Safety Guidelines for Manual Starting and Stopping of Generator Sets

With the increasing power demand and rising stability requirements, generator sets, as critical backup power equipment, make their manual starting function particularly important. It is not only the cornerstone for ensuring continuous power supply to critical loads but also serves as the direct means for operators to restore power when automation systems encounter difficulties. Below are the safety guideline for manual starting and stopping of generator sets.

I. Necessary preparations before manual starting generator set

1. Safety check and system status confirmation

First, perform a safety check. Ensure there are no flammable materials around the generator set, ventilation is adequate, and the exhaust pipeline is unobstructed. Carefully inspect the genset's exterior for any damage and check the control panel for any illuminated alarm indicators. Meanwhile, confirm that safety equipment such as the emergency stop button and protective covers are in proper working condition.

Next, confirm the system status. Set the generator set's control switch to the Manual position to disengage automatic mode. If a manual power transfer is required, set the Automatic Transfer Switch (ATS) to Manual or Generator Priority mode.

2. Fuel and lubrication system preparation

Ensure the diesel fuel tank has sufficient fuel, with the level at least above one-third. In addition, check the engine oil level, confirming it is within the marked range, typically between the L (Low) and H (High) marks.

3. Cooling system and battery check

Check if the radiator coolant or antifreeze is sufficient, and ensure the water temperature gauge needle is at its initial position. Close the battery switch, then measure the battery voltage. Diesel engines typically require 24V, while gasoline engines require 12V.

4. Load and line connection

Before starting, connect the load equipment to the generator set, but keep the circuit breaker in the OFF position to avoid inrush current impacting the equipment. Additionally, carefully inspect the output cables for any damage and ensure the grounding wire is securely connected.

II. Manual starting generator operation steps

1. Pre-start warm-up and starting method

Pre-start warm-up (Applicable in winter or low-temperature environments): First, open the fuel valve. Then, press and hold the preheat button (if the unit is equipped with a preheating device) for 30 seconds to 1 minute to raise the engine block temperature. During this time, closely observe whether the preheat indicator light illuminates to confirm the preheating system is working normally.

Starting operation: Insert the start key into the ignition switch on the control panel and turn it clockwise to the START position. Hold it there for 3-5 seconds, listening carefully for the exhaust sound or observing the tachometer to determine if the engine has successfully ignited. If the starting attempt is unsuccessful, wait 10 seconds before repeating the operation to avoid excessive battery discharge.

2. Post-start checks and abnormal situation handling

After starting the generator set, pay attention to changes in various indicators. Typically, oil pressure should rise above 0.3 MPa within 10 seconds of starting, indicating the lubrication system is normal. In addition, the water temperature should gradually rise to the range of 60-90°C (specific values may vary by model). Furthermore, the generator output frequency should stabilize at 50Hz or 60Hz, and the voltage should remain at the rated value, such as 380V or 220V.

If the oil pressure does not rise or the water temperature rises abnormally, stop the engine immediately and check the oil pump or cooling system to ensure equipment safety. If the frequency fluctuation exceeds ±5%, adjust the engine speed control knob to restore stability.

3. Manual power transfer

After confirming the generator set is running stably, manually close the output circuit breaker to transfer the load from the mains supply to the generator power. During this process, continuously monitor whether the load current is within the rated range to prevent damage from overload operation.

III. Manual stopping generator set operation process

1. Load unloading and engine shutdown

Before stopping, first disconnect all non-critical loads to gradually reduce the generator set's load. Subsequently, turn the output circuit breaker to the OFF position, completely disconnecting the generator from the load.

Turn the control switch to the STOP position. The engine will begin idling, typically for a period of 3-5 minutes. During this time, closely monitor the water temperature, ensuring it drops below 70°C, and note if the oil pressure returns to zero. Once these conditions are met, the engine will shut down automatically. In case of an emergency, immediately press the red emergency stop button, the engine will stop rapidly. After stopping, be sure to check the cause of any fault (e.g., high water temperature, low oil pressure), eliminate safety hazards, and then reset the relevant buttons.

2. Post-stop Inspection and Maintenance

After stopping the generator set, close the fuel valve to prevent fuel leakage. Then, carefully inspect all components of the generator set for signs of oil or water leaks, and record the operating parameters in detail. If the generator set will be out of service for an extended period, it is recommended to start and run it once every two weeks to prevent component corrosion.

IV. Safety precautions

When operating the generator set, a series of safety regulations must be followed. Before starting, ensure you stay clear of the exhaust pipe to prevent burns from hot gases. Furthermore, strictly avoid opening the control cabinet or inspection covers while the genset is running to ensure equipment safety. Operators must wear insulated gloves, safety goggles, and anti-slip shoes to ensure personal safety.

In the event of an emergency such as a fuel leak, stop the engine and cut the power immediately. meanwhile, use a dry powder fire extinguisher for initial fire suppression, ensuring the incident is handled promptly and effectively.