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OPERATOR & MAINTENANCE MANUAL

 

 

PAGE

4

 

2.3

 

Safety

 

During

 

Installation

 

&

 

Initial

 

Start

up

 

 

All

 

installation

 

and

 

repair

 

procedures

 

must

 

be

 

carried

 

out

 

by

 

competent

 

and

 

adequately

 

trained

 

personnel.

 

 

Installation

 

of

 

the

 

generator

 

must

 

be

 

in

 

accordance

 

with

 

Clause

 

4.

 

 

Ensure

 

all

 

emergency

 

procedures

 

are

 

adhered

 

to.

 

 

Ensure

 

that

 

the

 

appropriate

 

PPE

 

is

 

worn

 

while

 

working

 

on

 

the

 

generator.

 

 

Under

 

no

 

circumstances

 

are

 

any

 

guards,

 

panels

 

or

 

insulating

 

materials

 

to

 

be

 

tampered

 

with.

 

 

Do

 

not

 

leave

 

any

 

flammable

 

liquids

 

or

 

materials

 

near

 

the

 

generator

 

or

 

any

 

other

 

part

 

of

 

the

 

electrical

 

installation.

 

 

Take

 

extreme

 

caution

 

to

 

avoid

 

risks

 

of

 

electrocution.

 

Ensure

 

that

 

all

 

earthing

 

installations

 

have

 

been

 

fitted

 

according

 

to

 

the

 

Electrical

 

Standards

 

and

 

all

 

local

 

regulations.

 

 

Ensure

 

all

 

connections

 

and

 

wires

 

are

 

insulated.

 

Do

 

not

 

leave

 

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

 

auxiliary

 

service

 

connections

 

are

 

correct.

 

 

Check

 

that

 

the

 

phase

 

rotation

 

matches

 

the

 

power

 

supply.

 

 

Ensure

 

the

 

correct

 

ventilation

 

of

 

the

 

premises

 

so

 

that

 

all

 

exhaust

 

gases

 

are

 

released

 

to

 

the

 

atmosphere

 

and

 

verify

 

that

 

they

 

are

 

in

 

a

 

safe

 

position

 

away

 

from

 

all

 

doors,

 

windows

 

and

 

air

 

intakes.

 

 

Make

 

sure

 

there

 

are

 

no

 

leaks

 

in

 

the

 

oil

 

and

 

fuel

 

pipes.

 

 

Never

 

stand

 

under

 

or

 

close

 

to

 

any

 

object

 

that

 

is

 

being

 

hoisted

 

or

 

lifted

 

into

 

position.

 

2.4

 

Safety

 

During

 

Operation

 

 

Only

 

competent

 

and

 

adequately

 

trained

 

personnel

 

are

 

to

 

access

 

the

 

operating

 

area

 

of

 

the

 

generator.

 

 

Always

 

wear

 

ear

 

protection

 

when

 

the

 

generator

 

is

 

in

 

operation.

 

 

Before

 

operating

 

the

 

generator,

 

make

 

sure

 

the

 

earth

 

spike

 

is

 

connected

 

to

 

the

 

earth

 

point

 

in

 

front

 

of

 

the

 

plant.

 

 

Before

 

starting

 

the

 

engine,

 

turn

 

off

 

any

 

connected

 

loads

 

and

 

set

 

all

 

circuit

 

breakers

 

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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