ANKA+ UNMANNED AERIAL

VEHICLE (UAV) SYSTEMS

1st February 2022

GENERATORS D LEVEL MAINTENANCE

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 Contents
 GENERAL OVERVIEW FOR GENERATOR

 MEPS GENERATOR

 General overview

 How it is work Meps Generator

 Maintenance

 GDT&AGP-450 GENERATORS

 General overview

 How it is work GDT&AGP-450 GeneratorS

 Maintenance

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 GENERAL OVERVIEW FOR GENERATORS

What is a generator?

 A generator is an electrical generator that converts mechanical energy into electrical energy. It is a backup
energy source. The generator is usually used in places where there is a frequent power outage and in
areas where there is no power grid at all. It can be used as a backup power supply, or in some cases it can
also be used as the main power supply.

How does a generator work?

 The generator consists of an alternator and an engine. The motor and the alternator are connected to each
other. In the engine part of the generator, fuels such as gasoline, diesel fuel, natural gas are burned and
converted into heat energy, and then into mechanical energy. This mechanical energy produced in the
engine is transmitted to the alternator connected to the engine. The alternator is magnetized by mechanical
rotational action and generates electrical energy.

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 GENERAL OVERVIEW FOR GENERATORS

 Main Part of Generators

• Engine
• Alternators
• Control Board
• Chassis and Fuel Tank
• Cabin or Container
• Lubraticion System
• Cooling and Exhaust System
• Starter and Batteries

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 GENERAL OVERVIEW FOR GENERATORS

 Engine: It is the part where the fuel is burned and the heat energy is converted into mechanical energy.
The larger the engine, the more electricity can be generated.

 Alternator(s): It is the part where electricity is generated. In an alternator, mechanical energy is converted
into electrical energy.

 Control Panel: It is the part where the technical values of the generator are displayed that determines when
the generator will be activated when the network is disconnected. It can be called the brain of the
generator.

 Chassis and Fuel Tank: The part on which the generator is mounted is the chassis. The chassis is also
often used as a fuel tank. Fuel tanks can be located on the chassis, as well as as as a separate tank
outside the chassis.

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 GENERAL OVERVIEW FOR GENERATORS

 Radiator: It is the propeller that cools the heated engine.

 Cabin: If the generator is to be placed in an external environment, it is placed in a cabin to avoid being
affected by weather conditions or making noise.

 Lubrication System: The engine needs to be lubricated, and this is carried out by an oil pump and a
reservoir connected to the engine.

 Exhaust System: It allows the outside of the exhaust gas produced by the engine to be disposed of.

 Starter and Batteries: Just like in a car or truck, an electric starter is required for the generator to start
working. This engine is powered by a separate charger or a battery charged by the generator output itself.

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 MEPS GENERATORS
 SYSTEM DEFINITION

Mobile Electric Power Supply is a unit consisting of a 30 ft container, an external regulator which
regulates the city mains voltage coming to GCS, an external Uninterruptible Power Supply (UPS), and a Dual
Generator Set which supplies the GCS. MEPS ENSURES THAT; GCS is supplied through the mains, GCS
is supplied through the generators GCS is supplied through SUPS.

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 MEPS GENERATORS

GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS

Generator Brand Isbir Electricity Industry Inc. Engine Brand Deutz BF04M2012C

Manufacturer Information İŞBİR Manufacturer Information Deutz

Engine Power 71kW
Power 2x40 kVA Stroke 4
Production Type Dual Synchrounous Number of Cylinders 4
Voltage 400/231 V Revs. 1500 rpm
Frequency 50Hz Cooling Water Cooled
Current 2x57,8 A Cylinder Diameter 101 mm
Power Factor (Cos ɸ) 0.8 Course 126 mm
Revs. 1500 rpm/min Compression Ratio 19
Phase 3 Ignition System Direct Injection
Waveform Sinusoidal Governor Type Electronic
Connection Method Star Fuel Consumption 202 g/kwh @ 1500 rpm
Control Mode EASYGEN 3200 Filters Exchangeable (Fuel,Oil,Air)
Communication Type TCP/IP Dry Weight 509kg
Usage Options Manual/Automatic Dimensions Width 560mm x Lenght 661mm x Height 832mm

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 MEPS GENERATORS

 GENERATOR VIEW

Left Side of View

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 MEPS GENERATORS

 GENERATOR VIEW

Left Side of View

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 MEPS GENERATORS

 ENGINE:

• The engine is the source of the input mechanical energy to the generator. The size of the engine is directly proportional to the
maximum power output the generator can supply. There are several factors that you need to keep in mind while assessing the
engine of your generator.

• Type of Fuel Used – Generator engines operate on a variety of fuels such as diesel, gasoline, propane (in liquefied or gaseous
form), or natural gas. Smaller engines usually operate on gasoline while larger engines run on diesel, liquid propane, propane gas,
or natural gas. Certain engines can also operate on a dual feed of both diesel and gas in a bi-fuel operation mode.

• Overhead Valve (OHV) Engines versus non-OHV Engines – OHV engines differ from other engines in that the intake and exhaust
valves of the engine are located in the head of the engine’s cylinder as opposed to being mounted on the engine block. OHV
engines have several advantages over other engines such as:

• Compact design • Simpler operation mechanism • Durability

• Durability • User-friendly in operations

• Low noise during operations • Low emission levels

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 MEPS GENERATORS

 ENGINE:

• Cast Iron Sleeve (CIS) in Engine Cylinder – The CIS is a lining in the cylinder of the engine. It reduces wear and tear, and ensures
durability of the engine. Most OHV-engines are equipped with CIS but it is essential to check for this feature in the engine of a generator.
The CIS is not an expensive feature but it plays an important role in engine durability especially if you need to use your generator often or
for long durations.

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 MEPS GENERATORS

 ENGINE

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 MEPS GENERATORS

 ENGINE

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 MEPS GENERATORS

 ALTERNATOR: The alternator, also known as the ‘genhead’, is the part of the generator that produces the electrical output from the mechanical input supplied by
the engine. It contains an assembly of stationary and moving parts encased in a housing. The components work together to cause relative movement between
the magnetic and electric fields, which in turn generates electricity.

• Stator – This is the stationary component. It contains a set of electrical conductors wound in coils over an iron core.

• Rotor / Armature – This is the moving component that produces a rotating magnetic field in any one of the following three ways:

 By induction – These are known as brushless alternators and are usually used in large generators.

 By permanent magnets – This is common in small alternator units.

 By using an exciter – An exciter is a small source of direct current (DC) that energizes the rotor through an assembly of conducting slip rings and brushes.

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 MEPS GENERATORS

 The rotor generates a moving magnetic field around the stator, which induces a voltage difference between the windings of the stator. This produces the
alternating current (AC) output of the generator.

 The following are the factors that you need to keep in mind while assessing the alternator of a generator:

• Metal versus Plastic Housing – An all-metal design ensures durability of the alternator. Plastic housings get deformed with time and cause the moving parts of
the alternator to be exposed. This increases wear and tear and more importantly, is hazardous to the user.

• Ball Bearings versus Needle Bearings – Ball bearings are preferred and last longer.

• Brushless Design – An alternator that does not use brushes requires less maintenance and also produces cleaner power.

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 MEPS GENERATORS

 The rotor generates a moving magnetic field around the stator, which induces a voltage difference between the windings of the stator. This produces the
alternating current (AC) output of the generator.

 The following are the factors that you need to keep in mind while assessing the alternator of a generator:

• Metal versus Plastic Housing – An all-metal design ensures durability of the alternator. Plastic housings get deformed with time and cause the moving parts of
the alternator to be exposed. This increases wear and tear and more importantly, is hazardous to the user.

• Ball Bearings versus Needle Bearings – Ball bearings are preferred and last longer.

• Brushless Design – An alternator that does not use brushes requires less maintenance and also produces cleaner power.

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MEPS GENERATORS

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 MEPS GENERATORS

 Control Panel : This is the user interface of the generator and contains provisions for electrical outlets and controls. The following article provides further details
regarding the generator control panel. Different manufacturers have varied features to offer in the control panels of their units. Some of these are mentioned
below.

• Electric start and shut-down – Auto start control panels automatically start your generator during a power outage, monitor the generator while in operation,
and automatically shut down the unit when no longer required.

• Engine gauges – Different gauges indicate important parameters such as oil pressure, temperature of coolant, battery voltage, engine rotation speed, and
duration of operation. Constant measurement and monitoring of these parameters enables built-in shut down of the generator when any of these cross
their respective threshold levels.

• Generator gauges – The control panel also has meters for the measurement of output current and voltage, and operating frequency.

• Other controls – Phase selector switch, frequency switch, and engine control switch (manual mode, auto mode) among others.

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MEPS GENERATORS

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MEPS GENERATORS

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 MEPS GENERATORS

 Chassis and Fuel Tank: The fuel tank usually has sufficient capacity to keep the generator
operational for 6 to 8 hours on an average. In the case of small generator units, the fuel
tank is a part of the generator’s skid base or is mounted on top of the generator frame.

Chassis

Fuel Level
Fuel depot
Gauge

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 MEPS GENERATORS

 Starter and Battery: It provides the start-up energy of the motor. The “+” “-“ poles on the
battery is connected to the starter motor via cables. The Group circuit breakers on the
chassis are opened Starter battery group acts and the motor is started on.

Starter

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 MEPS GENERATORS

 Battery charger: The steart function of a generator is battery-operated. The battery charger
keeps the generator battery charged by supplying it with a precise ‘float’ voltage. If the float
voltage is very low, the battery will remain undercharged. If the float voltage is very high, it
will shorten the life of the battery. Battery chargers are usually made of stainless steel to
prevent corrosion. They are also fully automatic and do not require any adjustments to be
made or any settings to be changed. The DC output voltage of the battery charger is set at
2.33 Volts per cell, which is the precise float voltage for lead acid batteries. The battery
charger has an isolated DC voltage output that does interfere with the normal functioning of
the generator

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 MEPS GENERATORS

 Lubricating System: Since the generator comprises moving parts in its engine, it requires
lubrication to ensure durability and smooth operations for a long period of time. The
generator’s engine is lubricated by oil stored in a pump. You should check the level of
lubricating oil every 8 hours of generator operation. You should also check for any leakages
of lubricant and change the lubricating oil every 500 hours of generator operation.

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 MEPS GENERATORS

 Cooling and Exhaust System :

• Cooling System: Continuous usage of the generator causes its various components to get
heated up. It is essential to have a cooling and ventilation system to withdraw heat produced in
the process.

• Exhaust System: Exhaust fumes emitted by a generator are just like exhaust from any other
diesel or gasonline engine and contain highly toxic chemicals that need to be properly managed.
Hence, it is essential to install an adequate exhaust system to dispose of the exhaust gases. This
point can not be emphasized enough as carbon monoxide poisoning remains one of the most
common causes for death in post hurricane affected areas because people tend to not even think
about it until it’s too late.

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 EMSA GDT GENERATOR

 Emsa Generator is designed as a whole to provide high quality and confidence. Also, Generator has
Engine, Alternator, Chassis an Fuel Tank, Cooling System, Exhaust System and Control Panel.

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 EMSA GDT GENERATOR

 DIESEL ENGINE : Diesel engine driving the generator is selected as it is specifically manufactured for generators and as it is reliable. Engine is a
4-stroke industrial heavy-duty type engine and it is provided with all accessories to provide reliable power. Exchangeable dry-type air filter,
mechanical or electronic engine speed control governor are some of these accessories.

 ENGINE ELECTRICAL SYSTEM : Engine electrical system is a 24 or 12 V D.C. system with negative ground. This system consists of the
electrical starter, battery and battery charging alternator. One battery for 12 V electrical system, and two batteries of maintenance-free or less
maintenance type are provided for 24 V electrical system. Other types of batteries may also be provided if required.

 COOLING SYSTEM : Engine cooling system is either air cooled or water cooled. Air cooled system includes a high fan that provides cool air to
the inside of the engine in order to cool the engine. Water cooled system consists of the radiator, fan, circulation pump and thermostat. An
internal fan to cool alternator coils is available in the alternator.

 ALTERNATOR : Output voltage and power of the generator is generated by a cage protected, self-excited, self-regulated, brushless alternator
confirming with IP 21-23 protection standard (protected against particles and dripping). A terminal box made of steel plate is installed on the
alternator.

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 EMSA GDT GENERATOR

 FUEL TANK AND CHASSIS : Engine and alternator are installed on a steel chassis. There is a fuel tank
available inside the chassis. A separate fuel tank may be provided for high power generators or as per the
request of the customer.
 VIBRATION ISOLATORS: Vibration insulators are used to reduce the vibration of the engine and to prevent
transfer of vibration to the floor where the generator is placed. These insulators are placed between the
engine and alternator legs and the chassis. Special insulators to be installed between the chassis and the
floor are provided with the generator. It shall be installed while the generator is placed on the installation
area.
 MUFFLER AND EXHAUST SYSTEM: Exhaust muffler is installed on the exhaust outlet with the pipe
equipment on generators with cabinets. It is provided separately on some models of generator with or
without cabinet. It shall be installed so that gas leak is prevented before the commissioning of the generator.
Muffler and exhaust system reduces the noise generated by the engine and directs the exhaust gases for
safe discharge.
 CONTROL SYSTEM : Manual or automatic control system and panel placed on the generator to protect the
generator from possible faults, and to control the output and operation of the generator. These systems are
described in detail in section 6 of the manual.

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EMSA GDT GENERATOR

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EMSA GDT GENERATOR

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EMSA GDT GENERATOR

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 EMSA GDT GENERATOR
POSSIBLE REASONS OF FAULTS AND TROUBLESHOOTING
ALTERNATOR FAULTS AND TROUBLESHOOTING
FAULT:
• Alternator has no output voltage.

REASON:
• Loss of magnetism in stator windings.
If the alternator is equipped with excitation winding, contact the same ends of a 9.5 V dry battery to the + and -
terminals.
• Loose contact on the panel or terminal connections.
Open the panel cover and check whether the cable ends are loose,
and similarly whether the terminal ends are loose.
• Disconnection in the warning button.
Check all connections, especially the alternator line terminal
connections.
• Fault in rotating diodes.

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 EMSA GDT GENERATOR
Test the diodes one by one with the diode test section of the
multimeter, and replace the faulty diodes.
• Engine speed is too low.

Increase the speed of the drive machine to nominal value.

• Regulator board is faulty.

Replace the board that is not regulating.

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 EMSA GDT GENERATOR
POSSIBLE REASONS OF FAULTS AND TROUBLESHOOTING
ALTERNATOR FAULTS AND TROUBLESHOOTING
FAULT:
• Alternator has no output voltage.

REASON:
• Fault in rotating diodes.
Test the diodes one by one with the diode test section of the
multimeter, and replace the faulty diodes.

• Engine speed is too low.

Increase the speed of the drive machine to nominal value.

• Regulator board is faulty.

Replace the board that is not regulating.

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 EMSA GDT GENERATOR
POSSIBLE REASONS OF FAULTS AND TROUBLESHOOTING
ALTERNATOR FAULTS AND TROUBLESHOOTING
• FAULT:
• Voltage is lowered as the alternator is loaded.

REASON:
• Regulator board is faulty.
Set the output voltage to 400 V with the regulator potentiometer at idle operation. Replace the board if voltage is
dropped as the alternator is loaded after this setting.

• Speed loss of the drive machine is too high. Check the power of the drive machine.

• Alternator is overloaded.
Do not load above the nominal value.

• Rotating diodes are faulty.

Check the diodes with multimeter. Replace the faulty ones.

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 EMSA GDT GENERATOR
POSSIBLE REASONS OF FAULTS AND TROUBLESHOOTING
DIESEL ENGINE FAULTS AND TROUBLESHOOTING
FAULT:
• Starter rotates the diesel engine slowly.
REASON:
• Battery discharged
• Weak contact of battery cables
• Starter fault
• Incorrect lubricating oil viscosity
FAULT:
• Oil pressure is too low
REASON:
• Oil viscosity is incorrect
• Not enough oil in the sump
• Pressure indicator faulty
• Oil filter is dirty

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 EMSA GDT GENERATOR
DIESEL ENGINE FAULTS AND TROUBLESHOOTING
FAULT:
• Diesel engine is difficult to start or will not start
REASON:
• Starter cannot rotate the diesel engine
• Fuel circuit has air in it
• Fuel tank is empty
• Fuel pipe is blocked
• Fuel control solenoid is faulty
• Fuel filter is dirty
• Heater does not operate
• Exhaust pipe is blocked
• Poor fuel quality
• Fuel tank ventilation is blocked
• Fuel pre-pump is faulty
• Injectors are faulty or their setting is incorrect
• Oil sensor / switch or connection are faulty

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EMSA GDT GENERATOR

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ANKA+ UNMANNED AERIAL
VEHICLE (UAV) SYSTEMS

1 st February 2022

ANY QUESTION

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