APPARENT POWER
Active P.
(kW)

Apparent P.
(kVA)
Active power = Apparent power x Power factor Cos 
P = U x I x cos 
kWe = kVA x cos 
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ELECTRIC POWER / MECHANIC POWER
Alternators do not transform the entire power supplied. Their performance () is around 0,9.
Mechanic power = Electric power : 
P engine = elec. P. : 
(kW = kWe : )
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MECHANIC POWER : UNITS
The engines power rating is expressed with various units depending on the countries.
•In CV (« horse power »)
1 CV = 0,736 kW
•In « British horse power »
1 BHP = 0,746 kW
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MECHANICAL POWER RATING : CALCULATION OF DEMAND
We can determine the requested power for the engine from the demand in electric power
P eng. = U x I x cos  : 
Theoretical example : one installation requesting
- 500 amps
- 380 volts
- Power factor 0,8
- Performance 0,9
In Kilowatt : 168,9 kW
In HP : 229,5 Cv
In « British Horse Power » : 226,4 BHP
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VARIOUS TYPES OF POWER RATINGS
STANDARD
Power ratings for the GENERATING SET application are defined in the ISO 8528 international standard.
VARIOUS TYPES OF POWER RATINGS
PRP (Prime Power) : formerly known as Continuous Power
Available power (under variable load) 24H/24 with possibility of an overload of 10 % every 12 hours.
ESP (Emergency Standby Power) : formerly known as Standby Power
Power available (under variable load) limited to one 500 hours operating duty per year without possibility of
overload of 10% every 12 hours.
COP (Continuous Power) : power rating available (under constant load) 24H/24.
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VARIOUS TYPES OF ENGINES
COMBUSTIBLE
- Petrol
- Diesel
- Gaz (GPL, natural gaz , biogaz)
- Domestic Diesel oil
- Bunker C fuel
OPERATING CYCLES
- 2 strokes (mix of petrol + oil)
- 4 strokes (pure combustible)
SPEED
- Fast engines 3000 / 3600 rp/mn (50/60 Hz) – standby duty
- semifast engines1500 / 1800 rp/mn – continuous duty
- Slow engines 750 / 1000 / 1200 rp/mn – energy production / high power ratings
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DIESEL ENGINE
EXHAUST OUTLET
HOT WATER OUTLET
TURBOCOMPRESSOR
FAN
AIR INLET
CHARGING ALTERNATOR
FUEL FILTER
OIL FILTER
ENGINE POWER OUTPUT
WATER PUMP
STARTER
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DIESEL ENGINE
EXHAUST OUTLET
TURBOCOMPRESSOR
AIR INTAKE
HOT WATER OUTLET
FAN
ENGINE POWER OUTPUT
COLD WATER INLET
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AIR SYSTEM
EXHAUST OUTLET
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AIR INTAKE
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COOLING SYSTEMS
There are various types of cooling systems (see drawings on next pages) :
• AIR COOLING
TURBO NOT COOLED
SIMPLE CIRCUIT
TURBO COOLED
• WATER COOLING
DOUBLE CIRCUIT
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TURBO COOLED
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WATER COOLING SYSTEM
WATER TANK
RADIATOR
WATER PUMP
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VARIOUS TYPES OF WATER COOLING SYSTEMS
1) A single water system
Turbocompressor
John Deere « T »
Turbo with water cooled overfeeding air supply (see B)
Volvo « TWD »
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VARIOUS TYPES OF WATER COOLING SYSTEMS
2) Double circuit
Turbo with water cooled overfeeding air supply (see B)
NB : these engines are not advised for installations with separated air coolers
John Deere « H »
Volvo « TAD » and MTU – Series 2000
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VARIOUS TYPES OF WATER COOLING SYSTEMS
3 ) Water double circuit HT and BT
MTU : 4000 Series
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FUEL SUPPLY CIRCUIT
Separated fuel tank
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Integrated fuel tank
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FUEL SUPPLY CIRCUIT
Ligne d’injection
Valve de fermeture
Pompe à injection
Tuyauterie fuel
retour
Filtre fuel optionnel /
séparateur d’eau
Filtre fuel
Orifice remplissage et
bouchon
Tuyauterie fuel
aller
¼ du volume du réservoir
Trou d’homme
event
5% du volume du réservoir
Cloisons de séparation
Vanne de vidange
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FUEL SUPPLY CIRCUIT
Mechanic fuel pump (JOHN DEERE)
Electric fuel pump (MITSUBISHI)
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Fuel filter
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VARIOUS TYPES OF INTAKE
• One engine creates a mix air / combustible in
proportions enabling the complete combustible
combustion.
• Ideal mixture : 1 volume of fuel (combustible)
implies 35 volumes of air.
• To increase the engine maximal power, one needs
to increase both fuel and air quantity.
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VARIOUS TYPES OF INTAKE
• The maximum air volume that can be assimilated by an
engine equals its cylinder capacity.
• For one given cylinder capacity, the admitted air intake
quantity is :
- Proportional to its pressure
- Conversely proportional to its temperature
• To increase the power, one has to increase the air admitting
pressure to lower its temperature
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VARIOUS TYPES OF INTAKE
• In the basic engine, plungers, suck the air getting down in the cylinders :
ENGINE « NATURAL SUCTION »
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VARIOUS TYPES OF INTAKE
• To increase the intake air pressure one uses
a turbocharger : exhaust gaz drive one
turbine
« TURBO » ENGINE
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VARIOUS TYPES OF INTAKE
• To lower the air temperature, an intercooler
(air or water) is mounted in the intake
circuit.
INTERCOOLER ENGINE
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PRE-HEATING
Pre-heating of water cooled engines is ensured through
a resistor mounted in the water system to maintain the
water temperature to its nominal value (x°C).
The resistor is supplied in single phase or three phases (depending on the type). Its power is of 0,3 up to
9 kW.
The resistor is supplied by the mains.
In order to preserve its longevity, the resistor is in some cases equipped with a thermoregulator.
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SUSPENSIONS
Suspensions (rubber blocks) are intended to reduce vibrations between two parts.
Usually used between :
- skeleton genset (engine + alternator) and the frame
- Radiator and frame
The measuring unit for suspensions is the shore.
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SPEED REGULATION
As seen already , the engine speed must be constant. To achieve
this it is necessary to adjust it.
The regulation is a device which purpose is to maintain or vary
an operating element on a machine : current, voltage, frequency,
speed, pressure, power rating, output, etc…
The speed control is the key to the thermal engine regulation.
The speed regulation will act on the quantity of energy injected to the engine (fuel, gaz, petrol) to adapt it
to the load in order to maintain the engine speed within pre-determined limits.
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SPEED REGULATION
There are two types of speed regulations :
LEVIER DE COMMANDE CARBURANT
- Mechanical : the regulator is composed of
flyweights acting under the effect of the
centrifugal force.
 Precision is of +- 3%
RESSORT
DE REGULATION
ET DE STATISME
AJUSTAGE
VITESSE
- Electronics : see hereafter
AXE MOBILE
MASSELOTTE
REFERENCE
 Precision is of +- 1%
The mechanical regulation
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THE ELECTRONIC SPEED REGULATION
The pick-up sensor measures the engine speed and sends this information to the electronic regulation.
The actuator is a mechanical system acting on the injection pump. The actuator control is managed with the
electronic governor.
Speed
control unit
Electric
actuator
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Pick-up
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THE ELECTRONIC SPEED GOVERNOR
Actuator
Pick-up
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THE ELECTRONIC SPEED GOVERNOR
Speed governor (panel opened)
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LUBRIFICATION OF THE DIESEL ENGINE
Lubrification has 3 goals :
 lubrification of moving parts in friction
- Bearings
- Bearing surfaces
- Gearing
- Segmentation and liners
 Cooling of parts submitted to
temperature
- Turbo
- Plungers cap
- Injection mump
 Removal of impurities resulting from wear
and combustion
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DIESEL ENGINE LUBRIFICATION
Drain pump
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Oil filter
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ENGINE SAFETIES
On modern engines, numerous securities are available . Amongst the most common let’s mention :
- Oil pressure
- Water temperature
- Water level
- Overspeed
- Level of combustible
But also :
- Oil temperature, combustible pressure , combustible temperature, etc…
-Safeties can have one or two thresholds (alarm or fault)
- 1 threshold : Alarm or fault = signals the fault to the user or stops the engine
- 2 thresholds : Alarm and fault = signals the fault to the user and stops the engine
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ENGINE PERFORMANCE
COMBUSTION HEAT DISTRIBUTION
3%
23%
40%
34%
Effective power
Cooling system
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Exhaust gas
Radiation and convection
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THE ALTERNATOR : EXPLODED VIEW
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VOLTAGE REGULATION
In order to supply the most stable voltage ,
the alternator is fitted with a voltage
regulator.
Depending on the requested voltage
precision, usually between +/- 5% up to
+/- 1%, regulators are +/- complex.
For example, all gensets from the ranges
MONTANA, NEVADA, ATLANTIC and
EXEL are fitted with electronic voltage
regulators with a precision of +/- 1%.
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6 THREADS ALTERNATORS COUPLING
230 / 400 V 3 PHASES + NEUTRAL
STAR CONNECTION
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230 V 3 PHASES
DELTA CONNECTION
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12 THREADS ALTERNATORS COUPLING
SERIES DELTA CONNECTIONS
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PARALLEL STAR COUPLING
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SERIE STAR COUPLING
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ELECTRICAL CONNECTIONS
Each genset is fitted with one terminal box which purpose is to :
- Connect the genset circuit-breaker to the utilization
- Connect the genset earth terminal to the installation earth
- Connect the genset auxiliaries
(battery charger, mains detection, pre-heating, etc…)
- Connect the modules
( remote transfert, safety genset, etc…)
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Manual
Auto
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ALTERNATOR PROTECTION
The alternator protection is ensured with the CIRCUIT-BREAKER.
Definition : The circuit-breaker is an electric equipment which role is to :
- Isolate the genset from its utilization (power cut device)
- Ensure the magnetic protection (short-circuit)
- Ensure the thermal protection (overcurrent)
 MAGNETO-THERMAL PROTECTION
Control :
There are circuit breakers
- with manual command
- with electrical command.
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ALTERNATOR PROTECTION
There are two types of MANUFACTURE :
-MODULAR
Casted casing, maximal intensity : 125 Amps
-COMPACT
Possibility to adjust the magnetic and thermal threshold
from 125 Amps up to several thousand of Amps.
Disjoncteur modulaire
NUMBER OF POLES :
-BIPOLAR ( 2 poles) single phase (1 phase + neutral)
-THREE POLAR (3 poles) three phases without neutral (3 phases)
-FOUR POLAR (4 poles)
Three phases with neutral (3 phases + neutral)
Disjoncteur compact
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INTRODUCTION
The generating set control command is ensured with the electric panel enabling :
CONTROL
To watch the various genset parameters
-Mechanical (pressure, temperatures, levels, etc…)
-Electrical (voltage, intensity, power ratings, etc…)
COMMAND
To change the status of the genset (start-up, standstill, coupling, etc…)
Command is ensured either through :
- Ignition key
- Pushing-button
- keyboard
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VARIOUS TYPES OF PANEL
There are three types of panels :
•MANUAL PANEL (M50 or M150) :
To start-up the generating set manually with an ignition key.
•AUTOMATIC PANEL (TELYS) :
The automatic panel enables to start the generating set without human intervention closing-up the external
contact. It also enables to start-up the genset in manual mode.
•COUPLING (PROCESS) :
To put in parallel 2 or several generating sets between each others or networked
Interest : In most cases, this enables to add their respective power
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MANUAL PANEL : M50 OR M150
Manual start panels fitted on the generating set side.
These panels include :
- Measuring / control equipments
(ignition key, testing lights, emergency stop button, hours
counter…)
M50
- Operating lights
(charging alternator fault, oil pressure failure, water
temperature fault…)
M150
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AUTOMATIC PANEL : TELYS
This control command panel integrates all the
genset’s controls, securities and status
display.
With a very user-friendly man/machine
interface , 150 configuration parameters
available in reading mode to check the genset
operating status or through access code for
their modification.
All gensets from 16 kVA onwards can be
equipped.
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AUTOMATIC PANEL : TELYS
The display module is comonly called interface man/machine .
It is the only visible contact between the user and the generating set.
28 pulse keys diameter 10 and diametrer 13, finger-guided for a better centring
LCD screen with integrated back light , with 8 lines of
21 characters
8 VISUALISATION LEDs
For alarms, defects, status
- oil pressure defect
- water temperature defect
- no-start fault
- overspeed defect
- genset ready to supply
- charging alternator failure
- general alarm
- general failure
1 POWER-ON key with
integrated LED (after
automatic extinction)
15 PROGRAMMING keys
4 selecting keys
SELECTION for operating
modes with integrated LEDs
integrated for selection
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4 VISUALISATION keys for electrical
values and engine parameters
2 RESET keys
(FAILURE and TEST LEDs)
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2 keys OPENING and
CLOSING genset output
with integrated LED
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ATS’s
Definition : The ATS enables to select one source of energy amongst
2 existing. It includes two contactors (2, 3 or 4 poles).
The ATS is separated from the genset and is usually fitted the closest
possible to the installation circuit-breaker.
Protection :
-Mechanical
A locking system avoids the locking or simultaneous
opening of both contactors.
-Electrical
Each contactor is protected with one thermal relay
(overcurrent)
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ATS
E le c t r i c i t é
d e F ran c e
NETWORK
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INSTALLATION
Installation of one generating set must meet
with certain rules which must be strictly
followed to obtain a correct operating of the
equipment
The non-respect of the fundamental
principles exposes the whole installation to
damages and abnormal wear and tear.
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INSTALLATION : A FEW RULES TO RESPECT
INSTALLATION ROOM
It must be located nearby the electric panel.
The choice of the local must take into account :
- Noise disturbance
- Combustible supply
- Burnt gaz exhaust
- Access to the genset for maintenance.
Doors opening impossible. Maintenance and repair Exhaust and ventilation correct
difficult
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Ground uneven : genset
unstable position
Plan for example :
- One anti-vibrations flagstone underneath the
generating set, when located near sensitive
premises.
- sound traps fitted within the inlet and outlet
air ducts.
- Exhaust silencers adapted
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INSTALLATION : A FEW RULES TO RESPECT
VENTILATION
The heat released by the generating set must be evacuated outside the local, in order to ensure a good operating.
These calories released from the generating set are from various origins :
- Cylinders cooling
- Dissipation of the engine block as well as the exhaust pipe
- Dissipation of the alternator
It is necessary to equip the local with air inlets and outlets adapted to conditions of use and to the cooling system.
Insufficient ventilation would provoke an increase of the ambient temperature leading to at least a drop in power ,
indeed the genset shutdown.
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THE GENERATING SET INSTALLATION
COMBUSTIBLE
One has to respect certain rules regarding distribution and storage.
One usually fits a daily tank as well as a storage tank on fixed installations. Both these tanks can become one if the
genset fuel consumption is low.
EXHAUST OF BURNT GAZ
Some constraints must be respected :
-Load drops
-Isolation
-Suspensions
-Noise level
-Air pollution
One must remember that the more winding a circuit is the more load drops it provokes.
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THE GENERATING SET INSTALLATION
START-UP
The type of starting systems directly depends on the engine temperature conditions. Therefore for starts with very
low temperatures one has to foresee start-up devices such as intake air pre-heating, gazoil pre-heating…
In some cases, two starters are fitted on the generating set, the second one acting as the standby one.
COOLING
Three types of heat production must be evacuated or recovered :
- engine cooling water
- ventilating air from the local
- exhaust gaz
Specific systems are fitted in order to canalize this heat : radiator, air cooler, sewage water exchanger , ventilation…
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NOISE LEVEL
Noise level is expressed in decibels (dB). Some examples :
Levels of acoustic
pressure in dB
120
Boiler works
Engine test bench
Air hammer
Pain threshold
100
Sales yarn spinning
Inside of a bus
Car hooter
80
Conversation
Street with a poor traffic
Radio of poor intensity
Quiet countryside
40
20
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Examples
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NOISE LEVEL
The new noise level standard requested by the directive2000 / 14 CE is in force within the European Union and
affiliated countries. It sets a limit regarding the acoustic power expressed in LWA (and no longer a noise level limit )
to every generating sets, the generating set operating at ¾ of its nominal power.
The authorized acoustic power variates depending on the power rating portion of the equipment according to the
following distribution :
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GENSET Power rating
Noise level
From 0 up to 2 kW
LWA 97
From 2.1 up to 3.1 kW
LWA 98
From 3.2 up to 10 kW
LWA 99
From 10.1 up to 31.9 kW
LWA 98
From 32 up to 316 kW
LWA 99
From 317 up to 400 kW
LWA 100
Above 400 kW
No limits
FORMATION TECHNICO-COMMERCIALE (NIVEAU I)
The acoustic power takes into account the noise
level but also the equipment measuring surface.
Limiting the acoustic power and no longer the
pressure enables to set comparison equivalences
between a portable genset and a soundproofed
container.
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