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PROMAC. LEADING THE WAY.
OPERATOR & MAINTENANCE
MANUAL
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S80PS
GENERATING SET
OPERATOR & MAINTENANCE MANUAL
Table of Contents
1. Foreword ..................................................................................................
2. Safety Information.............................................................................................. 2
2.1 General Safety Precautions ...................................................................................... 3
2.2 Safety During Transportation .................................................................................. 3
2.3 Safety During Installation & Initial Start-up ........................................................... 4
Edition B B
Date 2011-06-07
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2.4 Safety During Operation .......................................................................................... 4
2.5 Safety Around Diesel Engines ................................................................................. 5
2.6 Safety During Maintenance ..................................................................................... 5
2.7 Symbols and Their Meanings .................................................................................. 6
3. Specifications and Parts Introduction ............................................................. 9
3.1 Specifications ........................................................................................................... 9
3.1.1 Use ................................................................................................................ 9
3.1.2 Main Specifications ..................................................................................... 10
3.1.3 Design Ambient Conditions ........................................................................ 10
3.2 Generator Specifications ........................................................................................ 11
3.3 Generator Layout and Major Components ............................................................ 13
3.4 Control Cabinet and Panel ..................................................................................... 15
3.4.1 Control Cabinet ........................................................................................... 15
3.4.2 Control Panel............................................................................................... 18
3.4.3 AMF 25 Controller....................................................................................... 23
3.5 Generator Wiring Diagram .................................................................................... 34
4.1. Noise consideration ............................................................................................... 35
4.2. Acoustic Material consideration ........................................................................... 35
4.3 Fire protection ........................................................................................................ 35
4.4 Mounting Arrangement .......................................................................................... 36
4.6 Indoor Installation .................................................................................................. 40
4.7 MECHANICAL CONNECTIONS ........................................................................ 41
4.7.1 Fuel system ................................................................................................. 414.7.2 Lubrication system ...................................................................................... 43
4.7.3 Exhaust system ........................................................................................... 45
4.7.4 Ventilation and cooling system................................................................... 45
4.8 Load Connections .................................................................................................. 46
4.8.1 Sizing Load Cables ....................................................................................... 46
4.8.2 Connecting Load Cable................................................................................ 46
4.9 Earth Connections .................................................................................................. 47
4.10 Battery Connections ............................................................................................. 47
4.11 ATS Connections ................................................................................................. 48
5. Operation ........................................................................................................... 49
5.1 General Pre-check Before Starting ........................................................................ 49
5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting ............................. 50
5.2.1 Engine oil..................................................................................................... 50
5.2.2 Fuel.............................................................................................................. 51
5.2.3 Coolant ........................................................................................................ 51
5.3 Manual Start-up ..................................................................................................... 52
5.4 Automatic Start-up ................................................................................................. 52
5.5 During Operation ................................................................................................... 53
5.6 Stopping Generator Under Manual Operation Mode ............................................. 54
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5.7 Stopping Generator Under Automatic Operation Mode ........................................ 54
5.8 Shutting Down Genset ........................................................................................... 54
5.9 Lifting and Transportation ..................................................................................... 55
5.10 Overnight Storage ................................................................................................ 55
5.11 Long-term Storage ............................................................................................... 55
6. Maintenance...................................................................................................... 55
6.1 Periodic Maintenance Schedule ............................................................................. 56
6.2 New Machines ....................................................................................................... 57
6.3 Air Cleaner ............................................................................................................. 57
6.3.1 Clean Air Filter Element .............................................................................. 57
6.3.2 Change Air Filter Element ........................................................................... 57
6.4 Engine Coolant ....................................................................................................... 57
6.4 Engine Coolant ....................................................................................................... 58
6.5 Engine Oil and Oil Filter ........................................................................................ 59
6.5.1 Change Engine Oil ....................................................................................... 59
6.5.2 Change Oil Filter.......................................................................................... 59
6.6 Fuel Filter ............................................................................................................... 60
6.6.1 Drain Water / Sediment in the Fuel Filter .................................................. 60
6.6.2 Change Fuel Filter ....................................................................................... 60
6.7 Troubleshooting ..................................................................................................... 60
6.7 Troubleshooting ..................................................................................................... 61
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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 thegenerator.
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 writtenapproval 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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OPERATOR & MAINTENANCE MANUAL
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2. Safety Information
This manual contains important instruction that should be followed during installation and
maintenance of the generator and batteries
Before operating the machine, read the operators manual and become familiar with it and
the equipment. Safe and efficient operation can only be achieved if the equipment is
correctly operated and maintained. Many accidents are caused by failure to follow
fundamental rules and precautions.
This symbol, the industrys 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 read the instructions and safety regulations before you attempt
to operate or maintain this machine.
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, could result
in serious injury or even death
Indicates a hazardous situation which, if not avoided, could result
in minor or major injury
Indicates additional information important to a procedure
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OPERATOR & MAINTENANCE MANUAL
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2.1 General Safety Precautions
Check that all necessary or available guards are correctly fitted. DO NOT dismantle or
disable any safety devices.
Check the generator is securely mounted.
Check all mechanical connections are satisfactory.
Check all electrical connections are correct, safely insulated and suitably earthed.
Ensure that the earth spike is connected to the earth point in front of the plant.
All service and maintenance personnel must be competent and adequately trained.
Always dispose of any rags used to clean up fuel or oil in appropriate bins.
Always disconnect the main battery before commencing maintenance operations.
Ensure that the appropriate Personal Protective 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 any access doors open.
Ensure the 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 securely fixed.
When relocating the generator only lift from designated lift points.
Do not use the lifting points located over the engine, alternator or any other
components.
If the generator is damaged during transport, repairs should only be carried out by
an authorised service agent.
Unpacking must be carried out carefully, avoiding any damage to the goods
particularly when using levers, saws or any other metallic tools.
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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 generators
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
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OPERATOR & MAINTENANCE MANUAL
PAGE-5
to the OFF position.
Do not operate the generator in any poorly ventilated areas.
Do not handle any wires or connections when the generator is operating.
Do not touch any rotating machinery.
Do not move the generator when it is operating.
Do not connect or disconnect loads whilst the generator is operating. High voltage is
present whenever the engine is running. Loads should be connected correctly before
starting the engine.
Do not smoke near the generator or any other fuel sources.
Do not point the exhaust towards people or buildings.
Use the emergency stop button only in an actual emergency. Do not restart the
engine until the problem has been verified and corrected.
2.5 Safety Around Diesel Engines
Do not operate the engine 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 radiator cap. Coolant that is hot and under
pressure may cause serious burns.
Do not add coolant, oil or fuel to a hot engine. Allow the engine to sufficiently cool
first.
Do not touch the engine and muffler while the engine is running. Allow the engine to
sufficiently cool before any maintenance is performed.
Do not smoke in the vicinity of the generator.
Consistently monitor the exhaust system 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 competent and
adequately trained 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.
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Do not remove the radiator cap while the engine is running. Allow the coolant to
sufficiently cool before removing the radiator cap. Coolant that is hot and under
pressure may cause serious burns.
Only correct plugs are to be used in electrical outlets.
Ensure all naked flames have been extinguished before refuelling.
Periodically check the clamping and insulation of all electrical connections.
Ensure that the appropriate PPE is worn while working on the generator.
2.7 Symbols and Their Meanings
The following symbols 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 when an emergency
occurs.
4. Do not disassemble the machine.
Warning
1. To prevent hearing loss, wear hearing protection.
2. Avoid spraying water into generator.
3. Avoid hand injury in rotating belts and pulleys.
4. Mechanical moving parts can cause 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.
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Warning
Always refuel with the engine stopped and in a
well-ventilated area. Do not smoke or allow open flames
or sparks in or near the area where refuelling is
performed or where fuel is stored.
Warning
Do not operate while transporting. Ensure panel latches
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 servicing.
2. Read the Operator Manual for instructions.
Warning
Do not manipulate the generator with the switch on.
Warning
Engine exhaust can cause serious injury or even death.
Hot surfaces can burn skin.
Danger
High voltage.
Warning
Do not clean the alternator with water
Warning
High temperature.
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Caution
Check the engine oil level before starting the engine.
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 inlet
Note
Fuel inlet
Note
Phase connection points.
Note
Earth connection points.
Note
Water inlet.
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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 & Size
3. Specifications and Parts Introduction
3.1 Specifications
3.1.1 Use
The generator can be used as a power supply for two main types of services:
Continuous service Used for the production of electrical energy for variedpurposes: motion force, lighting, heating, etc.
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Emergency service Used to rectify main supply interruptions or to faceconsumption peaks.
3.1.2 Main Specifications
Reliable and powerful Perkins engine and Leroy Somer alternator.
Operation: Using the advanced Intelilite AMF 25 Controller, allows for simpleand convenient fingertip control through the front control panel or by PC
connection. The Intelilte AMF 25 Controller also monitors the engine and the
alternator displaying all warning alarms and performing automatic shutdowns on
fault signals.
50C designed cooling system.
The engine and alternator have rubber av mounts installed to reduce vibration.
High anti-corrosion protection.
Easy maintenance: Wide doors are designed to allow easy access formaintenance and cleaning.
Super quiet performance: Acoustic insulation installed inside all of the panelsand doors and an oversized muffler to minimise noise.
Engine and alternator can resist any direct impact stress.
Control cabinet can reach IP66 protection. Canopy can reach IP44 protection.
Double bunded fuel tank protection.
Leak proof base: All drain points are located on the inside.
Muffler with spark arrester.3.1.3 Design Ambient Conditions
Installation: Outdoors and indoors in a well-ventilated area.
Temperature: -15C to 50C.
Relative humidity: Less than 80%.
Altitude: To a maximum of one thousand (1000) metres above sea level.
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3.2 Generator Specifications
TABLE 2: GENERATOR SPECIFICATIONSITEM UNIT DATA
Model S80PS
Rated OutputkVA 80
kW 64
Rated Voltage V 415 / 240
Power Factor 0.8
Rated Frequency Hz 50
Rated Speed rpm 1500
Phase / Wire 3-Phase / 5-Wire
Noise Level dB(A)@7m 69.8
ENGINE SPECIFICATIONS
Model Perkins (UK), 1104C-44TAG1
Number of Cylinders 4 vertical in-line
Bore mm 105 / 4.13
Stroke mm 127 / 4.99
Engine Speed rpm 1500
Prime Power kW 80
Standby Power kW 88
Compression Ratio 18.2:1
Displacement L 4.4
Cooling System Water-cooled
Battery Voltage V 12
Type of Oil 20W50-CF4 Upgrade
Type of Fuel 0# or 20# Light Diesel
Fuel Tank Capacity L 510
ALTERNATOR SPECIFICATIONS
Model Leroy Somer LSA43.2 L8
Exciter Brushless
Excitation System AREP
Insulation Type Class H
DIMENSION
Length mm 2830
Width mm 1060
Height mm 1890
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Dry Weight kg 1815
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3.3 Generator Layout and Major Components
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TABLE 3: CONTROL CABINET
REF NAME DESCRIPTION
1 Canopy Size: 2630 x 1060 x 1490mm2 Fire extinguisher bracket Designed for 9kg ABE fire extinguisher
3 Field wiring cabinet
4 Base Size: 2830 x 1060 x 400mm
5 Control cabinet assembly
6 Spark Arrestor Rating: 8m3/min
7 Alternator LSA43.2 L8
8 Diesel engine Perkins 1104C-44TAG1
9 Radiator 50C
10 Muffler Rating: 12m3
/min
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3.4 Control Cabinet and Panel
3.4.1 Control Cabinet
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TABLE 4: CONTROL CABINET
REF NAME DESCRIPTION
1 Relays DC 12V
2 Circuit Breaker 6A 1P3 Circuit Breaker 32A 1P
4 Circuit Breaker 16A 1P
5 Relays DC 12V (start relay and fuel start relay)
6 Terminals DC 12V
7 Battery Charger
8 DC Regulator Module
9 Terminals AC 240V
10 RCD/MCB Combo 10A 2P (Protects the battery charger)
11 Circuit Breaker 10A 3P
12AMF/Island Mode
Selector Switch
Refer to Note 1
13Double action RCD
bypass switch
Refer to Note 2
14 Earth Bar
15 Neutral Bar
16 Neutral Bar
17 Earth Bar
18 MEN Bar19 Terminal Empty
20 Diode ZP5A
Note 1: With the switch in AMF mode, 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 require the Intelilite AMF 25 Controller to be in AUTO mode.
NOTE 2: The RCD bypass switch has a protective cap to prevent accidental operation. The
machines are delivered with the switch in the off position and the cap down. In this
configuration the adjustable earth leakage relay (16) will monitor any earth leakage current.
If a leakage current greater than the relay setting is detected the shunt trip will trip the Main
Circuit Breaker. When the RCD bypass switch is on and the cap is in the up position, the earth
leakage relay will be bypassed.
This operation must only be carried out by a licensed electrician.
NOTE 3: The MEN connection terminals are provided to facilitate simple connection and
disconnection of the MEN Link. The MEN Link (18) is connected on the alternator side of thetoroids for the earth leakage protection. If the load side has another MEN Link connected,
the generator side MEN Link must be disconnected. A spare terminal (9), is provided. The
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PAGE-17
earth leakage relay must also be bypassed (in the control cabinet).
This operation must only be done by a licensed electrician.
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3.4.2 Control Panel
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TABLE 5: CONTROL PANEL
REF NAME DESCRIPTION
1 Control Cabinet Lamp Switch
2 Control Cabinet Lamp3 RCD Status Lamp
4RCD Status Lamp Globe Test
Button
5Mains / ATS Battery Charging
Lamp
6Mains / ATS Battery Charger
Selector Switch
7 Audible Alarm
8 Master Control Switch
9 Controller Intelilite AMF 25
10 Earth leakage relay Schneider Vigirex RH99P; Panel mounted
11 RCD Test Point 10A ,Test Point
12 Push Button Mains connected, two pole RCD Test button
13 Test Point Switch 20A,Lockable
14 Circuit Breaker 50A 3P,General purpose outlets
15 Circuit Breaker 2A 2P, Test point
16 RCD 63A 4P,30mA
17 Circuit Breaker 20A 3P,General purpose outlets
18 GPO Switch 150A,Lockable
19 Main Circuit Breaker 125A 3P
20 RCD 40A 4P, 30mA
21 RCD/MCB Combo 20A 2P
22 RCD/MCB Combo 16A 2P
23 Door Lock
1. Control Cabinet Lamp Switch
The Control Cabinet lamp switch (1) is used to illuminate the control cabinet
lamp (2).
2. Control cabinet lamp.
The control cabinet lamp (2) is located above the controller.
3. RCD Status Lamp
The RCD Status Lamp (3) indicates the status of the RCD. When the RCD Status
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Lamp is illuminated the earth leakage relay (ELR) is protecting the outlets
and main field wiring terminals. If the RCD Status 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/ATS Battery Charging Indicator Lamp
The indicator (5) will illuminate when the 12V main battery is being
charged by either the mains inlet power or ATS power.
6. Mains/ATS Battery Charge Select Switch
The switch (6) is used to select the source of the battery charging power,
either Mains Inlet or ATS.
7. Audible Alarm
IF the AMF controller senses a fault . The Audible Alarm (7) will sound.
8. Master Control Switch
The switch (8) energises the control panel.
9. Controller (AMF 25)
The generator controller AMF 25 (9) is a microprocessor-based control
unit containing all of the necessary functions for the protection and
control of the generator. It also monitors the three-phase AC voltage &
current. The unit is equipped with a liquid crystal display, to present all
values and alarms.
10. Earth Leakage Relay (ELR)
The generator is equipped with an earth leakage relay
(10). There are two different types of relays, the standard
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configuration is RH99P, which is panel mounted. The other is RH99M, din rail
mounted, located in the control cabinet.
11. RCD Test Point
The RCD Test Point (11) is used to test the earth leakage protection
function. When an earth leakage greater than the adjustable ELRs
setpoint occurs, the main circuit breaker (19) will shunt trip.
12. Mains RCD Test Pushbutton
Depressing the Mains RCD Test Pushbutton (12) allows power to the
RCD Test Point (11).
13.Test Point Switch
The test point switch (13) is used to isolate the RCD Test Point (11)
14.Circuit Breaker (50A 3P)
The three-phase circuit breaker (50A 3P) (14) is located
on the control panel. When the electric current in the
5-pin socket circuit is above 50A, this breaker will turn tothe OFF position automatically and interrupt power
from the in the load side of RCD to the respective GPO in the field wiring
cabinet.
15. RCD Test Point Circuit Breaker (2A,2P)
The two pole RCD Test Point Circuit Breaker (15) is located on the
control panel and protects the RCD Test Point (11).
16.Three Phase Earth leakage Residual Current Device (RCD) (63A,4P,30mA)
The Three Phase Residual Current Device (16) is located on the control
panel. When a residual current of greater value than 30mA is detected
this device will automatically trip to the fault position. This will
interrupt power from the load side of RCD to the respective GPO in the
field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating RCD.
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17. Three Pole Circuit Breaker Protecting 20A Three Phase Outlet
The Three Phase Circuit Breaker (21) is located on the control panel.
When the electric current in the three phase outlet circuit is above 20A,
this breaker will automatically trip to the fault position. This will
interrupt power from the the load side of RCD to the respective GPO in
the field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating circuit breaker
18. GPO Switch(150A)
The GPO switch (18) is used to disconnect the power to all outlets.
19.Main Circuit Breaker (125A 3P)
The lockable three-phase circuit breaker (125A 3P) (19) is located on the
control panel. When the electric current exceeds 125A, it will
automatically trip to the fault position and interrupt all power from
the load side of the circuit breaker.When earth leakage fault occurs
above 30mA, this breaker will turn to the OFF automatically and
interrupt all power from the load side of breaker. Note: Generator will
still supply power on the line side of breaker.
20.Three Phase Earth leakage Residual Current Device (RCD) (40A,4P,30mA)
The Three Phase Residual Current Device (20) is located on the control
panel. When a residual current of greater value than 30mA is detected
this device will automatically trip to the fault position. This will
interrupt power from the load side of RCD to the respective GPO in the
field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating RCD.
21. Single Phase RCD/MCB Combo Protecting 20A Single Phase
Outlet
The 20A Single Phase RCD/MCB Combo device (21) is
located on the control panel. When the electric
current is greater than 20A or a residual current of
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greater value than 30ma is detected, this device will automatically trip
to the Fault position. This will interrupt 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 reinstating RCD/MCB.
22. Single Phase RCD/MCB Combo Protecting 16A Single Phase Outlet
The 16A Single Phase RCD/MCB Combo device (22) is located on the
control panel. When the electric current is greater than 20A or a
residual current of greater value than 30ma is detected, this device will
automatically trip to the Fault position. This will interrupt power from
the load side of the RCD/MCB to the 16A single phase GPO in the field
wiring cabinet. RCD capability exists to protect the end user.
Note: If a fault occurs, test accordingly before reinstating RCD/MCB.
3.4.3 AMF 25 Controller
TABLE 5: PUSH BUTTONS
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REF NAME DESCRIPTION
1START button. Works in MAN mode only. Press this button
to initiate the start sequence of the engine.
2
STOP button. Works in MAN mode only. Press this button
to initiate the stop sequence of the gen-set. Repeatedpressing 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 acknowledge
alarms and deactivate the horn output. Inactive alarms will
disappear immediately and status of active alarms will be
changed to "confirmed" this will allow the alarm to reset
when the fault condition is alleviated.
4 HORN RESET button. Use this button to deactivate thehorn output without acknowledging the alarms.
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5
MODE LEFT button. Use this button to change the mode.
NOTE:
This button will not work if the controller mode is locked by
one of the binary inputs: Remote OFF, Remote MAN,
Remote AUT, Remote TEST.
6
MODE RIGHT button. Use this button to change the mode.
NOTE:
This button will not work if the controller mode is locked by
one of the binary inputs: Remote OFF, Remote MAN,
Remote AUT, Remote TEST.
7GCB button. Works in MAN mode only. Press this button to
open or close the GCB manually.
NOTE:
Certain conditions must be valid otherwise GCB closing is
blocked.
8
MCB button. Works in MAN mode only. Press this button to
open or close the MCB manually.
CAUTION!
Pressing this button can disconnect the load from the mains
supply!
GEN-SET OPERATION INDICATORS
9
Gen-Set Failure. If a Gen-set failure fault is detected 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 Volt age OK. If the generator voltage is within the preset limits the GreenLED will be illuminated.NOTE:
The limits for the generator voltage and frequency are given by set points in theGenerator Protection Parameters.
11GCB ON. If the Generator Circuit Breaker (GCB) is closed the Green LED will beilluminated.It is driven by the GCB CLOSE/OPEN output (AMF 8/9) or by the GCB feedbacksignal (AMF 20/25).
12MCB ON. If the Mains Circuit Breaker (MCB) is closed the Green LED will beilluminated.It is driven by the MCB CLOSE/OPEN Output (AMF 8/9) or by MCB feedbacksignal (AMF 20/25).
13 Mains Voltage OK. If a Mains Voltage is present and within limits the Green LED
will be illuminated.
14Mains Failure. If a mains failure is detected the Red LED will start flashing. The
LED will be constantly illuminated after the gen-set has started and connected to
the load.
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DISPLAY AND CONTROL BUTTONS
15 Graphic B/W display, 128 x 64 pixels
16PAGE button. Use this button to switch between display
pages.See Display Screens and Pages Structure for more details.
17 UP button. Use this button to move up or increase a value.
18 DOWN button. Use this button to move down or decrease a
value.
19ENTER button. Use this button to finish editing a set point or
moving right 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 pagesconsist of screens which display the measured values, ie. voltages,
current, oil pressure etc. The calculated, values i.e. gen-set power, statistical data & alarm list
are displayed on the last screen.
2. The Set Points pagescontain all the set points categorized by their groups and also aseparate page for entering the password.
3. The History Log pages display the history log in chronological order with the most recent recorddisplayed first.
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Alarms
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Browsing ECU Alarms
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WARNING:
ONLY press emergency stop button in the case of an actual emergency.
Note: Stopping the generator under load may cause mechanical damage!
1.
Emergency Stop Switch
The generator is equipped with two red emergency stop switches. One switch
(15) is located in the field wiring cabinet, the second is adjacent to the control
cabinet. 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 reset emergency stop.
Note: The cabinet emergency stop has a protective cover, which has to be lifted to be
activated.
2. GPO Manual Switch
The lockable GPO Manual Switch is used to isolate the respective GPO.
3. General Purpose Outlet (GPO) (Manually switched 20A 5pin, three-phase)
The generator is equipped with two 415V three-phase GPO (3) rated at 50A.
The GPO connects through the main line circuit breaker. It is also protected
by its own RCD & circuit breaker located in the control cabinet.
4.General Purpose Outlet (GPO) (Manually switched 20A 5pin, three-phase)
The generator is equipped with one 240V three-phase GPO (4) rated at 20A.
The GPO connects through the main line circuit breaker. It is protected by
TABLE 7 OUTPUT TERMINAL ASSEMBLY
RE
F
NAME DESCRIPTION
1 Emergency stop switch
2 GPO manual switch
3 50A 5-pin GPO Three Phase
4 20A 5-pin GPO Three Phase
5 15A 3-pin GPO Single Phase
6 ATS connector
7 Tie bar
8 20A 3-pin GPO Single Phase
9 10A Male 3 flat pin mains inlet Single Phase
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its own RCD/MCB combo breaker located in the control cabinet.
5.General Purpose Outlet (GPO) (15A, single-phase)
The generator is equipped with two Auto switched 240V single-phase GPOs (5)
rated at 15A. Both are connected through the main line circuit breaker. Each
GPO is protected by its own RCD/MCB combo breakers located in the control
cabinet.
6. ATS Connector
The generator is equipped with an Automatic Transfer Switch (ATS) plug on
the left side of the control panel. The customer can select an appropriate
automatic transfer switch (ATS) and connect it to the generator
7.Tie Bar
The Tie Bar is used to protect the wiring cables by tied them on it.
8.Safety Micro Switch
The generator is equipped with one 240V single-phase GPO (8) rated at 20A.
The GPO connects through the main line circuit breaker. It is protected by
its own RCD/MCB combo breaker located in the control cabinet.
9.Mains Inlet for Battery Charging (10A male 3 flat pin, single phase)
The generator is equipped with one 240V single phase 3 flat pin inlet, (14)
rated at 10A. It connects to the battery charger through an RCD/MCB combo
breaker, which is located in the control box.
.
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3.5 Generator Wiring Diagram
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4. Installation
A diesel generator is a high-speed piece of rotating equipment. To ensure reliability and
safety the installation must be given thorough attention.
Before installing the unit, we must consider all environmental factors. Generator installation
must comply with local building codes, fire regulations and environmental requirements. Usethese instructions as a general guide only, the complete installation must comply with all
local, state, and federal building codes, fire ordinances, and any other applicable regulations.
4.1. Noise consideration
Because noise eafects the surrounding environment, it is important to consider noise factors
when installing a generator. The generator has been acoustically treated, but if more
stringent local environmental specifications require additional noise attenuation, please
consider adding noise barriers or the construction of special rooms, etc.
4.2. Acoustic Material consideration
Consider the following when selecting acoustic material:
Foam is not recommended as an acoustic material, because of its low density it is apoor acoustic insulator. And not all foams are fire retardant.
A concrete block enclosure is an excellent barrier in regards to noise reduction. The
blocks may be filled with sand to make the wall denser. However, concrete housingtends to become hot and supplementary cooling methods will be required for
correct engine performance.
4.3 Fire protection
Each country has its own rules and regulations controlling the design of buildings to prevent
fires. Fire departments are reliable sources of information to determine installation
compliance. The installation of generators, must comply with the provisions of the local fire
department. Fire protection systems must be consistent with the requirements of therelevant authorities.
1. The genset room cannot be used for storage.
2. Because of the fuel used the genset room must be consdered as a key target area for fire
prevention.
3. The generator must be treated as a high-temperature device, exhaust pipe temperatures
can reach 500C.
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4.4 Mounting Arrangement
The base is used to support the unit and its accessories, its carrying capacity should be 2 to 5
times the total mass of the generator, but also able to absorb the unbalanced force
generated by the machine. The generator is specially designed to minimize the vibration of
the unit. If an installation requires 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 base is calculated as the basis:)(mm
LWD
GKH
=
K: Safety factor, typically value is 2;
G: Genset weight;
D: Cement density, typically value is 2400;W: Base width;
L: Base length;
The Figure below shows a typical foundation installation.
TABLE 7 FOUNDATION
REF DESCRIPTION
1 Floor slab
2 Sand or gravel
3 Foundation
4 Genset
5 Sealant material
6 Grout
7 Anchor nut
8 Foundation bolt
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When designing the base, we need to pay specific attention to the following:
The generator base must be isolated from the building foundation.
Depth and width to meet the basic requirements.
Foundation must be strong enough to take the impact and running force of the
machine.
Ensure that no vibration is transmitted to the building foundation when the unit
starts.
Ease of maintenance and servicability operations.
When calculating the length L and width B of the base allow an additional
100-300mm on each side.
The base should be higher than engine room floor by 20-300mm.
Mounting the Generator
The generator is mounted on a steel-base tank that provides
adequate support. Vibration isolators are recommendedbetween the base tank and the foundation 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 and floor foundation.
Mount the generator on a substantial and level base such as
a concrete pad. Use 20mm anchored mounting bolts to
secure the vibration isolators to the base tank using flat or
bevel washers and a hexagonal nut for each bolt. The isolators should be located as shown
on the generator outline drawing.
Incorrect installation or service can result in severe personal injury or death, and/or
equipment damage. Only qualified service personnel should be allowed to perform electrical
and mechanical component installation.
Never install the genset near combustible materials. Locate the genset such that combustible
material can not accumulate under the machine. The possibility exists of fire or explosion,
causing damage to the equipment and or severe bodily harm or even death!
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CAUTION:Pay close attention to ventilation when operating the generator inside confined spaces and
enclosed areas. The engine exhaust contains noxious elements. Engine exhaust must be
routed to a ventilated area.
4.5 Outdoor InstallationInstall the generator in an area that is free of debris, and overhead obstructions. Make sure
the generator is on secure level ground so that it cannot slide or shift around. Also install the
generator in a manner so that the exhaust gases will not be discharged in the direction of
nearby buildings.
The installation site must be relatively free from moisture and dust. All electrical equipment
should be protected from excessive moisture. Failure to do so will result in 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 parts.
The canopy is designed to provide cooling and ventilation for the generator. Several factors
should be carefully considered when selecting a location for installation.
For effective cooling and maintenance, the generator should be mounted on a hard,
flat, non-combustible, level surface. A concrete pad is ideal and provides a secure
installation.
The installation area should be well ventilated.
Drainage must be adequate to ensure the concrete pad is free from standing water. Installation should prevent build-up of leaves, grass, sand, 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.
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4.6 Indoor Installation
Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed
indoor, the exhaust fumes must be vented to the outside. The engine should be installed at
least 1000mm from any outside wall. Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine to heat excessively and possibly
burn the valves.
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 a room or enclosure are:
Never use the generator room for storage.
The room must be large enough to contain the generator and all the accessories.
1200mm must be allowed on the two sides and 1000mm in front of the engine forservice access. Allow clearance between hot parts of the system (exhaust) and
structural members of the building (see figure below).
On the generator end of the engine, allow a space equal to the length of the
generator.
The generator installation must comply with all of the current relevant standards
and local authority requirements.
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Room Location
A separate building located on the site away from the main building is the most
desirable.
Maintain the building at a satisfactory temperature
Ensure the generator is installed in a way that it will not compromise reliability from
any emergency loads.
Note
The generator can be used at temperatures between -15 to 50C, An ambient temperature
that is outside these temperatures will cause damage to the equipment, when the
temperature is too low, the metal will become very weak; when the temperature is too high,
the engine temperature may rise to a point where damage is caused to the engine and other
components such as piston rings. In order to protect the engine, when the ambient
temperature is around 50C, or close to -15C, the equipment load must be reduced or
engine life may be compromised.
4.7 MECHANICAL CONNECTIONS
After considering all applicable codes and laws and finding a suitable location for the
generator set, the installer should consider the mechanical connections that will be
necessary to make during installation. The four (4) systems that could require mechanical
connections are the following:
Fuel system
Lubrication system
Exhaust system
Ventilation and cooling system
4.7.1 Fuel system
The fuel system feeds fuel from the fuel tank to the combustion chamber. Its an important
part of engine.
The general fuel system of diesel engine is shown in the diagram below:
WARNING:
The floor foundation load-carrying capacity must be checked and must not exceed
the weight of the generator and its associated equipment.
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Fuel from the tank flows in the fuel lines and is injected from the nozzle via the fuel injection
pump. Overflow fuel returns to the tank. The system includes filters to protect it from
entrance of air, water and dust. While the engine is running, fuel is fed into the pump by the
fuel feed pump after passing through the fuel filter where any foreign matter is removed.
The fuel camshaft actuates the injection pump and force feeds fuel to the injection nozzle
through the injection pipe. Fuel is then sprayed through the nozzle into the combustion
chamber. The fuel discharged after lubricating and cooling the injection nozzle is returned tothe fuel tank through the over-flow pipe.
Base Tank
Base mounted fuel tanks are used to store fuel directly underneath the Genset, eliminating
the need for a remote main fuel supply tank and/or auxiliary fuel transfer pumps. This
mounting arrangement offers the convenience 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 increase the height of the
generator set since the tank base is usually matched to the generator skid dimension.
Remote tank
Remote tanks are used when the engine fuel pump does not have the capacity to draw the
fuel from the base tank; or the base tank is overhead and presents problems of high fuel
head pressure for the system. In high ambient conditions, the day tank temperature might
need to be considered. Warm fuel returning from the engine fuel injection pump should not
be returned to the day tank if possible. As fuel temperature increases, fuel density and
viscosity decrease, reducing maximum power output and lubrication of fuel handling parts
such as pumps and injectors. This may be avoided by returning the fuel back to the supply
tank rather than the day tank.Engines need to maintain some of the oil pump pressure and return oil pressure when the
engine is working. When using a remote fuel tank, the height difference between the pump
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and the fuel tank generates a differential pressure, the differential pressure will affect the
work of the engine.
When the fuel tank is above the pump, correct fuel return may become an issue, and the
tubing will have to be able to withstand a positive pressure. If the differential pressure is too
large, fuel leaks may become a concern.
When the fuel tank is below the pump, the fuel supply may become an issue, and the tubingwill have to be able to withstand a negative pressure. If the differential pressure is too large,
fuel supply may become a concern.
Fuel Filter and Fuel/Water Separator
The fuel filter located between the tank and the
injection pump prevents foreign matter from
entering the injection pump. A standard filter
uses a paper element (filtration diameter less
than 15). Normally filter elements or cartridges
must be changed every 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 fuel
refineries, petrochemical plants, chemical plants,
natural gas processing plants and other
industrial sources.
Three-way valvesValves used to switch between the base
tank and a remote tank. Normally, the
three-way valves are open to the base tank.
When a remote tank is used simply open
both of the valves to allow connection to
the remote tank. The figure shown below
shows the three-way valves in the default
location connected to the base tank.
4.7.2 Lubrication system
All moving parts of the engine must be lubricated to function correctly. For this purpose, the
lubricating oil circulating through the engine has a number of functions. In addition to
reducing friction, the oil cools the engine, controls expansion and dispersion of bearing areas,
provides a sealing action, prevents rusting, seals out dust, and purifies products generated in
the cylinders by incomplete combustion.
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CLASSIFICATION OF ENGINE OIL
SAE (Society of Automotive Engineers) Standards are generally used to classify engine oil
viscosities. Viscosity is a principal property of oil, the higher the viscosity, the thicker the oil
film formed over the metal surface will be and the lower the viscosity, the thinner the film
thickness becomes.
Viscosity varies with temperature. The higher the temperature, the lower the viscosity and
vice versa. Engine oil should have the appropriate viscosity and have properties which are
not affected by viscosity changes caused by temperature changes. In other words, engine oil
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 commercially for all-season use.
Oil viscosity changes in cold temperature as crystallization of the wax element contained in
oil proceeds, and fluidity is finally lost. Incorrect selection of oil cannot only increase
resistance for cold starting but also affect lubrication of each part. Oils for low
temperature, containing additives for lowering the pour point, should be used. The following
diagram shows how to select lubricants.
Warning
Poor quality oil will shorten engine life. Use only the specified lubricating oils. Important
points regarding lubricating oil are described below.
NoteThe use of synthetic oil is not recommended.
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4.7.3 Exhaust system
Exhaust system components installed on any genset must be approved and correctly
installed to meet the codes and regulations required by local government.
A muffler and spark arrester have been installed in your genset. If a generator is used in a
forest, on brush or grass covered unimproved land it must be equipped with a Spark
Arrestor. It is the responsibility of the generator owner or operator to maintain the entireexhaust system in good working condition.
Engine exhaust must be routed away from building
intake vents, windows, doorways and other
openings.
Because the exhaust discharge is in a vertical
position it may be possible for raim water to enter
the muffler. A drain valve has been provided at the
base of the muffler to remove any 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 heat dissipation must be
carefully considered. The generator has been
specially designed to operate in ambient
temperatures to 50C.
If the generator is used outdoors, ensure that no
objects (such as plastic bags, etc.) are allowed to
block the air inlet. The engine exhaust
temperature is extremely high, do not vent
towards any objects that cannot withstand high
temperatures.
The machine is provided with cabinet filters that
must be cleaned regularly. In dusty
environments, the cabinet filters must be
cleaned daily. Remove the cabinet filters as the
follow steps: Loosen the philips head screw at
the top of the grille, remove the limit stop, andthen slide the air filter out.
If the generator is used indoors, make sure that there is adequate ventilation to the air inlets
and outlets, and that the engine's exhaust is ducted out of room.
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4.8 Load Connections
4.8.1 Sizing Load Cables
Selecting the load cables, number of cores and diameter, based on its allowable
amperage and the distance between the generator and the load is critical.
Correct selection should be carefully calculated. It is recommended that there is a
maximum 5% marginal drop only for the rated voltage between the load and generator
via the cables. This should be considered when selecting the cable.
DANGERIf 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 injury, reduced performance or damage to machinery.
4.8.2 Connecting Load Cable
The generator is ready for field connections. The cables should be connected to the
Main wiring terminals which are located inside the field wiring cabinet.
WARNING:
Before connection, the following precautionary measures must be taken
Connection must only be carried out by a licensed electrician.
Battery must be disconnected.
The control power switch must be set to the OFF position.
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4.9 Earth Connections
The generator and electrical components have their respective earth wires which are all
connected to the main earth bar in the control cabinet.
Multiple Earthed Neutral (MEN) is installed on this
generator.
4.10 Battery Connections
The battery cables should be disconnected when the
generator is required to be transported or be stored for
long periods. Reconnect the battery 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 theterminal 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 the generator.
WARNING:
Do not dispose of the battery in a fire. The battery may explode. Battery electrolyte solution
is caustic and can cause severe burns and blindness. If electrolyte contacts skin or eyes,
immediately flush the area with water and urgently seek medical attention.
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WARNING:
Do not operate the generator before connection of the ATS.
4.11 ATS Connections
The generator is equipped with an Automatic Transfer Switch (ATS) plug on the left side of
the control panel. The customer can select an appropriate automatic transfer switch (ATS)
and connect it to the generator.
Connect the wire between the generator set and ATS plug.
Connect the wires between the generator main wiring terminals
and the ATS wiring terminals.
Connect the wires between the mains supply wiring terminals
and the ATS wiring terminals.
Connect the wires between the load wiring terminals and the
ATS wiring terminals.
The ATS is controlled by the PLC module which can monitor 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.
THE ATS LOCATION IS IMPORTANT, THE FOLLOWING MUST BE OBSERVED:
The ATS should be located inside the building near the main switchboard.
Locate the ATS in a clean, dry, well ventilated location, away from excessive heat.
When the ambient air is above 40C (104F), fuses and circuit breakers must be
de-rated. Allow adequate working space around the transfer switch.
Never install control wires in the same conduit with mains wiring.
ATS and all equipment must be installed in accordance with relevant local and
national codes and regulations.
If the ATS is mounted outside, it must be protected from the environment. Do not mount the ATS on the generator.
Do not mount the ATS where flammable liquids or vapours are present.
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5. Operation
5.1 General Pre-check Before Starting
Before starting the generator, check each item below:
Check engine oil, fuel and coolant.
Check for leakage at the hose connections.
Check to make sure there are no obstructions lodged in vents, near the radiator or
around the cooling fan.
Ensure that nothing is contacting the muffler or exhaust pipes.
Check the generator is earthed and the earth spike is installed and tested as per
local regulations.
Make correct terminal connections. TEST accordingly.
Check that all electrical connections were made in compliance with local regulationsand 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 to the terminals. Tighten the clamps if
necessary.
Close and secure side panel access doors.
Review and follow safety instructions at the front of this manual.
Warning:
1. Failure to follow the procedures listed in this manual may cause injury to personnel or
damage to the generator. Ensure all persons setting up the generator are certified or
fully trained on the installation of the generator.
2. Always wear protective gloves, clothes and other P.P.E. as required.
WARNING:
Do not use the machine when any leak is found. Repairs are to
Be carried out by trained personnel and according to regulations.
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5.2 Checking Engine Oil, Fuel 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 all the way in.
The appropriate level should be between the lower limit and
upper limit 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 than FULL
mark on the dipstick.
Tighten the oil inlet cap and close the access door.
CAUTION: If the generator is not level when checking the engine oil, you cannot obtain an
accurate oil level reading.
Do not overfill the engine oil. The level cannot exceed the upper limit. An excessive
amount of engine oil may damage the engine.
Do not smoke and extinguish any naked flames before adding engine oil.
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5.2.2 Fuel
Remove the fuel inlet cap and check the fuel level in the tank.
Adding Fuel:
Select the correct fuel.
Loosen the fuel inlet cap and remove it. Fill the fuel through the inlet until the fuel is slightly
less than the full-tank level
Tighten the fuel inlet cap.
5.2.3 Coolant
Remove the radiator cap, check coolant level in the tank.
Adding Coolant:
Remove the coolant inlet cap.
Remove the 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 cause
explosive release of coolant when the radiator cap is removed. Shut off engine and
allow it to cool. Do not remove cap unless the radiator and the engine are cool to
touch with bare hands. Slowly loosen the cap to the first stop to release all pressure,
then remove cap.
CAUTION:
1. Do not smoke while you are refuelling an engine.
2. Do not refuel an engine near open flames or sparks.
3. Always stop the engine before refuelling.
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DANGER:
Before turning the Main Circuit Breaker (19) to ON, make sure all loadcircuit breakers and switches are positioned to OFF. Failure to do so may
cause an electric shock to the operator.
Do not touch any wires or connections when the generator is running, thismay result in serious injury or death.
5.3 Manual Start-up
Carefully read the illustration on the control cabinet and control panel (PLC), then
proceed according to the following operation steps:
1. Set every circuit breaker and load switch to the OFF position.
2. Turn the Main Circuit Breaker (19), Circuit Breaker (14, 15, 17), RCD/MCB (21, 22),
RCD (16, 20),GPO Switch(18) to the OFF position.
3. Open the side access door and turn on the engine battery switch, then close the
door.
4. Turn the Master Control Switch (8) to the ON position.
5. Select manual mode.
6. Press the START button (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 starts, allow allow approximately five minutes for the
engine to warm.
8. Turn the Circuit Breakers ON (19, 14, 17 ), turn the GPO Switch(18), RCD/MCB (21,
22), RCD (16, 20) ON. This will allow power to all of the respective outlets (GPOs &
main terminals). The external load can now be switched on.
5.4 Automatic Start-up
Follow steps 1 to 4 as described above (see 5.3).
Select AUTO mode.
Press the START button (5), the module will proceed with its normal auto start
sequence.
The module will monitor the incoming AC mains supply. If the mains supply is
satisfactory, the ATS will carry the mains loads and the generator will not run. On
the contrary the generator will run the supply power if the mains supply is
unsatisfactory.
The generator will operate up to 5 seconds (Warm up Mode).
PLC will automatically switch (ATS) load circuit breaker to ON, generator will
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supply power.
NOTE: Before operating 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
Buttons and .
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 fuel.
Check for any unusual vibration or noise.
Check for any unusual colour from the exhaust. Under normal conditions the
exhaust gas has no colour. If the engine cannot run because of low fuel, bleed the air
from the fuel system.
Loosen air release bleed bolt on the fuel filter.
Bleed the air in the fuel system for about 30seconds.
Tighten the bolt.
CAUTION:
1. If a fault is detected, stop and isolate the machine immediately.
2. Generator to be repaired by certified or fully trained personnel (refer to
troubleshooting guidelines 6.7).
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5.6 Stopping Generator Under Manual Operation Mode
1. Turn off every RCD/circuit breaker.
2. Turn the Main Circuit Breaker (19), Circuit Breaker (14, 15, 17), RCD/MCB (16,
18), RCD (21, 22), GPO Switch( 18)to the OFF position.
3. Press the Stop button (6).
4. Allow the engine to remain idle for approximately one minute to cool down.
5. Turn off the Master Control Switch (8).
6. Open the side access door and turn off the battery isolator switch, then close
the door.
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 load to OFF position.
Turn off the Master Control Switch (9).
Open the side access door and turn off the engine battery switch, then close thedoor.
5.8 Shutting Down Genset
The generator is equipped with an automatic shutdown feature. The LCD will display
the fault.
Warning:
In the event of a shutdown alarm, turn off the engine. Generator must be repaired by
certified or fully trained personnel according to the troubleshooting guidelines (see
6.7).
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5.9 Lifting and Transportation
Lifting: The top of the generator has two lifting lugs and
the four chassis angles have four holes attached to the
lifting frame inside the housing. Refer to the technical datafor the weight of the generator. Make sure the lifting
device has sufficient capacity to lift the unit safely. When
lifting the generator, attach a hook or sling securely to the
lifting lug.
Transportation: When transporting the generator, it should
be secured correctly with ropes tied to the roping lugs at
the top of the generator.
5.10 Overnight Storage
When storing 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 canenter the generators electrical / mechanical systems and damage may result.
5.11 Long-term Storage
If the generator will not be used for more than two months, the following procedures need
to be performed.
Close and padlock all access doors. Remove the start key.
Avoid storing generator in a dusty, humid environment.
Refer to and follow the engine manufacturers recommendations for long-term storage.
These procedures are designed to help minimize engine corrosion.
6. Maintenance
Before performing any checks or maintenance, stop the engine and remove the start key.
For detailed maintenance procedures on the engine, refer to engine operator's manual.
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6.1 Periodic Maintenance Schedule
SERVICE ITEMS
DAILY
ORAFTER
8 HRS
WEEKLY
ORAFTER
50 HRS
MONTHLY
ORAFTER
100 HRS
SIX
MONTHS
OR
AFTER
250 HRS
YEARLY
OR
AFTER
500
HRS
TWO
YEARS
ORAFTER
1000
HRS
Check various meters and
alarm lamps
Check 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/sedimentfrom 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 unit inside & outside Change coolant Pressure test cooling
system
Clean inside fuel tank
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6.2 New Machines
Run the generator at least 60 100% of continuous load for the first 100 hours.
Change engine oil and replace oil filter after the first 50 hours.
6.3 Air Cleaner
6.3.1 Clean Air Filter Element
Loosen clips in the air cleaner and remove the dust cap.
Remove the air filter element which contains a primary filter and a safety filter.
Loosen the safety filter from the primary filter.
Use compressed air to flush the safety filter and primary filter from 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 cleaner andremove the dust cap.
Remove the air filter element.
Loosen the safety filter from theprimary filter.
Change the primary filter.
Reinstall the air cleaner in thereverse 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; and the safety filter every
500 hours or as required.
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6.4 Engine Coolant
Changing Coolant:
Open the radiator drain ball valve, located on the top of the generator base tank,
and drain coolant.
After draining, close the drain ball valve.
Remove the coolant inlet cap.
Remove the radiator cap.
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
explosive release of coolant when the radiator cap is removed. Shut off engine and
allow it to cool. Do not remove cap unless the radiator and the engine are cool to
touch with bare hands. Slowly loosen the cap to the first stop to release all pressure,
then remove cap.
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6.5 Engine Oil and Oil Filter
6.5.1 Change Engine Oil
Open the oil drain ball valve.
Open the access door.
Open sump and oil ball valve which is under the oil
pump.
Use oil pump to drain engine oil.
After draining, close the oil drain ball valve and oil
ball valve.
Loosen and remove the oil inlet cap; add oil to the oil inlet through an outside oil filter
until the level is slightly less than the upper limit by checking the oil level on the oil gauge.
Tighten 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.
Lubricate the new gasket with oil.
Screw the new filter into place and tighten it until thegasket touches the seal surface. Tighten accordingly.
Supply engine oil as described in 6.5.1.
WARNING:
1. If the generator is not level when checking the engine oil, you cannot obtainaccurate oil level.
2. Do not overfill the engine oil. The level cannot exceed the upper limit becausethe excessive amount of engine oil may damage the engine.
3. Do not smoke or be near an open flame when adding engine oil.
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6.6 Fuel Filter
6.6.1 Drain Water / 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 will oil.
Screw the new filter into place and tightenaccordingly.
DANGER:
Do not smoke while you are refuelling an engine. Do not refuel an engine nearopen flames or sparks. Always stop the engine before refuelling.
Wear protective gloves, goggles and clothing when changing the fuel filter.
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6.7 Troubleshooting
When performing any troubleshooting, follow the guidelines. If further clarification is
required please contact our authorised service agent.
TROUBLE CAUSES SOLUTIONS
Low engine oil pressure
1. Lubricant oil is insufficient 1. Add lubricant oil
2. Oil hose has leak 2. Tighten or change oil hose
3. Oil filter is clogged 3. Change oil filter
4. Wrong oil is used 4. Change to correct oil
High coolant
temperature
1. Coolant is insufficient 1. Add coolant
2. Coolant pipe has leak 2. Tighten or change coolantpipe
3. Fan belt is loose 3. Tighten the belt
4. Radiator core is clogged 4. Clean radiator core
5. Water temp sensor is
defective5. Repair or change the sensor
6. Engine thermostat is
defective
6. Repair or change the
thermostat
Low fuel level
1. Fuel is insufficient 1. Add fuel2. 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 filter is clogged4. Drain water/sediment or
change fuel filter
5. Fuel level sensor is defective 5. Repair or change the sensor
Cannot turn the breaker
to on
1. The main breaker position is
located between on and off
1. Turn off and on.
2. Replace breaker if faulty
2. Short circuit on the load 2. Check and repair the loadcircuit
Controller not working
1. The controller cable is
disconnected from the
battery
1. Connect the controller cable
to the battery
2. The battery power is
insufficient
2. Charge the battery with the
utility power
3. The DV fuse is damaged 3. Change the DV fuse
Voltage drops when
connecting to the load
1. Loads total exceeds the
rated current
1. Decrease the loads to meet
the rated output
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2. Battery output is low 2. Charge the battery
3. Battery is deteriorated 3. Change the battery
4. Battery terminal is loose 4. Tighten the terminal
Starter
motor
drives, but
engine
cannot start
1. Fuel is insufficient 1. Add fuel
2. Fuel hose has leak 2. Tighten or change fuel hose
3. Fuel filter is clogged3. Drain water/sediment or
change fuel filter
4. Gauze filter is clogged 4. Clean or change 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 orChange fuel filter
3. Gauze filter is clogged 3. Clean or change gauze filter
4. Lubricant oil is insufficient 4. Add lubricant oil
5. Air is mixed in fuel line 5. Bleed the air
6. Air filter element is clogged6. Clean or change air filter
element
Muffler releases black
smoke
1. Wrong fuel is used 1. Change to correct fuel
2. Air filter element is clogged 2. Clean or change air filterelement
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Promac Sales
Email: [email protected]
Phone: +61 8 6254 1800
Fax: +61 8 6254 1899
Ofce: 11 Poole Street, Welshpool,
Western Australia, 6106
Postal Address: PO Box 538, Welshpool,
Western Australia, 6986