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OPERATOR & MAINTENANCE MANUAL

PAGE

‐

1

1.

Foreword

Thank

you

for

purchasing

your

new

Nugen

soundproof

diesel

generator.

The

Operator

and

Maintenance

Manual

must

be

read

and

understood

prior

to

operating

the

generator.

This

manual

contains

information

for

the

correct

operation

and

maintenance

of

your

generator

and

important

safety

and

installation

information,

including

troubleshooting

guidelines.

This

manual

must

be

kept

with

the

generator

at

all

times.

This

manual

does

not

cover

the

diesel

engine

and

alternator

maintenance

procedures.

Please

consult

the

engine

and

the

alternator

operation

and

maintenance

manuals

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!

Use

only

in

open

well

ventilated

areas

or

vent

exhaust

outside!

DISCLAIMER

STATEMENT

Promac

Sales

Pty

Ltd

publishes

the

technical

information

in

this

manual

as

an

aid

to

its

customers

and

to

the

public.

The

information

included

in

this

manual

is

based

on

sound

engineering

principles,

research,

extensive

field

experience,

and

technical

judgments.

This

mater

is

subject

to

change

in

light

of

developments

in

technology

and

field

experience.

Use

or

adoption

of

the

information

contained

in

this

manual

is

voluntary.

Promac

Sales

Pty

Ltd

reserves

the

right

to

change

any

portion

of

this

information

without

notice.

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Содержание S10KS

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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