威尔信柴油发电机维修培训技术资料威尔信柴油发电机 威尔信柴油发电机维修

1、威尔信柴油发电机维修培训技术资料一、威尔信的介绍英国公司专业生产发电机组，控股股东为卡特公司（美国公司），威尔信公司主要擅长发电机组的控制系统现已开发多种控制系统，如：1001（手动）、2001（自动）、4001、4001E（高级自动）、6001（并机、并网、监控），以及ACCESS40000（自启动并带监控功能）。威尔信生产的发电机组范围较广（4KW-2200KW）全部生产，是世界知名的三大品牌之一。威尔信发电机组的引擎全部采用伯琼斯柴油机（原劳斯莱斯），现已被美国卡特控股，发电机主要采用法国利莱森玛（过去采用过英国的史丹福）。威尔信香港公司主要工作是销售及维修，并对特殊客户对控制装置进行改

2、装。二、发电机组的组成（三个部分：A、引擎B、发电机C、控制装置）发动机引包括3.1524、1000、2000、3000、4000等系列，其中1000、2000系列部分或全部将升级为电喷机组，威尔信的目标是将所有机组都升级为电喷机组以符合欧洲二号排放标准。发电机:法国利莱森玛生产，标准转速为1500r/min，二极、三线四相制，中性线直接接地，AVR（电压稳压器）控制电压。控制装置:主要作用是对发动机及发电机进行全部控制，例如：水温、油压、电压等三、发动机（引擎）下面主要讲解：（1）基本工作原理（2）排气系统（3）燃油系统（4）冷却系统（5）启动系统（6）润滑系统（1） 基本工作原理:吸气冲程

3、：将空气及燃油吸入汽缸中，并使之充分混合,压缩冲程：将燃油混合气进行压缩，一般压缩为16左右做功冲程：将混合气体压缩到一定比例，温度升高到400以上，混合气体自行燃烧（爆炸过程）D、排气冲程：将燃烧后的废气排出机体（排烟温度为400-500）（2）排气系统机组运行后一般为自行吸气排气。但为了提高效率及燃烧的利用率，威尔信机组基本采用涡轮增压系统，就是利用机组排放的废气，利用增压器将吸入的空气进行压缩，以提高吸气冲程中氧气的含量提高燃料利用率和增加功率。（3）燃油系统威尔信电机组，小于880KW以下的机组一般都带有可供6-8小时的燃油箱。燃油经低压油泵吸入到滤清器将燃油中的杂质及水分过滤，再经过

4、高压油泵增压按时按量喷入汽缸中进行燃烧。A、机械调速：经过机械飞轮式相应装置调节喷油量以达到控制转速的目的B、电子调速：通过测定主轴的转速来微调转速使之始终达到1500r/min,而不论其是带载还是不带载。燃油的标号一般使用0#柴油，冬季根据机房条件不同，4以下建议用-10#柴油，原因，因为冬季柴油机不好启动。（4）冷却系统冷却系统使机体及内部保持在104以下，否则易产生抱缸等故障，影响使用寿命，柴油机在使用过程应保持在80-90之间为最佳，温度过低不易启动，并对带载能力有限制，温度过高对机体有损伤。为达到上述目的，冷却系统分为大循环和小循环。机组启动初期，大循环关闭，小循环启动，目的是机体能

5、够迅速升温。当温度达到一定高度时，关闭小循环开启大循环使机体温度降低，当热平衡达到一定程度后，保持此平衡，使机组处于最佳温度。而控制此平衡的为调节阀（节流阀），此为自动调节，不需人为控制。当机组发生高水温报警时，可以检查冷却液水平，是否超载及节流阀是否损坏。一般温度下，60节流阀开始打开，95完全打开。（5）润滑系统润滑系统的目的：给所有运动幅之间减小摩擦系统，包括齿轮间、缸套与汽缸之间，窝轮增压器转轴-曲柄轴承等等。一般工作原理：经过油泵将润滑油加压到一定程度（应过滤清器、油冷器）一般为4-6bar,通过管道分流到不同的运动部件进行润滑，最后回到油底壳进行冷却。润滑油最佳工作温度为90-10

6、5。温度过低精度加大，将阻碍运动（冬季启动困难方面之一），温度过高精度降低，润滑效果降低，因而日常使用中应注意记录压力值，若发现油压有1 bar以下的下降，应考虑更换柴油机及滤清器。（6）启动系统发电机组的启动一般为电池带动一直流电机将发电机组的转速达到450r/min以上以启动机组。四、发电机结构类似于一般异步发电机，物理原理为导线切割磁力线产生电压及电流，它原理与电动机相反，电动机是将电能转化为机械能，而发电机是将发动机的机械能转化成电能，刚才讲了产生电压需要运动和磁场线，运动由发动机产生，而磁力线或磁场由谁产生呢？发电机转动初期，由于发电机有剩磁，产生一个很小的电流将此电流整流，利用直流

7、电产生一个较大电流，周而复始就产生一个大的电压，而当电压达到我们所需的电压时，我们将整流电流稳定，这样我们能得到一个恒久而稳定的电压，将此电压输出即可。而此过程很快不到一秒种即可完成，而完成此功能的装置为电压稳定器，我们称AVR。发电机一般工作稳定，故障率很低。主要故障为AVR损坏，具体表现为无电压输出。五、控制系统控制系统的故障最高，应特别注意。平常应经常熟悉控制原理图。最简单的控制系统是控制发电机水温、机油压力和发电机电压。当水温过高、机油压力过低及发电机无电压输出时，控制系统将发出：高水温报警、低油压报警及启动失败报警，并立即停车。现阶段随着控制技术的不断发展，发电机组的技术水平主要表现

8、在控制系统上，而最终的发展方向是无人值守，并可以在世界各地通过网络监控发电机组的运行状况，现阶段基本达到这一水平。威尔信的控制装置，基本上是采用美国的技术，因为美国公司是威尔信的大老板并且美国在控制方面领导世界潮流。具体的个部分功能将根据实物具体讲解。六、自启动功能自启动功能的工作原理是通过一装置检测市电的状况，如发现下列情况无市电，市电电压高低超出规定范围，或市电缺相等故障，此装置将向发电机组发出启动信号。当这一装置检测市电正常时，将取消启动信号使发电机组停止运转。这一装置为自动转换柜（ATS）。其中十个电位器可调节，电压及多种转换时间延时。包括：市电及油机电的范围调整、市电检测时间、转换过

9、程时间、油机延时启动时间、市电再转换时间及油机冷却时间。这些电位器出厂时已调好，客户不能自行调整。 FG Wilson diesel generator maintenance training dataFG Wilson generating sets training handoutsFirst, theWill a letter of introductionBritish company specializing in the production of generator sets, the controlling shareholder of Carter (U.S.), Will

10、 letter company mainly specializes in the generator set control system has been developed a variety of control systems, such as: 1001 (manual), 2001 (auto), 4001 4001E (advanced auto), 6001 (and the machine, and network monitoring), as well as ACCESS40000 (start and with the monitoring function). FG

11、 Wilson generator sets a wide range (4KW-2200KW) All production, is one of the three world-renowned brand. FG Wilson generator set engine Boqiong Si diesel engine (Rolls Royce), and now Carter Holdings, generators, France, Leroy-Somer (past Stanford, UK).Will believe that Hong Kong company sales and

12、 repairs, modifications and special customer control device.Second, theThe composition of the generating units (three parts: A, the engine B, generators C, control device)A,Engine engineIncluding 3.1524,1000,2000,3000,4000 other series, 1000, 2000 series part or all of the upgrade to EFI unit, Will

13、the letter's goal to upgrade all units to comply with Euro II emission standards for the EFI unit .B,GeneratorFrance, Leroy-Somer production, the standard speed is 1500r/min, two pole, three-wire four-phase system the neutral wire directly to ground, the AVR (voltage regulator) control voltage.C

14、,Control devicesThe main role is full control of the engine and generator, such as: water temperature, oil pressure, voltage, etc.Third, theEngine (engine)The following explain: (1) the basic working principle (2) exhaust system (3) fuel system (4) cooling system (5) start the system (6) lubrication

15、 system(1) The basic working principleA,The suction stroke: inhalation of air and fuel in the cylinder, and make it fully mixedB,Compression stroke: to compress the fuel mixture, usually compressed into about 16C,Power stroke: the compressed gas mixture to a certain percentage, the temperature rises

16、 to above 400 , the gas mixture to combustion (explosion)D,Exhaust stroke: The exhaust gas after combustion of the body (exhaust gas temperature of 400-500 ° C)(2) Exhaust SystemPlant operation, generally self-inhale exhaust. However, in order to improve the utilization efficiency and combustio

17、n Will the letter unit basic turbo system is to use the unit emissions, the use of the turbocharger inhaled air to be compressed in order to improve the oxygen content of the suction stroke to improve fuel utilization and increase power.(3) fuel systemWill the letter turbines, less than 880KW unit g

18、enerally with a fuel tank for 6-8 hours. The fuel is inhaled by the low pressure pump to the filter will be impurities in the fuel and water filtration, and then through the high pressure pump booster on time and quantity injected into the cylinder for combustion.A,Mechanical governor: mechanical fl

19、ywheel corresponding device to adjust the fuel injection quantity in order to achieve the purpose of speed controlB,Electronic speed control: by the determination of the speed of the spindle to fine-tune the speed to make it always reach 1500r/min, regardless of their load or not load.0 # diesel fue

20、l label use in general, depending on the room conditions in winter, 4 -10 # diesel oil, because the following recommendations, because the bad start of winter diesel.(4) cooling systemSo that the body and internal cooling system maintained at below 104 , otherwise prone to holding tanks and other fa

21、ilures, affecting life, diesel engine during use should be kept between 80 -90 for the best, the temperature is too low and difficult to activate and with a carrying capacity limit, the temperature is too high on the body damage.To achieve the above purpose, the cooling system is divided into a larg

22、e loop and small loop. Unit start early, large circulation shut down, start small cycles, the body can quickly heat up. , Close small cycles to open large loop so that the body temperature is reduced when the temperature reaches a certain height, when the heat balance reaches a certain level to main

23、tain this balance, so that the unit is in the optimum temperature. For the regulating valve (throttle) control this balance, this is adjusted automatically, without human control. Unit of high water temperature alarm, you can check the coolant level is overloaded and throttle valve is damaged. Avera

24、ge temperature 60 throttle open, 95 fully open.(5) The lubrication systemThe purpose of the lubrication system: for all sports sites to reduce the friction system, including gears, between the liner and the cylinder, turbocharger shaft Warrant - crank bearings and so on.Generally works: After the pu

25、mp, lubricating oil pressure to a certain extent (filter, oil cooler) is generally 4-6bar, diverted to different moving parts are lubricated through a pipe, and finally back to the sump for cooling. Lubricating oil temperature 90 -105 . Temperature is too low accuracy to increase, will hinder the mo

26、vement (winter start one of the difficulties), reduce the temperature too high precision, reduced lubrication, and therefore should pay attention to the daily use record pressure values, if it is found that the oil pressure 1 bar following a decline in should consider replacing the diesel engine and

27、 the filter.(6) start the systemGenerating units at the start battery is generally driven by a DC motor generator set speed 450r/min above to start the unit.Fourth, theGeneratorStructure similar to the general induction generator voltage and current physical principles for the wire cutting the magne

28、tic field lines, it principle and the motor, the motor converts electrical energy into mechanical energy, the generator engine mechanical into electrical energy, have talked about the generated voltage need for movement and the magnetic field lines, the movement generated by the engine, while the ma

29、gnetic field lines or magnetic field who is going to produce it?Rotating the initial generator, the generator residual magnetism, a small current of this current rectifier, using direct current to produce a larger current cycle to produce a large voltage when the voltage reaches the desired voltage,

30、 we will be rectified current stable, so that we can get a long-lasting and stable voltage, this voltage output can be. This process quickly less than one second to complete, and the completion of this function the device, we call the AVR voltage stabilizer.The generator is generally stable, very lo

31、w failure rate. Damage to the main fault for the AVR, specific performance is no voltage output.V.Control systemThe highest failure of the control system, special attention should be. Usually should always be familiar with the control schematic. The most simple control system is to control the gener

32、ator temperature, oil pressure and generator voltage. When the water temperature is too high, too low oil pressure and generator voltage output, the control system will be sent to: The high water temperature alarm, low oil pressure alarm and start to loseFailure alarm, and immediately stopped.As the

33、 control technology continues to evolve at this stage, the technical level of the generator set mainly in the control system, and the final direction of development is unattended, and around the world through a network to monitor the operating conditions of the generating units at this stage to achi

34、eve the basic this level.Will the letter is basically a control device, using U.S. technology, U.S. companies is Will the big boss of the letter and the United States in the control and leadership to the world trend.Specific part of the function will be based on the kind of specific explanation.6.Se

35、lf-starting functionSince the launch of the feature works through the status of a device to detect market power, such as the following situations without electricity, mains voltage level within the prescribed scope or mains missing equal failure, this device will be generating set to issue a start s

36、ignal. When this device to detect the mains is normal, and will cancel the start signal generator set to stop running. This device is automatically converted to cabinet (ATS). Ten potentiometer adjustable voltage and a variety of conversion time delay. Include: mains and oil range of mechanical and

37、electrical adjustments, electricity detection time, the time of the conversion process, the oil-delay start-up time, the mains and then convert the time and oil cooling time. The potentiometer is factory tuned, the customer can not adjust.VII.Generating units use the Note:A,Before starting work:a ch

38、eck the battery voltage and capacityb check the oil level via the dipstick to check oil and diesel and oil quality. If little can be added, if the poor quality should consider replacing.c Check the diesel oil level, if not more, consideration should be given to filld check the coolant water levele c

39、heck each pipeline is whether leakage, if so, shall promptly tightenf to check the wiring and insurance is goodB,Start should be noted that:a check oil pressure and record the oil pressureb check the voltage output is normal.c Check the current is overloadedd check the water temperature rise is unif

40、orme Note the generator set with or without abnormal noisef observe the smoke situation, when the startup of a unit or low winter temperatures, the concentration of smoke, which is a normal phenomenon; as the oil temperature increased, the concentration will be getting smaller and smaller until normal.C,Shutdown should pay attention to:a shutdown is stable, there may be a vibration, is also normal. The reason is that a component resonance.VIII.Routine maintenanceRoutine maintenance unit outside of clean, remove dust conducive to the cooling unit; use a good quality diesel; require