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OPERATOR & MAINTENANCE MANUAL

 

 

PAGE

‐

17

 

 

TABLE

 

5:

 

CONTROL

 

PANEL

 

REF

 

NAME

 

DESCRIPTION

 

1

 

Control

 

Cabinet

 

Lamp

 

Switch

 

 

2

 

Control

 

Cabinet

 

Lamp

 

 

3

 

RCD

 

Status

 

Lamp

 

 

4

 

RCD

 

Status

 

Lamp

 

Globe

 

Test

 

Button

 

 

5

 

Mains

 

/

 

ATS

 

Battery

 

Charging

 

Lamp

 

 

6

 

Cam

 

Lock

 

 

 

7

 

Mains

 

/

 

ATS

 

Battery

 

Charger

 

Selector

 

Switch

 

 

8

 

Audible

 

Alarm

 

 

9

 

Master

 

Control

 

Switch

 

 

10

 

Controller

 

Intelilite

 

AMF

 

25

 

11

 

Earth

 

Leakage

 

Relay

 

(ELR)

 

 

Schneider

 

Vigirex

 

RH99P;

 

Panel

 

mounted

 

12

 

RCD

 

Test

 

Point

 

Push

 

Button

 

Mains

 

connected,

 

two

 

pole

 

RCD

 

Test

 

button

 

13

 

RCD

 

Test

 

Point

 

10A

 

,Test

 

Point

 

14

 

Test

 

Point

 

Isolator

 

2A

 

2P,

 

Lockable

 

15

 

Outlet

 

Isolator

 

50A

 

2P,

 

Lockable

 

16

 

Shunt

 

Trip

 

 

17

 

Main

 

Isolator

 

50A

 

2P

 

18

 

RCD/MCB

 

Combo

 

20A

 

2P

 

19

 

RCD/MCB

 

Combo

 

16A

 

2P

 

20

 

RCD/MCB

 

Combo

 

16A

 

2P

 

 

Summary of Contents for S10KS

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

Page 2: ...S10KS GENERATING SET OPERATOR MAINTENANCE MANUAL Edition A A Date 5 May 2011...

Page 3: ...tor Specifications 11 3 3 Generator Layout and Main Components 12 3 4 Control Cabinet and Panel 14 3 4 1 Control Cabinet 14 3 4 2 Control Panel 16 3 4 3 AMF25 Controller 21 3 5 Generator Wiring Diagra...

Page 4: ...Automatic Operation Mode 51 5 8 Shutting Down Genset 51 5 9 Lifting and Transportation 52 5 10 Overnight Storage 52 5 11 Long term Storage 52 6 Maintenance 52 6 1 Periodic Maintenance Schedule 53 6 2...

Page 5: ...anuals if necessary This manual is not to be reproduced in any form or by any means without the express written approval of Promac Sales Pty Ltd ENGINE EXHAUST can cause serious injury or even death U...

Page 6: ...mbol the industry s Safety Alert Symbol is used throughout this manual and on labels attached to the machine itself It warns of the potential for personal injury It is essential that you carefully rea...

Page 7: ...ive Equipment PPE is worn while working on generators Stay clear of any moving parts 2 2 Safety During Transportation Always shut the engine down before transporting Never transport the generator with...

Page 8: ...any of the generator s electrical terminals unprotected Ensure all connection points and their accessories have been correctly earthed Verify and ensure that all electrical power connections and auxil...

Page 9: ...ine when the air cleaner is removed Engine backfire can cause serious burns Do not remove the radiator cap while the engine is running Allow the coolant to sufficiently cool before removing the radiat...

Page 10: ...s are used on the product and throughout this manual TABLE 1 SAFETY LABELS LABEL DESCRIPTION 1 Read the Operator Manual 2 No sparks or naked flames near the machine 3 Press the emergency stop switch w...

Page 11: ...s and caps are secure for transporting or relocating Warning Read this label before lifting and transporting Only use designated lifting points on generator Warning 1 Disconnect the battery before ser...

Page 12: ...ne Warning High voltage Note 1 Check the coolant level in the radiator 2 Check the coolant level in the overflow bottle 3 Check the engine oil level Warning Not a lifting point Note Lubrication oil in...

Page 13: ...ERATOR MAINTENANCE MANUAL PAGE 9 Note Forklifting point Note Bottom drain bund Diesel fuelling point Coolant refill point and type of coolant Main Isolator Switch Off On Switch Circuit Breaker Type Si...

Page 14: ...displaying all warning alarms and performing automatic shutdowns on fault signals 50 C designed cooling system The engine and alternator have rubber av mounts installed to reduce vibration High anti...

Page 15: ...CATIONS Model Kubota D1105 BG Number of Cylinders 3 Bore mm 78 Stroke mm 78 4 Engine Speed rpm 1500 Prime Power kW 8 0 Standby Power kW 8 8 Compression Ratio 24 1 Displacement L 1 123 Cooling System W...

Page 16: ...OPERATOR MAINTENANCE MANUAL PAGE 12 3 3 Generator Layout and Major Components...

Page 17: ...x 1060 x 1070mm 2 Fire extinguisher bracket Designed for 9kg ABE fire extinguisher 3 Field wiring cabinet 4 Base Size 2390 x 1080 x 400mm 5 Control cabinet assembly 6 Spark Arrestor Rating 8m3 min 7...

Page 18: ...OPERATOR MAINTENANCE MANUAL PAGE 14 3 4 Control Cabinet and Panel 3 4 1 Control Cabinet...

Page 19: ...ode the controller will be in Automatic Mains Failure function With the switch in ISLAND mode the generator can be remotely started by closing the remote start terminals Both AMF and Remote Start requ...

Page 20: ...OPERATOR MAINTENANCE MANUAL PAGE 16 3 4 2 Control Panel...

Page 21: ...y Charger Selector Switch 8 Audible Alarm 9 Master Control Switch 10 Controller Intelilite AMF 25 11 Earth Leakage Relay ELR Schneider Vigirex RH99P Panel mounted 12 RCD Test Point Push Button Mains c...

Page 22: ...Lamp is not illuminated the ELR relay is bypassed 4 RCD Status Lamp Globe Test Button The RCD Status Lamp Globe Test Button 4 is used to test the function of the globe of the RCD status lamp 3 5 Main...

Page 23: ...2 allows power to the RCD Test Point 13 13 RCD Test Point The RCD Test Point 13 is used to test the earth leakage protection function When an earth leakage greater than the adjustable ELR s setpoint o...

Page 24: ...t power from the load side of the RCD MCB to the 20A single phase GPO in the field wiring cabinet RCD capability exists to protect the end user Note If a fault occurs test accordingly before reinstati...

Page 25: ...ng or holding the button for more than 2s will cancel the current phase of stop sequence ramping the power down or cooling and the next phase will continue 3 FAULT RESET button Use this button to ackn...

Page 26: ...the Red LED will start flashing After pressing the Fault Reset button the LED will turn off if no alarm is active or will become constant if the alarm is still active 10 Gen Set Voltage OK If the gen...

Page 27: ...in the history page Display Screens and Pages Structure The displayed information is structured into pages and screens Use the PAGE button to scroll through the pages 1 The Measurement pages consist o...

Page 28: ...OPERATOR MAINTENANCE MANUAL PAGE 24 Alarms...

Page 29: ...OPERATOR MAINTENANCE MANUAL PAGE 25 Browsing ECU Alarms...

Page 30: ...OPERATOR MAINTENANCE MANUAL PAGE 26...

Page 31: ...OPERATOR MAINTENANCE MANUAL PAGE 27...

Page 32: ...OPERATOR MAINTENANCE MANUAL PAGE 28 3 4 5 Field Wiring Cabinet...

Page 33: ...If the load side has another MEN Link connected the generator side MEN Link must be disconnected A spare terminal 4 is provided The earth leakage relay must also be bypassed in the control cabinet Thi...

Page 34: ...binet The two switches are wired in series When activated the emergency stop activated by pushing the red button will turn off the fuel solenoid resulting in the engine shutting down Rotate button to...

Page 35: ...OPERATOR MAINTENANCE MANUAL PAGE 31 3 5 Generator Wiring Diagram...

Page 36: ...ustic Material consideration Consider the following when selecting acoustic material Foam is not recommended as an acoustic material because of it s low density it is a poor acoustic insulator And not...

Page 37: ...equires greater noise and vibration attenuation the generator should be installed in a manner that reduces the impact of vibration on buildings The base height is calculated as follows The depth H of...

Page 38: ...on to provide stable operation and avoid installation damage Bolting the generator directly to the floor or foundation can result in excessive noise and vibration and possible damage to the generator...

Page 39: ...deterioration of the insulation and will result in short circuits Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator part...

Page 40: ...OPERATOR MAINTENANCE MANUAL PAGE 36...

Page 41: ...indoors it must be protected from the environment while having good ventilation and cooling Some considerations for planning a room or enclosure are Never use the generator room for storage The room...

Page 42: ...r to protect the engine when the ambient temperature is around 50 C or close to 15 C the equipment load must be reduced or engine life may be compromised 4 7 MECHANICAL CONNECTIONS After considering a...

Page 43: ...ience of having a fuel supply tank mounted at the generator These tanks are designed to be contained in a rectangular base on which the engine generator set is mounted Generally these tanks only incre...

Page 44: ...ery 400 hours Air trapped in the filter is purged by the vent plug Fuel water separator is a device designed to separate gross amounts of fuel and suspended solids from the wastewater effluents of fue...

Page 45: ...il must have a high viscosity index Multi grade oils having relatively low viscosity For example SAE 10W 30 can provide superior lubrication at both low and high temperatures Such oils are available c...

Page 46: ...unwanted water This process must be completed whilst the engine is shut down as it may cause injury 4 7 4 Ventilation and Cooling system As the generator produces a high volume of heat ventilation and...

Page 47: ...the cable DANGER If the load exceeds the allowable amperage overheating may cause damage to cables If the cables are too long there will be excessive voltage drop It may result in fire personal injur...

Page 48: ...ery cables before running the machine Connect the red cable to the positive terminal post Connect the black cable to the negative terminal post WARNING If the terminal is not connected it may result i...

Page 49: ...the incoming AC mains supply If the mains supply is satisfactory the load is run through the ATS and the generator will not run On the contrary the generator will run if the mains power is abnormal T...

Page 50: ...ith local regulations and standards Make sure the fan belt and hoses on the engine have no loose connections or are fraying Tighten or replace as required Check the battery cables are firmly secured t...

Page 51: ...e 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 than FULL mark on the dipstick Tighten the oil inlet...

Page 52: ...e radiator cap Fill coolant up to the radiator inlet top Reinstall and tighten the coolant inlet and radiator caps WARNING Avoid injury The coolant will be hot and can burn skin Built up pressure may...

Page 53: ...5 the fuel solenoid is energised and after a one second delay the starter motor will crank the engine for the duration of the crank timer preset on PLC three attempts 7 After the engine successfully s...

Page 54: ...on the LCD or audible alarm Check for any leakage of coolant oil or fuel Check for any unusual vibration or noise Check for any unusual colour from the exhaust Under normal conditions the exhaust gas...

Page 55: ...or 5 7 Stopping Generator Under Automatic Operation Mode If the mains supply returns and the generator does not stop running follow the steps listed below Turn every switch and circuit breaker on the...

Page 56: ...ng the generator overnight make sure all access doors are closed and padlocked CAUTION Do not store generator in a low lying area as large quantities of water can enter the generators electrical mecha...

Page 57: ...ine 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...

Page 58: ...om inside Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube Reinstall the air cleaner in the reverse order 6 3 2 Change Air Filter Element Loosen clips in the air...

Page 59: ...Pour new coolant into the radiator up to the radiator inlet top Close the radiator cap and coolant inlet cap WARNING Avoid injury The radiator will be hot and can burn skin Built up pressure may cause...

Page 60: ...ighten the oil inlet cap and close the access door 6 5 2 Change Oil Filter Drain engine oil completely as described in 6 5 1 Loosen and remove the oil filter Add engine oil into a new oil filter Lubri...

Page 61: ...drain fuel and water Loosen and remove fuel filter Add fuel into a new fuel filter Lubricate the new gasket will oil Screw the new filter into place and tighten accordingly DANGER Do not smoke while y...

Page 62: ...ve 6 Repair or change the thermostat Low fuel level 1 Fuel is insufficient 1 Add fuel 2 Fuel hose has a leak 2 Tighten or change fuel hose 3 Fuel tank has a leak 3 Repair or change fuel tank 4 Fuel fi...

Page 63: ...nge gauze filter 5 Air is mixed in fuel line 5 Bleed the air Engine starts but stalls at once 1 Fuel hose has a leak 1 Tighten or change fuel hose 2 Fuel filter is clogged 2 Drain water sediment or Ch...

Page 64: ...EADING 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 Austra...

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