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AirMan SDG25SV- 8E1 Instruction Manual

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Summary of Contents for AirMan SDG25SV- 8E1

  • Page 2 Preface Thank you for choosing “AIRMAN”  Keep this manual at hand and refer to it as necessary.  If this manual is missing or damaged, order a new copy from our office or your nearest dealer. Make sure that the manual is included with the machine when it is handed over to another user.

  • Page 3: Table Of Contents

    Table of Contents 1. Major Components ----------------------------------------------------------------------------- 1-1 Internal Components --------------------------------------------------------------------------------------------- 1- 1 2. Transportation and Installation ------------------------------------------------------------- 2-1 Transporting Machine -------------------------------------------------------------------------------------------- 2- 1 Conditions of Installation ---------------------------------------------------------------------------------------- 2- 2 Grounding ----------------------------------------------------------------------------------------------------------- 2- 5 Selecting Cable ---------------------------------------------------------------------------------------------------- 2- 8 Fuel Pipe Selector Valve ---------------------------------------------------------------------------------------- 2- 9 3.
  • Page 4 Safety This section explains safety precautions for operation, inspection, maintenance, installation, movement and transportation. Read these safety requirements carefully and fully understand the contents before starting the machine. For better understanding of the precautions in this manual and on this machine, safety precautions are classified into “DANGER”, “WARNING”...
  • Page 5 Safety ◆ If you have any questions about the machine, please contact our office or your nearest dealer. Be sure to have your machine’s serial number to assist in providing the correct information for you. A plate stamped with the model and serial number is attached to side of the machine. ※...
  • Page 6 Safety [Safety Warning Labels] Following labels are attached to the machine. Keep them clean at all times. If they are damaged or missing, immediately place an order with your nearest dealer for replacement. Part numbers are indicated on the lower right corner of the label. Adhere a new one to the original location.
  • Page 7 Safety  The locations of the safety warning labels are as follows. Radiator casing Battery 11 3 A220177...
  • Page 8 Safety  Never touch the control panel during operation. Be aware that a voltage of several hundred volts is applied to the control panel.  Be sure to stop the engine and turn control power switch OFF whenever the control panel has to be checked or operated. Disconnect the negative battery terminal during checking and maintenance.
  • Page 9 Safety  Be sure to stop the engine and let the coolant water sufficiently cool down before draining it.  If the drain valve is opened before the coolant water is cool enough, hot water could jet out, causing burns or scalding. H990432 ...

  • Page 10: Major Components

    1. Major Components 1.1 Internal Components 7 8 9 A220344 Description Function Control Panel Controlling device; various meters and controls. Output Terminal Outlet port for AC power. Voltage Selector Switch Switching output voltage. DOC(Diesel Oxidation Catalyst) Catalyst for oxidizing exhaust gas. Engine Driving the generator.

  • Page 11: Transportation And Installation

    2. Transportation and Installation 2.1 Transporting Machine When loading and unloading machine, be sure to use the lifting bail provided on the center of the machine top. 2.1.1 Lifting <Procedure> 1. Before lifting the unit up, make sure to check the lifting bail [A] for any cracks or loosened bolts.

  • Page 12: Conditions Of Installation

    2. Transportation and Installation 2.2 Conditions of Installation The machine has to be installed on a dry, firm, and level area.  The machine should be operated in the following conditions: Ambient temp: 5°F to 104°F (-15°C to 40°C)  Humidity: Less than 85% ...
  • Page 13 2. Transportation and Installation  Never locate the unit with the exhaust muffler facing ○ any private house.  As the exhaust gas from the engine is poisonous, never direct it to any other persons passing by. × Private house A050505 In case that the machine is installed indoors ...
  • Page 14 2. Transportation and Installation  The unit should be installed within 5 ﾟ degree inclination.  If installation site is not flat, put square bar under the unit so as to install it horizontally.  Avoid installing the unit in a damp place or a place where water collects.

  • Page 15: Grounding

    Load Grounding Rod Grounding Rod A220345 2.3.2 Grounding System AIRMAN’s generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The AC neutral wire (N) is connected to the system ground.
  • Page 16 2. Transportation and Installation 2.3.3 GFCI Receptacles  All of the 20 ampere 120 volt receptacles on the generator are protected by a GFCI (Ground-fault circuit interrupter) for protection against the hazards of ground fault currents. An example of ground-fault current is the current which would flow through a person who is using an appliance with faulty insulation and, at the same time, is in contact with an electrical ground such as a plumbing fixture, wet floor, or earth.
  • Page 17 2. Transportation and Installation 2.3.4 Connections to a Building's Electrical System Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes.

  • Page 18: Selecting Cable

    2. Transportation and Installation 2.4 Selecting Cable  Select a cable with sufficient diameter by considering the permissible current on the cable and the distance from the generator to the load.  If the current flowing to the load exceeds the permissible current of the cable, resultant overheating may burn the cable.

  • Page 19: Fuel Pipe Selector Valve

    2. Transportation and Installation 2.5 Fuel Pipe Selector Valve 2.5.1 Overview This valve is designed to feed fuel directly from an external fuel tank or from the installed fuel tank as described below. 2.5.2 Operation method <Procedure> 1. Machine is delivered from factory with fuel line piping and selector valves built in as shown in the following Fig.1.
  • Page 20 2. Transportation and Installation  Always keep watching the fuel feeding conditions while feeding fuel from the external fuel storage tank.  Make sure to change the handles of the selector valves to the predetermined positions. If you make a mistake in turning the handles, it can burst the fuel pipe and cause overflowing.

  • Page 21: Operation

    3. Operation 3.1 Control Panel 8 11 A220347 1. Inverter indicator lamp 6. Voltage Adjuster 2. Panel Light 7. Control Power Switch 3. Control Panel 8. Inverter output switch 4. Circuit Breaker 9. Inverter frequency adjuster 5. Panel Light Switch 10.
  • Page 22 3. Operation Control Panel Navigation button Display Monitor lamp Stop/Reset button Auto Mode button Start button Manual Mode button Alarm mute button A180097E [How to switch monitor] 1. Items shown below can be selected by pressing◄ or ► button. Status Engine Generator Alarms...

  • Page 23: Connecting Loads

    3. Operation 3.2 Connecting Loads Select a cable with sufficient diameter by considering the load capacity and the distance from the generator to the load. Use terminals for connection and securely fasten them. (See 2.4)  After checking phase number and voltage of the load, 3-Phase output terminal make sure to connect them correctly.
  • Page 24 3. Operation 3.2.1 Output Terminal connections  Voltage can be selected with voltage selector switch. Voltage Selector Switch Output terminals 3φ INV 480V 3φ 480V A040156-1 A230001 Voltage Selector Switch Output terminals Output terminals Output terminals 3φ 240V/139V 3φ 240V 1φ...
  • Page 25 3. Operation 3.2.2 Inverter Output  When using the inverter output to use the submersible pump, make sure that the total output of the submersible pump does not exceed the total output shown in the table below. Otherwise, an overload may cause the protective function of the invertor to stop the output of the inverter.
  • Page 26 3. Operation 3.2.3 Auxiliary AC Power GFCI RECEPTACLES BREAKER AUX. RECEPTACLES BREAKER Auxiliary AC Power Auxiliary AC Power will be available, will be available only independent of the when the voltage position of voltage selector switch is selector switch. turned to 240/120V. GFCI RECEPTACLES.
  • Page 27 3. Operation 3.2.4 The Maximum Combined Simultaneous Power Consumption The following chart shows the maximum power available from the 120V-20A GFCI receptacles during simultaneous consumption (main terminals and receptacles) for both single or 3-phase settings. Values shown in the left column give the maximum current available at the 120V-20A GFCI receptacles compared to the value of the simultaneous current consumption from the main terminals.

  • Page 28: Engine Oil･Coolant･Fuel

    3. Operation 3.3 Engine Oil・Coolant・Fuel 3.3.1 Engine Oil Use engine oil recommended below. Be sure to use CJ-4 class or higher engine oil or superior class. (Using engine oil with poor quality may shorten the life of the engine). Classification API service classification CJ-4 class or higher Viscosity SAE10W-40 (as ex-factory)
  • Page 29 3. Operation 3.3.2 Coolant Coolant freezing could cause cracks of cylinder and radiator. Be sure to always use mixture of LLC (antifreeze) and soft water (like tap water) of good quality.  When water with dirt, sand, or dust, or hard water such as well water (ground water) is used, deposits can form inside the radiator or on the cylinder head and resulting in engine overheat from poor coolant flow.

  • Page 30: Before Starting The Unit

    3. Operation 3.4 Before Starting the Unit Be sure to check the unit before operation. When any abnormality is found, be sure to repair it before starting. Be sure to make daily check before operation. If the unit is operated without prior check and without noticing its abnormality, such operation could cause seizure of components or may even cause fire.

  • Page 31: Clean Instruments In Control Panel

    3. Operation 3.4.2 Check Coolant Level  Check the coolant level in the surge tank. If it is lower than the limit, open the cap and refill the coolant. (Level must be kept above LOW.)  If the coolant in the reserve tank is exceedingly low or empty, remove the radiator cap and check the amount of coolant in the radiator.
  • Page 32 3. Operation 3.4.4 Check Fuel Before starting operation, make sure to check the level of residual fuel so that fuel shortage during operation can be avoided. If necessary, drain condensate accumulated at the bottom of the fuel tank.  Refilling fuel tank should be done in an outdoor well-ventilated place. ...
  • Page 33 3. Operation 3.4.6 Check Interior Periodically check the inside of the generator for dust and flammables  Please wear personal protective equipment, such as a helmet, safety glasses, earplugs, safety shoes, gloves, and a mask as appropriate to the work environment. ...

  • Page 34: Check Thermo Label Of Alternator

    3. Operation 3.4.8 Check Thermo Label of Alternator Thermo label on the stator irreversibly changes its color from white to brown by reaching or exceeding 212°F (100℃), that signalize overload during operation. Do not overload the generator.  Remove the trash and dust from the generator inside by Stator thermo label 212°F (100℃) compressed air blowing.

  • Page 35: Operating Procedure

    3. Operation 3.5 Operating Procedure Make sure that all enclosure doors are closed before starting. 3.5.1 Operating Procedure To start, please follow the procedure below. Manual Start Procedure [When using the 3-phase 240V, single-phase 240V output] <Procedure> 1. Set the circuit breaker [A] on the instrument panel to [OFF] position. 2.
  • Page 36 3. Operation Check frequency and voltage <Procedure> 1. After warming up, display Generator monitor and press ▲▼ to show [Generator Frequency] . Check that the frequency of the generator is at 60Hz after warm up. (See 3-2) Monitor Screen 2. Press ▲▼ to show [Generator Voltage] and adjust to rated voltage with a voltage adjuster [F]. Display Voltage Adjuster Operation with Load...
  • Page 37 3. Operation [When using the Inverter output]  The inverter is best suited for direct start, 3-phase 480V submersible pumps. It cannot be used to start submersible pumps with a star-delta winding.  The use of the inverter can limit current during the direct-online starting of the submersible pump. You can operate a larger pump, compared with normal direct-online starting.
  • Page 38 3. Operation  To turn on or off the inverter output—use the inverter output switch [F] on the instrument panel.  Do not turn on or off the circuit breaker with the inverter output switch [F] turned on. Otherwise, the lifetime of the inverter may be reduced.
  • Page 39 3. Operation Auto Start 1. Cable connection method of remote control switch. The remote control terminal [J] is provided inside the output terminal. Perform cable connection as  shown below for remote control operation of the machine. For this cable connection job, make sure to remove the battery cathode cable terminal.
  • Page 40 3. Operation 2. Function [When using the 3-phase 240V, single-phase 240V output]  When the start signal activates in stand-by mode, it starts the unit. (This includes preheating.) When the stop signal activates, the unit will continue to operate for 15 seconds to cool down, then the unit stops and is placed again in stand-by mode.
  • Page 41 3. Operation 3. Starting Action  If the engine will not start after cranking for 10 seconds, stop it for 8 seconds before trying again. If the engine will not start even after cranking is repeated three times, the SHUTDOWN lamp [I] will illuminate due to Fail to Start error.
  • Page 42 3. Operation 3.5.2 Wiring work of inverter remote control terminals Remote operation terminal board [K] of the inverter is provided inside the output terminal board. If you wish to operate inverter control remotely, please prepare power, pilot lamp, switch and wiring as the drawing below.
  • Page 43 3. Operation 3.5.3 Meters and indicator lights during operation During normal operation, each indication of instruments is shown in the table below. Refer to the table for daily checks. Note: The values marked ＊ vary with location of the voltage selector switch. Monitor Lamp Voltage Frequency...
  • Page 44 3. Operation  Do not under any circumstance, open the portions below during operation. Coolant drain valve  Engine oil drain valve  PK0028  Never work nearby hot portions of the machine while it is running.  Do not touch hot portions of the machine while inspecting the machine when running.
  • Page 45 3. Operation 3.5.6 Fuel line air bleeding device If the machine runs out of fuel, bleed the air, according to the following procedures. A210293E <Procedure> 1. Refill the fuel. 2. Set the control power switch [A] to [ON] position. 3. When the stop mode indicator lamp [B] is lit, press the start button [C] to turn on the electromagnetic pump.

  • Page 46: Emergency Stop

    3. Operation 3.6 Emergency Stop 3.6.1 Emergency stopping procedures  If it is necessary to stop the generator for emergency, press the Emergency Stop button located under the control panel. When shutting down with the emergency stop button, the machine will stop immediately. Emergency stop button A180804...

  • Page 47: Failure And Troubleshooting

    4. Failure and Troubleshooting 4.1 Protection device To prevent issues during operation, this machine is equipped with various protection devices. 4.1.1 List of protective devices, warning lamps, and monitor alarms This machine is equipped with protective devices, and indicates the type of issue with lamps and messages on the monitor display as shown in the table below.
  • Page 48 4. Failure and Troubleshooting 4.1.2 Circuit Breaker  In case of an overload or short-circuited wire connection, the circuit-breaker trips.  When the breaker is tripped, stop the machine immediately and reset the circuit breaker after resolving the cause of the trouble. <How to reset>...
  • Page 49 4. Failure and Troubleshooting 4.1.4 Inverter Protection Function  When the inverter output switch [A] is in the“ON” position, the “Normal” lamp [B] on the inverter indicator section of the machine’s operating panel comes on.  If an inverter malfunction occurs, the inverter protection function is activated to stop the inverter output, and the fault lamp [C] on the inverter indicator section comes on.

  • Page 50: Troubleshooting

    4. Failure and Troubleshooting 4.2 Troubleshooting Should any trouble occur during operation, do not leave it. Investigate the cause and take appropriate measures. Read the manual carefully and fully understand what to do in case of trouble.  The better you understand the construction and function of the machine, the faster you can find a problem and solution.
  • Page 51 4. Failure and Troubleshooting Symptom Cause Counter measures Circuit breaker (1) Overloaded Reduce the load trips. (2) Short-circuit occurred at the load side. Get rid of cause of short-circuiting. Even when operated (1) Poor tightening of terminals Check/tightening at a rated speed, no (2) Broken or short-circuited circuit to Repair voltage or too low...
  • Page 52 4. Failure and Troubleshooting ［Inverter instrument panel indication］  This chapter describes about troubles of the inverter, which occur the most frequently. For the details and countermeasures, contact our office nearby or distributor because technical knowledge is required. Instrument Display name Contents panel indication Overcurrent...

  • Page 53: Periodic Inspection

    5. Periodic Inspection 5.1 Important Items at Periodic Inspection and Maintenance The following table shows the inspection and maintenance intervals under normal operation conditions. When used or operated under hard environmental conditions, it is impossible to warrant the machine even if the above conditions are performed according to the intervals listed in the above table.

  • Page 54: Maintenance Schedule

    5. Periodic Inspection 5.2 Maintenance Schedule Such items marked ○ shall be carried out by customers. For the following items or clauses marked ●, contact your nearest dealer because they require expert technical knowledge on them. The following table shows the intervals of inspection and maintenance under normal operation conditions.

  • Page 55: Periodic Replacement Parts

    5. Periodic Inspection Every Every Every Maintenance Daily 1,000 Ref. Remarks hours hours hours Check interior 3-13 ○ Check oil fence drain 3-14 ○ Check and clean of dustproof air filter 5-14 ○ Check terminal and wirings 5-12 Every 4 months ○...

  • Page 56: Maintenance Items

    5. Periodic Inspection 5.4 Maintenance Items 5.4.1 Change Engine Oil Every 250 Hours When checking, replenishing, and draining the engine oil, be sure to wait more than 10 minutes after engine stops to allow it to cool down. <Procedure> 1. Remove the engine oil filler port cap [C], and remove the drain plug [A] fixed outside, and then open the drain valve [B] fixed inside to drain oil.
  • Page 57 5. Periodic Inspection 5.4.2 Change Engine Oil Filter Element Every 500 Hours <Procedure> 1. Take out the oil filter element [A] using a filter wrench. 2. After coating fuel on the new oil filter element packing [B], screw it in. After the packing touches the sealing face, tighten another 2/3 turn with a filter wrench.
  • Page 58 5. Periodic Inspection 5.4.4 Maintenance of Battery Battery may generate hydrogen gas and may explode. Therefore, recharging should be done at a well-ventilated place.  Do not check the battery by short-circuiting the positive and negative terminals with a metallic piece.
  • Page 59 5. Periodic Inspection [How to use booster cable] <Procedure> To engine block 1. Stop the engine. 2. Connect one end of the (+) booster cable to the (+) Booster Booster cable (+) terminal of the machine battery. cable (-) 3. Connect the other end of the (+) booster cable to the (+) terminal of the external battery.

  • Page 60: Check Gfci Receptacles

    5. Periodic Inspection 5.4.6 Check Accumulations in Exhaust System Every 250 Hours When a diesel engine driven generator is continuously operated with less than 30% load or no load for a long time, carbon will be stuck inside the exhaust pipes, exhaust muffler, and engine body. Unburned fuel may also come out from connected portions of exhaust pipe and outlet port of the exhaust muffler.

  • Page 61: Check Insulation Resistance

    5. Periodic Inspection 5.4.8 Check Insulation Resistance Every 2 months or 250 Hours <Procedure> 1. Voltage selector switch to 3φ240V/139V or 1φ 240V/120V. 2. Remove the load side cable from the output terminal board. 3. Loose and remove the bolt (M6) securing the ground To Bonnet cable between [N] and [GROUND] on the output terminal board.

  • Page 62: Check Thermo Label On The Generator

    5. Periodic Inspection  When measuring insulation resistance, make sure to turn the voltage selector switch to 3φ240V/139V 1φ240V/120V before measurement. If measurement is carried out with the inverter selected, the inverter could become damaged.  Insulation resistance should be regularly checked or measured with a 500V insulation resistance meter. If it is reduced to lower than 1MΩ, it could cause an electrical leakage or a fire.

  • Page 63: Change Fuel Filter Element

    5. Periodic Inspection 5.4.11 Change Fuel filter Element Every 500 Hours <Procedure> 1. Loosen the drain plug [D] and air bleeding plug [E] to discharge the fuel inside the filter. After draining completed, tighten the drain plug and air bleeding plug securely.

  • Page 64: Check And Cleaning Of The Supply Pump Strainer

    5. Periodic Inspection 5.4.14 Check and Cleaning of the Supply pump strainer Every 500 Hours  Loosen the supply pump strainer [A] (joint bolt built-in type) and remove it. After washing it with diesel oil, blow dust and dirt off with high pressure air.

  • Page 65: Check Exhaust Flexible Pipe

    5. Periodic Inspection 5.4.16 Check Exhaust Flexible Pipe Every 4 months or 500 Hours  Check the flexible pipe between the DOC Exhaust flexible pipe and engine exhaust outlet for cracks and Crack exhaust gas leakage.  If any leak is found, take care to avoid getting burned by exhaust gas.
  • Page 66 5. Periodic Inspection 5.4.18 Check･clean and change of dustproof air filter Every 1,000 hours  Check the cleanliness of the dustproof air filter [A]. If there is dirt on the filter, remove the filter cover [B] on the front side of the inverter cover, and remove the dirt.
  • Page 67 5. Periodic Inspection 5.4.20 Check Each Rubber Hose Every year or 1,000 Hours Check all the rubber hoses for hardening, cracks, and fissures.  If any hardening, cracks, or fissures are found on a hose (air filter, intercooler, radiator, fuel and drain), replace it with a new one.

  • Page 68: Change Coolant (Llc)

    5. Periodic Inspection 5.4.22 Change Coolant Every 2 years When removing the radiator cap, be sure to stop the machine and wait until the coolant cools down. <Procedure> 1. To drain coolant, remove the radiator cap [A], then loosen the drain valve [B].

  • Page 69: Storage And Disposal

    6. Storage and Disposal 6.1 Preparation for Long-term Storage When the machine is left unused or not operated longer than half a year (6 months), store it in a dry place free of dust after the following treatments have been done to it. ...

  • Page 70: Specifications

    7. Specifications 7.1 Specifications Model SDG25SV-8E1 Specifications 3-phase, single-phase, Inverter selector type Exciting system Brushless Armature Connection Star with neutral Parallel zig-zag Single-Phase Phase number 3-phase 4 wires 3-phase 3 wires 3 wires Power Factor Frequency Rated Output kVA (kW) 18.75(15) 25(20) 14.4 (14.4)

  • Page 72: Outline Drawing

    7. Specifications 7.2 Outline drawing [Unit : in.] A220359_in...
  • Page 73 7. Specifications [Unit : mm] A220359_mm...

  • Page 74: Generator Wiring Diagram

    7. Specifications 7.3 Generator Wiring Diagram A220357E...

  • Page 75: Engine Wiring Diagram

    7. Specifications 7.4 Engine Wiring Diagram A220358E-1...
  • Page 76 7. Specifications A220199...

  • Page 77: Piping Diagram

    7. Specifications 7.5 Piping Diagram A180872E...
  • Page 81 ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. 8TH FLOOR SHINJUKU SAN-EI BLDG, 22-2 NISHI-SHINJUKU 1-CHOME,SHINJUKU-KU TOKYO 160-0023 JAPAN TEL:81-3-3348-7281 FAX:81-3-3348-7289 URL:http//www.airman.co.jp Copyright(C)2023 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved. 39600 48350 Printed OCT.2023...

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