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Summary of Contents for Kipor KDE11SS
- Page 1 WUXI KIPOR POWER CO., LTD. Operation Manual KDE11SS KDE13SS3 KDE16SS KDE20SS3 KDE25SS KDE30SS3 KDE30SS KDE35SS3 KDE35SS KDE45SS3 KDE60SS3 KDE75SS3 KDE40ST3 KDE100SS3...
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Page 2: Preface
Preface Thank you for purchasing our generator sets. Please read this instruction and ensure understand all regulations concerning handling, check and maintenance thoroughly prior to application. Failure to follow this instruction may cause serious accidents. Incorrect operation is likely to lead accidents. Operate and maintain the machine on the basis of thorough understanding of this instruction. -
Page 3: Table Of Contents
CONTENT Preface······································································································································· 1 1. Safety instruction ··················································································································· 3 2. Product instruction ················································································································· 8 3. Installation and transportation ···························································································· 11 4. Connection of load ············································································································· 13 5. Fuel, lubricant, cooling water, battery··················································································· 18 6. Running the generator ········································································································· 22 7. Periodical maintenance and service····················································································· 28 8. -
Page 4: Safety Instruction
1. SAFETY INSTRUCTION Please read and observe all safety and precaution information. Failure to observe them and incorrect operation can lead to serious injury even death. (1) Safety label The followings are illumination of the safety label. Indicates a strong possibility of severe personal injury even death if instructions are not followed. - Page 5 Matters need attention Operator's duties ■Don't operate the generator when the operator is very tired, drunk, or unconscious. ■ Be care to operate the generator set according to the instructions, otherwise it will cause an accident. ■Wear protective clothing and mask to avoid an unexpected hurt. ■Keep the children or pets away from the generator.
- Page 6 Electric shock ■It will cause electric shock even death if touch the naked cable during the running. Never touch the machine with wet hands, or electric shock will occur. ■Cut off the circuit to stop the generator before connecting the Running terminal.
- Page 7 loosened or missed. ■The generator set should be put on a level ground hard enough to afford its weight. ■If put a generator set on another generator, the weight and size of above one should be less than that of the other. ■Don't run the generators set when stacks together.
- Page 8 Noise ■Close the door of the super quiet generator when it is running. Otherwise its noise will reach a very high level. ■Open-frame generator would cause a hearing damage for its high noise level if stay at this condition for a long time. Put on the earplug if necessary or take other protective measures. Cable Connection ■Use a disconnecting switch for cable connection.
- Page 9 ■Anyone shouldn't stand under the lifted generator. ■Don't lift or move the generator when the engine isn't stop. Otherwise, it may break the cooling fan, and cause a fatal fault. ■Fix the generator with ropes, after putting a generator into the car. rope 绳...
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Page 10: Product Instruction
2. PRODUCT INSTRUCTION 2.1 Use and laws ■ This machine is portable and used as main or auxiliary power supply for outside work. Some countries regulate the connection of machine with inside distribution line accepting power from the power company. Please pay particular attention to and observe relevant laws and regulations in local countries and areas. - Page 11 2.2 Outlook and parts’ names (1) KDE11SS、KDE16SS、KDE13SS3、KDE20SS3 Water inlet Exhaust Lifting level Fixed level Fuel inlet Fuel outlet Water outlet Output panel Output panel Oil outlet Emergent stop button (2) KDE25SS、KDE30SS、KDE35SS、KDE30SS3、KDE35SS3、KDE45SS3、KDE60SS3、 KDE75SS3、KDE100SS3 1. Cabinet sidedoor 8. Lifting level 2. Cooling water inlet 9.
- Page 12 2.3 Inner structure Rainproof cap Engine Radiator Alternator Muffler Oil filter Oil water separator Air filter Overflow pot Battery Fuel filling pump of outer Fuel filling port of inner fuel tank fuel tank...
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Page 13: Installation And Transportation
3. INSTALLATION AND TRANSPORTATION 3.1 Installation Pay attention to the following items during installation: (1) Please install the machine on the flat and solid ground. Make sure bottom of the generator contacts ground evenly. Error may occur due to generator vibration. (2) If it is necessary to run the machine on the inclined ground, make sure the side with radiator upwards and inclination angle within 10°. - Page 14 3.2 Storage Poisonous Exhaust The poor ventilation will cause shortage of oxygen, which resulted in the poisoning even death. ■Don't operate the set in the building or poor-ventilated places. ■The unit can't be operated at the situations such as: indoor, store, subway, deck. ■The exhaust vent shouldn't open to the passenger and others.
- Page 15 3.3 Transportation Transportation attention Don't use rope or ladder to lift the generator. Otherwise, the generator may fall down and be broken. ■Lift the generator by using the lifting lever at the center of the engine cover. ■Anyone shouldn't stand under the lifted generator. ■Don't lift or move the generator when the engine isn't stop.
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Page 16: Connection Of Load
4. CONNECTION OF LOAD 4.1 Input power [Attended operations] If select the motor with improper capacity, it is possible to fail in starting the motor. Decide the capacity of motor as per followings: ●According to load type, purpose, start mode, quantity, loading factor, features of generator, and type of auto voltage regulator, the starting power is different. - Page 17 4.2 The grounding of the protection unit Electric Shock (1) It will result in electric shock even death if connected with the output terminals. ■ Cut off the breaker circuit of the control box and stop the engine before connecting the load. ■...
- Page 18 (2) Information of common grounding Implement grounding of outside box and loading equipments independently. However, common grounding is acceptable if independent grounding is difficult. ① Select the right grounding cable with the maximum diameter. ② Select the right grounding cable with the minimum grounding resistance. ③...
- Page 19 (2) The output power of the single-phase (230/240V) There are two connection methods for single-phase power: single-phase receptacle and three-phase joint, as indicated in the below drawing. Please select the proper connection method. Receptacle and breaker are two 15A circuits (W phase). Three-phase joint combines N-phase with U,V,W-phase.
- Page 20 Single-phase receptacle Breaker Breaker Single-phase receptacle ATS port Grounding nut Grounding nut Picture 1 Picture 2 ● Prevent overload of generator of single-phase power is used via single-phase receptacle. (3) When connect the load, you should take care of: ① Install a switch between output terminal and load to control the load connect. If supply the electricity for the appliance by using the breaker directly, there will be fault with the breaker.
- Page 21 The relations among of the allowable current, and length, section of the insulating cable (single core, multi-core) are as follows: (Presume that the use voltage is 220V and the potential is below 10V). The application of the single-core insulating cable Length Below 100m...
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Page 22: Fuel, Lubricant, Cooling Water, Battery
5. FUEL, LUBRICANT, COOLING WATER, BATTERY 5.1 Fuel 【Attended operation】 Only designated fuel is allowed. Otherwise it is impossible to take full use of engine performance even leads to errors. Choose the fuel type according to the temperature condition. Applicable for the international diesel standard. GB/T252-1994 light diesel 0# in summer, -10# , -20#, -30# in winter 1) Fuel type and air temperature Fuel type is classified according to the solidifying point. - Page 23 5.2 Lubricant 【Attended operation】 Only designated lubricant is allowed. Otherwise it may cause engine damages such as blow engine or cylinder scoring, or earlier wearing thus to reduce machine duration. (1) Selection of lubricant ● It is recommended to use original lubricant. ●Use 10W-30 and 15W-40 high-grade diesel lubricant (CD grade).
- Page 24 Use the same LLC for refilling. 【Attended operations】 ● Add anti-rustiness & anti-freezing liquid when handling cooling water. In the cold winter, frozen cooling water expands and damages parts in the cooling water pipe. Exclusive use of fresh water and rustiness of water pipe lead to bad cooling effect. ●...
- Page 25 5.4.1 Observe the followings when handling the battery ■ Charge the battery in the well-ventilated place. If charge the battery in the badly ventilated place, there is ignition or fire risk due to inflammable gas. ■ Prevent (+) pole from contacting (-) pole when connecting cable of battery. Incorrect connection may produce spark and ignite inflammable gas in the battery thus leading to explosion.
- Page 26 Temperature ℃ Charging ratio % 1.28 1.30 1.29 1.26 1.28 1.27 1.24 1.26 1.25 1.23 1.25 1.24 Remarks: ±0.01 tolerance is possible. Charge the battery immediately when the charging ratio is lower than 75%. (3) Charging attentions When charge the equipped storage battery: ●...
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Page 27: Running The Generator
6. RUNNING THE GENERATOR 6.1 Pre-start preparation Implement pre-start preparations in the following order upon preliminary use. 6.1.1 Fill fuel Recommended fuel type: GB/T252-1994 light diesel 0# in summer, -10#, -20#, -30# in winter ● Fill the proper fuel. Improper fuel may lead to risk of fire. Please confirm the type of fuel in advance. - Page 28 (2) Pipe connection 【Attention operations】 Idle running of fuel feed pump causes damage. Check the fuel level of outside fuel tank periodically. Cabinet side door Outside fuel tank Lathe dog Fuel pipe Fuel filter element Fuel pipe Make sure to fix the fuel pipe Inner diameter securely with lathe dog.
- Page 29 ● Fill water into overflow bucket of auxiliary tank d. Please take off the water inlet cover of auxiliary tank. Add cooling water up to the upper scale mark. Then re-mount the cover. e. Check if joints of rubber hoses connecting auxiliary tank and radiator are loose, released or damaged.
- Page 30 6.3 Running Following parts in the running generator are extremely dangerous, such as radiator fan, belt, engine, cylinder hood, exhaust pipe, muffle and other parts at high temperature and high voltage. ● Close the side door of running machine. ● Stop running machine before check and maintenance. Run the machine with all instruments on the operation panel.
- Page 31 ● Check lubricant level with oil gauge. ● Add recommended diesel lubricant from oil-inlet of gear chamber when oil level is insufficient. Check the lubricant with oil gauge. Add lubricant up to upper scale mark with check (refer to 6.1.3). 5) Check and fill cooling water Generator is still hot when machine is running or after machine stops.
- Page 32 6.3.2 Adjustment upon start and no-load Breaker Confirmation ● If the breaker at side of generator and loading equipments are at ON, please do not start the machine. Power is supplied to loading equipments and runs machine suddenly when engine starts, which leads to damage.
- Page 33 Black: Abnormal (insufficient combustion) Blue: Abnormal (Combustion of lubricant) White: Abnormal (No combustion of fuel or too much water contained in the fuel) ● Check the sound, running state and vibration ● Check leakage of fuel, lubricant and cooling water ●...
- Page 34 b. Turn off the breaker of generator. c. Run the generator for 5 minutes at zero load. d. Turn off the starting switch key to stop the engine. e. Pull out the key and keep it safely. 【Attended operations】 Never stop the engine emergently. Otherwise, the temperature of engine parts will rise rapidly, resulting in damage or scuffing of cylinder.
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Page 35: Periodical Maintenance And Service
7. PERIODICAL MAINTENANCE AND SERVICE Carry out periodic check Aging and poorer performance appear if engine runs for long time. Accident and error may occur if no check, maintenance or service, causing great consumption of fuel, bad exhaust and large noise. What’s more, the service life of engine becomes shorter. Routine and periodic check and maintenance can effectively avoid error or accidents. - Page 36 ■ Handle of poisonous engine oil, fuel, cooling water and battery, please refer to the related provision. Periodic check as per running record Establish the running record for daily operation, maintenance and check. Periodic check is divided into several intervals like 50 hours, 250 hours, 500 hours, 750 hours and 1000 hours.
- Page 37 7.1.1 Check for the initial 50 hours (1) Replace engine oil Replace engine oil in 50 Hrs for the first time, after the second time, replace it in 250 Hrs. a. Remove oil drain bolt, drain oil empty, and run the engine for 3-5 minutes. It is easy to drain oil out empty, if the engine warms.
- Page 38 c. To adjust the belt tension, please firstly screw off the fixed bolt of alternator. Then remove the alternator until the belt curvature is 10-15mm, the tension is 98.1N (10kgf). d. Screw on the fixed bolts. e. Keep the belt away from oil or dirty. Otherwise, the belt will skid or get longer. Replace the damaged belt in time.
- Page 39 Measure the insulation resistance once a month by using 500V insulating-resistance meter. Check if it is above 1MΩ. Measurement: Disassemble the three-phase cable, and turn breaker to ON. Measure the insulation resistance between output terminal and engine frame. It is possible for electricity leakage or fire hazard when the insulation resistance is lower than 1MΩ.
- Page 40 7.1.4 Check every 1000Hrs Check for every 1000 Hrs should cooperate with check for every 250,500 Hrs. (1) Clean the fuel tank Eliminate the sediment and water in the fuel tank. (2) Replace the air filter element Refer to the relative item. (Consult with the agent for the manufacturer and model of air filter) (3) Check anti-vibration material If the shockproof material damaged or distorted, you can consult with agent.
- Page 41 ◇Check and clean Replace ● Check & service item Daily check 50 hrs 250 hrs 500 hrs 1000 hrs Check engine oil ◇ Check the cooling water ◇ Check fan belt ◇ Check fuel, drain out sediment and ◇ ◇ impurity Check battery electrolyte ◇...
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Page 42: Troubleshooting
8. TROUBLESHOOTING 【Attended operations】 Immediately stop the running generator for check and repair if any abnormality is found. Continue running the abnormal generator may cause unexpected serious accidents. Rotating Part It's very dangerous to touch the rotating parts in the generator. ■Stop the engine to service and maintain the inner parts of the unit. - Page 43 Battery leakage liquid measure Battery unclamped or rusted Install after cleaning earth terminal Repair Start motor doesn’t run or imperfect its speed is so slow. Fuse disconnection Replace Start switch badness Replace Starter badness Replace The wire breaks Repair Speed handle lever trouble Repair No fuel oil Fill oil...
- Page 44 Check around Move thing If cooling-water lacked Check if cooling water lacked Fan strap loose Maintain fan strap Over hot Radiator cooling orifice walled up Clean radiator cooled part Thermostat abnormal Maintain thermostat Electrical fan abnormal Check and replace fuse Electrical fan abnormal Check and mend receptacle guarder Fault...
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Page 45: Long-Term Storage
9. LONG-TERM STORAGE Pay attention to the following items for long-term storage. 1) Drain off cooling water in cold season or at the status of long-term storage. (Mentioned action is no need if anti-freezing liquid is used.) a. Take off side door and open radiator cover. b. -
Page 46: Main Technical Specifications
10. MAIN TECHNICAL SPECIFICATIONS 10.1 Ambient condition power modification Modified coefficient table of ambient condition power The conditions of generator rated output: Altitude: 0 m Ambient temperature: 25℃ Relative humidity: 30% Ambient modified coefficient: C (Relative humidity 30%) Ambient temperature (℃) Altitude 0.98 0.96... - Page 47 10.2 Technical specifications (1) Single-phase Model KDE11SS KDE16SS Rated frequency 10.5 15.5 Rated output 10.5 15.5 Rated voltage 115/230 120/240 115/230 120/240 Rated current 74/37 87.6/43.8 113/56.5 129.2/64.6 Rated rotation speed r/minn 1500 1800 1500 1800 Single phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ)
- Page 48 Model KDE25SS KDE30SS KDE35SS Rated frequency Rated output Rated voltage 115/230 120/240 115/230 120/240 115/230 120/240 Rated current 174/87 200/100 200/100 234/117 260/130 292/146 Rated rotation speed r/min 1500 1800 1500 1800 1500 1800 Single phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ) Insulation grade...
- Page 49 (2) Three-phase Model KDE13SS3 KDE20SS3 Rated frequency 10.6 13.1 Rated output 10.5 13.6 Rated voltage 230/400 240/416 230/400 240/416 Rated current 15.3 18.2 24.5 27.8 Rated rotation speed r/min 1500 1800 1500 1800 Three phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ) 0.8(lag)
- Page 50 Model KDE30SS3 KDE35SS3 Rated frequency Rated output 19.2 22.4 22.4 Rated voltage 230/400 240/416 230/400 240/416 Rated current 34.6 38.4 40.4 48.6 Rated rotation speed r/min 1500 1800 1500 1800 Three phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ) 0.8(lag) Insulation grade...
- Page 51 Model KDE45SS3 KDE60SS3 Rated frequency Rated output 29.6 Rated voltage 230/400 240/416 230/400 240/416 Rated current 53.4 62.5 72.2 83.8 Rated rotation speed r/min 1500 1800 1500 1800 Three phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ) 0.8(lag) Insulation grade...
- Page 52 Model KDE75SS3 KDE100SS3 Rated frequency Rated output 49.6 Rated voltage 230/400 240/416 230/400 240/416 Rated current 89.5 138.8 Rated rotation speed r/min 1500 1800 1500 1800 Three phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ) 0.8(lag) Insulation grade...
- Page 53 Model KDE40ST3 Rated frequency Rated output Rated voltage 230/400 Rated current 54.8 Rated rotation speed r/min 3000 Three phase / Phase no./ Excitation mode Brushless self-excitation and constant voltage (with AVR) Power factor (cosφ) 0.8(lag) Insulation grade Pole number Model KM493G-1 Type Four cylinder, 4-stroke, direct injection...
- Page 54 WUXI KIPOR POWER CO., LTD. Beside Jingyi Rd Third-stage Development Section of Wangzhuang Industry Area, Wuxi High & New Technology Industry Development Zone Wuxi, Jiangsu Province, PRC TEL: 0086-510-85205041 FAX: 0086-510-85203796 E-MAIL: kipor@kipor.com Version 1, Printing date June.13, 2008. MADE IN CHINA...
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What do the different warning lights stand for?
Velve timing on generator