Nugen Nugen S150PS Operator'S Maintenance Manual Download Page 37

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OPERATOR & MAINTENANCE MANUAL

6.7 Troubleshooting

When performing any troubleshooting, follow the guidelines. If further clarification is
required please contact our authorized service agent.

Trouble

Causes

Solutions

Low engine oil pressure

1. Insufficient oil

Add lubricant oil

2. Oil hose has leak

Tighten or change oil hose

3. Oil filter is clogged

Change oil filter

4. Incorrect oil is used

Change to correct oil

High coolant temperature

1. Insufficient coolant

Add coolant

2. Coolant pipe has leak

Tighten or change coolant pipe

3. Fan belt is loose

Tighten the belt

4. Radiator core is clogged

Clean radiator core

5. Water temperature sensor is
defective

Repair or change the sensor

6. Engine thermostat is defective Repair or change the thermostat

Low fuel level

1. Insufficient fuel

Add fuel

2. Fuel hose has a leak

Tighten or change fuel hose

3. Fuel tank has a leak

Repair or change fuel tank

4. Fuel filter is clogged

Drain water/sediment or change
fuel filter

5. Fuel level sensor is defective Repair or change the sensor

Cannot turn the circuit
breaker on

1. The main breaker position is

located between on and off

Turn off and on.
Replace breaker if faulty

2. Short circuit on the load

Check and repair the load circuit

Control module (PLC) not
working

1. The control module cable is

disconnected from the
battery

Connect the module cable to the
Battery

2. Insufficient battery power

Charge the battery

3. The DV fuse is damaged

Change the DV fuse

Voltage drops when
connecting to the load

1. Total load exceeds the rated

current

Decrease the load to meet the
rated output

2. Load sharing to each phase is

unbalanced

Balance the loads to each phase.

Summary of Contents for Nugen S150PS

Page 1: ...PROMAC LEADING THE WAY OPERATOR MAINTENANCE MANUAL ...

Page 2: ...S150PS GENERATING SET OPERATOR MAINTENANCE MANUAL ...

Page 3: ...3 Ambient Condition 11 3 2 Generator Specifications 11 3 3 Appearance and Main Parts 13 3 4 Control Cabinet and Panel 14 3 5 Generator Wiring Diagram 17 4 Installation 18 4 1 External Installation 18 4 2 Internal Installation 18 4 3 Main Power with Automatic Mains Failure optional 20 4 4 Load Connections 20 4 4 1 Sizing Load Cables 20 4 4 2 Connecting Load Cable 21 4 5 Earthing Connections 21 4 6 ...

Page 4: ...the Generator 30 5 10 Lifting and Transporting 31 5 11 Overnight Storage 31 5 12 Long term Storage 31 6 Maintenance 32 6 1 Periodic Maintenance Schedule 32 6 2 New Machines 32 6 3 Air Cleaner 33 6 3 1 Clean air filter element 33 6 3 2 Change air filter element 33 6 4 Engine Coolant 33 6 5 Engine Oil and Oil Filter 34 6 5 1 Change engine oil 34 6 5 2 Change oil filter 34 6 6 Fuel Filter 35 6 6 1 Dr...

Page 5: ...ust be read and understood prior to operating the generator This manual does not cover the diesel engine and alternator maintenance procedures Please consult the engine and alternator operation and maintenance manuals if necessary The information contained in this manual was based on the generator in production at the time of publication Promac Sales Pty Ltd reserves the right to change any portio...

Page 6: ...is responsible for maintaining the Nugen generator in good safe working condition Carefully read the safety symbols attached to the generator and follow all instructions to avoid possible injury or death Indicates potential personal injury hazards Indicates a hazardous situation which if not avoided will result in serious injury or even death Indicates a hazardous situation which if not avoided co...

Page 7: ...or with air intake doors open Ensure fuel tank cap is securely tightened Drain fuel when transporting the generator over long distances or rough terrain In order to lift and transport the generator lifting machines of the appropriate capacity must be used All loose and pivoting parts must be safely fixed When relocating the generator only lift from the designated lift points Do not use lifting poi...

Page 8: ...ver stand under or close to any object that is being hoisted or lifted into position 2 4 Safety During Operation Only adequately trained and competent personnel are to access the operating area of the generator Always wear ear protection when the generator is in operation Before operating the generator ensure that the earth spike is connected to the earth point at the front of the plant Before sta...

Page 9: ...tem for leaks In the event of a leak repair immediately 2 6 Safety During Maintenance All checks or maintenance of the generator must be carried out by adequately trained and competent personnel Ensure that the engine has fully stopped before performing any maintenance Disconnect the terminals from the battery before operating any components of the electrical installation Do not remove the radiato...

Page 10: ...severe injury Safety Instructions Read the Safety Instructions before operation Warning Electric shock will cause serious injury or death Warning Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap Warning Always refuel with the engine stopped and in a well ventilated area Do not smoke ...

Page 11: ... battery before servicing 2 Read the Operator s Manual for instructions Warning Do not manipulate the generator with the switch on Warning Do not clean the alternator with water Warning High temperature Caution Check the engine oil level before starting the engine Note Water inlet Note Fuel inlet Danger High voltage Note Phase connection points Note Earth ...

Page 12: ...of operation via PC or front control panel In addition it will perform automatic shutdowns on fault signals Compatible with ATS systems 55 cooling system Engine and alternator has rubber mounts installed to reduce vibration High anti corrosion performance Easy maintenance Wide doors are designed to allow easy access for maintenance and cleaning Super quiet performance Oversized muffler and acousti...

Page 13: ... in line Bore mm in 100 3 94 Stroke mm in 127 5 0 Engine Speed rpm 1500 Prime Power kVA 150 Standby Power kVA 165 Compression Ratio 17 0 1 Displacement L 5 99 Cooling System Water cooled Battery Voltage V 12 Type of Oil CF4 SG15W 40 Type of Fuel 0 ASTM2 Fuel Tank Capacity L 570 Alternator Model Stamford UCI274F Exciter Brushless Excitation System Self exciting Insulation Type Class H Dimension Len...

Page 14: ...OPERATOR MAINTENANCE MANUAL 13 ...

Page 15: ...genset f Close genset circuit breaker g Open genset circuit breaker h Close main circuit breaker i Open main circuit breaker j Set ready to output k Manual mode selection l Auto mode selection m Lamp test n Activates the selected test in entered time o Charger AC failures p Low fuel level q Low oil pressures r High water temperature s Jumps from parameter settings to display t Enters value or ackn...

Page 16: ...utomatically switch to the OFF position and interrupt power from the circuit breaker to the main wiring terminals in the field wiring cabinet Warning Before shutting down the generator or performing any service ensure the main circuit breaker is in the OFF position Key Switch Rotating the key switch 7 to the ON position turns the control module on Control Cabinet Lamp Switch The lamp switch 8 once...

Page 17: ...n the case of an actual emergency Note Stopping the generator under load may cause mechanical damage ATS Input Plug connector The generator is equipped with an automatic transfer switch plug F which is used for connecting the generator to the ATS In the event of a supply interruption connection of an optional ATS can automatically transfer the mains supply to generator supply and vice versa Main W...

Page 18: ...OPERATOR MAINTENANCE MANUAL 17 3 6 Generator Wiring Diagram ...

Page 19: ... snow etc Serviceable access should be provided to allow the opening or removal of access panels doors for service and maintenance Keep the generator at least one metre away from buildings and other structures 4 2 Internal Installation Room Size If the generator is installed indoors it must be protected from the environment while having good ventilation and cooling Some considerations for planning...

Page 20: ...he most desirable Maintain the building at a satisfactory temperature Ensure the generator is installed in a way that will not compromise reliability from the emergency loads Warning The floor foundation load carrying capacity must be checked and must not exceed the weight of the generator and its associated equipment ...

Page 21: ...the generator is not running standby mode mains power must provide power to critical components Battery chargers block heaters space heaters and any other devices that must have power to maintain the generator components to allow fast trouble free starting when a demand is needed 4 4 Load Connections 4 4 1 Sizing Load Cables Selecting the load cables number of cores and diameter based on its allow...

Page 22: ...main earth bar in the control cabinet NOTE This generator has General Power Outlets GPO installed Main Earth Neutral MEN is installed on this generator Warning Earth spike must be installed Warning If the earth terminal is not connected it may result in injury or death All the doors must be earthed Main earth and earth spike should be installed and tested by a licensed electrician before running t...

Page 23: ...nerator will run The ATS location is important The ATS should be located inside the building as close as possible to the main switch board Locate the ATS in a clean dry well ventilated location away from excessive heat If the ambient temperature is above 40 C 104 F fuses and circuit breakers must be de rated Allow adequate working space around the transfer switch Never install control wiring in th...

Page 24: ...re check before Starting Before starting the generator check each item below Check engine oil fuel and coolant Check for leakage at the hose connections Warning If any leak is found do not use the machine Repairs are only to be carried out by trained personnel and according to regulations Ensure there are no obstructions lodged in vents near radiator or around fan Ensure that nothing is touching t...

Page 25: ... and Coolant Level Before Starting 5 2 1 Engine oil Ensure that the generator is on level ground before checking engine oil level Install the oil dipstick The correct level is between the lower and upper limit marks on the dipstick Add engine oil if the level is below the lower limit Select the appropriate engine oil Open the access door remove oil cap Add engine oil to bring oil level NO higher t...

Page 26: ...ore refuelling 5 2 3 Coolant Remove the coolant inlet and radiator caps check the coolant level in the tank Adding coolant Remove the coolant inlet cap Remove the radiator cap Fill coolant to the radiator inlet top Reinstall and tighten the coolant inlet and radiator caps Warning Avoid injury The radiator will be hot and can burn skin Built up pressure may cause explosive release of coolant when t...

Page 27: ...nd after a 1 second delay the starter motor will make the engine crank for the duration of the crank timer preset in PLC to 3 attempts After the engine successfully starts allow approximately five minutes to warm up Turn the Circuit Breaker ON 2 This will allow power to the main terminals The external load can now be switched on Upon sensing the correct voltage and frequency the PLC will display t...

Page 28: ...ing the automatic start up mode connection of ATS is required 5 5 During Operation Check the LCD reading of voltage current frequency by scrolling the Display Button w and v Check the LCD reading of engine oil coolant and fuel levels Check the LCD reading of engine oil pressure and coolant temperature Check for any alarm signal on the LCD or audible alarm Check for any leakage of coolant oil or fu...

Page 29: ...s not stop running follow the steps listed below Turn every switch and circuit breaker on the load to the OFF position Turn off the Key Switch 7 Open the side access door and turn off the engine battery switch then close the door 5 8 Protection 5 8 1 Displaying alarm signals The control module PLC has 3 ways of displaying alarm signals if a fault occurs The audible alarm will sound for ten seconds...

Page 30: ... the LCD The Alarm LED will flash Over speed If the engine speed exceeds the pre alarm level the module will display Over speed 1 on the LCD The Alarm LED will illuminate steadily Generator High Frequency Warning is configured If the PLC detects a generator output frequency in excess of the pre alarm level the screen will display G over frequency on the LCD The Alarm LED will flash Generator Low F...

Page 31: ...tects that the engine coolant temperature has exceeded the high engine temperature trip setting level after the run status timer has expired a shutdown will occur The LCD will indicate Watertemp 2 and the Alarm LED will flash Over speed If the engine speed exceeds the pre set trip a shutdown is initiated The LCD will indicate Over speed 2 and the Alarm LED will flash Over speed is not delayed it i...

Page 32: ...the weight of the generator Ensure the lifting devices have sufficient capacity to lift the unit safely When lifting the generator attach a hook or sling securely to the lifting lug Transporting When transporting the generator it should be safely secured with ropes tied to the roping lugs at the top of the generator 5 11 Overnight Storage When storing the generator overnight make sure all access d...

Page 33: ...k engine oil fuel and coolant level Check for leaks oil fuel and coolant Check air cleaner dust cap Check generator visually Check battery charging system Check drive belt tension Drain water sediment from fuel filter Drain water sediment from fuel tank Change engine oil and replace oil filter Change fuel filter element Clean or change air filter element Change Change Check cooling system Clean un...

Page 34: ...r filter element Loosen the safety filter from the primary filter Change the primary filter Reinstall the air cleaner in the reverse order Caution Do not remove the air cleaner while operating the generator or immediately after stopping the machine Do not start the engine after the air cleaner is removed The backfire can cause serious burns Change the primary filter every 250 hours or as required ...

Page 35: ...n the access door Open sump and oil ball valve located beneath the oil pump Use the oil pump to drain the engine oil After draining close the oil and oil drain ball valves Loosen and remove the oil inlet cap through an outside oil filter add oil into the oil inlet until the level is slightly less than the upper limit Tighten the oil inlet cap and close the access door 6 5 2 Change oil filter Fully...

Page 36: ... sediment in the fuel filter Loosen the drain plug to drain water and sediment Bleed the air and tighten plug 6 6 2 Change fuel filter Loosen the drain plug and drain fuel and water Loosen and remove fuel filter Add fuel into a new fuel filter Lubricate the new gasket with oil Screw the new filter into place and tighten accordingly Danger Do not smoke whilst refuelling an engine Do not refuel an e...

Page 37: ... or change the thermostat Low fuel level 1 Insufficient fuel Add fuel 2 Fuel hose has a leak Tighten or change fuel hose 3 Fuel tank has a leak Repair or change fuel tank 4 Fuel filter is clogged Drain water sediment or change fuel filter 5 Fuel level sensor is defective Repair or change the sensor Cannot turn the circuit breaker on 1 The main breaker position is located between on and off Turn of...

Page 38: ...is clogged Drain water sediment or Change fuel filter 4 Gauze filter is clogged Clean or change gauze filter 5 Air is mixed in fuel line Bleed the air Engine starts but stalls at once 1 Fuel hose has a leak Tighten or change fuel hose 2 Fuel filter is clogged Drain water sediment or Change fuel filter 3 Gauze filter is clogged Clean or change gauze filter 4 Insufficient oil Add lubricant oil 5 Air...

Page 39: ...LEADING THE WAY Promac Sales Email sales promac net au Phone 61 8 6254 1800 Fax 61 8 6254 1899 Office 11 Poole Street Welshpool Western Australia 6106 Postal Address PO Box 538 Welshpool Western Australia 6986 ...

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