Manual Operacao Amf25

7/28/2019 Manual Operacao Amf25

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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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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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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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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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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


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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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


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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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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PAGE-57

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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PAGE-58

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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PAGE-59

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

Manual Operacao Amf25

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