SmartGen案例 | 控制器起机失败原因有哪些？怎么解决？

控制器起机失败原因分析：

在很多时候，当用户在启动发动机的过程中，出现发电机组不能启动或启动不成功，由于发电机组用户对运行原理和机械结构不太了解，造成问题查找困难。本文就发电机组在使用时因为启动问题造成的故障给大家列举一下。

发电机组不能起动基本由以下几个原因引起的：

1.电气线路

2.机械结构

3.控制系统参数配置

电气线路

当电气线路或电气元器件出现故障时，在发电机组启动时，起动过程中可能会出现启动机没有工作，造成发电机组起动失败。

在排除电气线故障时，首先要确认控制器或起动信号输出正确。然后可以根据电气图纸或实际电气接线确认每个继电器或接触器的工作状态及电气线路是否正常。

机械结构

因为起动机部分的机械问题造成的起动失败，可能会出现起动机空转或打齿的情况。

当起动机出现空转时，有可能是发动机飞轮齿有损坏，起动机齿轮啮合不到发动机飞轮齿，造成起动机空转，此类情况就需要对发动机飞轮齿盘施行更换维修。

当起动机出现打齿时，是由于起动机齿轮在工作时和飞轮齿形成对齿，无法进行起动工作，此类情况可以再次对发动机进行启动操作，如果多次不能启动则检查起动机和发动机飞轮齿盘。

控制系统参数配置

当发电机组的起停控制使用控制器时，起动机的工作和停止是由控制器来控制。控制器对起动机的控制依据来源于发动机转速、油压和发电机组频率。当发电机组在启动过程中，控制器采集到的数据达到一定条件时，控制器控制起动机停止工作。

控制器可以设置起动时的发动机转速、油压、发电频率，当三个参数其中一个达到起动设置值时，控制器则认为发电机组起动成功，并停止起动机的运行,发电机组进入运行状态。

当参数设置有问题或控制器采集到的数据有问题时，会造成控制异常，进而造成发电机组运行故障。

常见的故障现象为按起动键后，发电机组没有任何动作，控制器显示发电机组运行，随后发电欠频、欠压或低油压报警。比较常见的现象为控制器启动条件设置有油压条件，如果在停机时，机油压力显示值超过了启动成功的油压设置值，在使用控制器起动时，控制则认为机组已经启动成功，就进入运行阶段；运行到开始监测报警时，由于发电机组并没有真正运行，控制器检测不到正常的电压，频率，油压和转速，控制器进行判断后发出报警。

当出现这种情况时，我们需要检查控制器参数显示和关于启动的参数设置，使相关参数设置在合理的范围内。

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SmartGen | Cause & Solution for Controller Start Failure

Controller Start Failure Analysis:

In many cases, when the user is starting engine, genset cannot start or start unsuccessfully. It is difficult to find problems due to users do not understand genset running principle and mechanical structure. This article gives a list of faults caused by starting problems in genset using. 

Genset start failure is basically caused by the following ways:

1.Electrical circuit

2.Mechanical structure

3.Controller parameter configuration.

Electrical Circuit

When electrical circuits or components have faults, starter may not work in genset starting, thus resulting in genset start failure.

When troubleshooting electrical problems, you should first confirm that controller or start signal outputs correctly, then confirm whether the operation status of each relay or contactor and electrical circuit is normal according to electrical drawing or actual electrical wiring.

Mechanical Structure

Start failure cause by mechanical problems with the starter section may result in idling or gear collision. When starter is idling, the flywheel teeth of engine may be damaged. The starter gears do not engage the engine flywheel teeth, causing the starter to idle. In this case, engine flywheel teeth plate needs to be replaced and repaired. 

When gear collision occurs, it is because the starter gear is engaged the flywheel teeth, so it is unable to start. In this case, you can try to start engine again. If it cannot start, then check starter and engine flywheel teeth plate.

Controller Parameter Configuration

When controller is used for start and stop control of genset, it can control starter running. The controller controls starter based on engine speed, oil pressure and genset frequency. When genset is starting, if controller measured data reaches certain condition, controller will control starter to stop.

Controller can set engine speed, oil pressure, gen frequency in starting, when one of them reaches set value, controller will consider that genset starts successfully and stop the starter, then genset will enter running status. When parameter setting or measured data has problem, control abnormal situation will appear, thus causing genset running fault.

The common fault phenomenon is that after pressing start key, genset has no action, controller displays “Genset Running”, then gen underfrequency, undervoltage or low oil pressure alarm will occur. A more common phenomenon is that when oil pressure is set in start conditions, if oil pressure value is greater than start success value in stopping, controller will assume that genset has started successfully in starting and enter running period. When it runs to monitor alarms, because genset is not really running, controller cannot detect normal voltage, frequency, oil pressure and speed, and will issue alarm after judging.

When this condition appears, we need to check controller parameter display and parameter setting about start, making related parameter in rational setting range.

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SmartGen | Latest Engineering Machinery Controller Application

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