DG Manual

Contents
DG Control Panel .................................................................................................................................. 2
1.

Generator Power Command switch ....................................................................................... 2

2.

Control supply switch: .............................................................................................................. 2

3.

Power relay switch: ................................................................................................................... 3

4.

Relay Controller:........................................................................................................................ 3

5.

Indicator lights: ......................................................................................................................... 4

6.

Control Buttons: ........................................................................................................................ 4

7.

Emergency Shutdown: ............................................................................................................. 5

Normal Switch Positions & Indicator Light Status ........................................................................... 6

Manually starting the DG..................................................................................................................... 7
Pumping the DG ................................................................................................................................... 8
Troubleshooting ................................................................................................................................... 9

DG Control Panel
1. Generator Power Command switch

When the Key is turned to O position, the generator will remain switched off.
When toggled to the right side, as in the picture, it will automatically turn on when the main
supply trips. In this mode the generator can be manually turned on by pressing the soft
button.

2. Control supply switch:

This switch toggles the auto power relay switch on & off.
If this is set to OFF, the relay will not switch the power to generator mode even if the Main
supply trips. Hence this switch must be kept at ON position at all times.

3. Power relay switch:

Power relay switch switches the power from the Mains to the Generator power when the
Main supply trips.
In must be set to AUTO mode denoted by A.

4. Relay Controller:

Secondary controller to the relay.

Normal position: 2. Auto

5. Indicator lights:

a. Emergency power Trip operated:

Indicates that the Emergency trip is pressed. The Generator wont operate till
the emergency switch is turned off.
b. DG Com Shutdown:
Usually is ON when DG shuts down due to a fault.
c. Alt. Fault:
When light is ON, there is some fault in the DG.
d. DG ON:
Switches ON when the DG is ON
e. Load on DG:
Switches ON when the Power relay switch has transferred load onto mains.
f.

Mains ON
Switches ON when the Main electricity supply is ON

g. Load on Mains
Switches ON when the Load is being run on the mains
h. DC Supply ON
i.

Battery Charger ON

6. Control Buttons:

a. DG Cont. ON
b. DG Cont. OFF
c. Mains Cont. ON
d. Mains Cont. OFF
e. Hooter Accept:
When the alarm of the DG starts ringing, press the button.
f.

Fault Reset:
To reset the fault. Press button. Press Hooter accept first.

7. Emergency Shutdown:

In case of any emergency during generator operator, press this button. If the button
is pressed, the emergency Power trip operated indicator light will turn on.
To reset, turn the button in the direction as indicated by the arrow. After resetting,
press the Hooter accept & Fault reset buttons in order.

Normal Switch Positions & Indicator Light Status

SN
1
2
3
4

Switch
AMF Relay
Control Supply Switch
Power Command
BE

SN

Light

Position
Automatic (denoted by A)
ON
Auto/Manual (Left side)
2. Auto
Status

Emerg. Trip Operated

OFF

DG Comm. Shutdown

OFF

Alt. Fault

OFF

DG ON

Load on DG

Mains ON

Load on DG

DC Supply On

----

Battery Charger On

----

ON (when DG is on)
ON (when DG is on & Main is OFF)
ON (when Main Supply is on)
ON (when Main Supply is on & DG
is OFF)

Manually starting the DG

1. Check the settings of the switches.
2. Press the Manual start button

Pumping the DG
This is usually required to be done when there is a cut in diesel supply. The cut in
supply may occur due to many reasons, but the main being reduced diesel levels.
The diesel levels can be checked using the indicator on the fuel tank.
1. Switch the DG to OFF mode
2. Open the side panel of the DG
3. Unscrew the pump lever

4. Use the lever to pump the DG by pulling it up & pushing it down repeatedly.
Do it 50-60 times till the lever motion starts turning hard.
5. Screw the lever back to closed position
6. Toggle the Power command switch to Auto/Manual position, reset faults (if
any) & Press manual start button, the generator should start.
7. Let the generator run for about 1 minute
8. Switch off the DG by switching Power Command key to O position then
reverse to back to Auto/Manual mode
9. Close & lock the side panels

Troubleshooting
1. DG did not start when Main supply tripped:
a. Check the positions of:
i. Control Supply Switch
ii. Emergency Trip
b. Reset any faults.
c. Start manually
2. DG started but the DG is not taking the load:
a. Check the positions of:
i. AMF Relay
ii. Power Command
iii. BE
b. Change positions.
3. DG started normally, but then shut down automatically & siren started:
a. Reset fault
b. Check diesel levels
c. Pump diesel
d. Start DG manually