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Hokuetsu AirMan SDG45SV-8E2 Instruction Manual

Engine generator, inverter
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Summary of Contents for Hokuetsu AirMan SDG45SV-8E2

  • 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- 4 Selecting Cable ----------------------------------------------------------------------------------------------------- 2- 7 Fuel Pipe Selector Valve ----------------------------------------------------------------------------------------- 2- 8 3.

  • Page 4: Proposition 65 Warning

    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. Always keep these labels clean. 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. Battery Fuel Tank VIEW A A240075...
  • 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 scalding water could jet out, causing burns. H990432 ...

  • Page 10: Major Components

    1. Major Components 1.1 Internal Components A240077 Description Function Control Panel (Operation Panel) Controlling device; various meters and controls. Terminal Board Outlet ports for AC power. Voltage Selector Switch Switching output voltage. DOC (Diesel Oxidation Catalyst) Catalyst for oxidizing exhaust gas. Engine Oil Filler Port Port for supplying / replenishing engine oil.
  • Page 11 1. Major Components A240078 Description Function Device that cools the air compressed by the engine Intercooler supercharger. For reducing noise and improving the power factor DC reactor during the use of the inverter. Inverter For controlling the output frequency and voltage. Battery Power source to start the engine.

  • Page 12: 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 13: Conditions Of Installation

    2. Transportation and Installation 2.2 Conditions of Installation  Always strictly use this machine in the operating environment as outlined below. Otherwise, serious failures can result. Ambient temp: 5°F to 104°F (-15°C to 40°C)  Humidity: Less than 85%  Altitude: Lower than 1,000m above sea level.
  • Page 14 2. Transportation and Installation In case that the machine is installed indoors  When installing indoors, both an intake port and Extended exhaust pipe an exhaust port must be used to improve air ventilation. Exhaust gas  Make sure to secure enough space in front of air outlet port suction port and to secure it after exhaust fume outlet port so that the engine will not get...

  • Page 15: Grounding

    2. Transportation and Installation 2.3 Grounding 2.3.1 Ground Terminal  The ground terminal [A] on the AC output terminal board is connected to ground of this unit and to the ground terminals of each outlet. A180816 Grounding method Grounding Terminal [A] Load Switch Load Grounding Rod...
  • 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: Connections To A Building's Electrical System

    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 melt 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 <Procedures> 1. Machine is delivered from the factory with fuel line piping and selector valves set 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 Operation Panel 3.1.1 Operation panel A240082 1. Inverter indicator lamp 6. Voltage Adjuster 2. Panel Light 7. Control Power Switch 3. Control Panel 8. Forward/Reverse switch 4. Circuit Breaker 9. Inverter output switch 5. Panel Light Switch 10.

  • Page 22: Control Panel

    3. Operation 3.1.2 Control Panel Navigation buttons Display Monitor lamps Stop/Reset button Auto Mode button Start button Manual Mode button Alarm mute button A180097E [How to switch between display screens] ◄ ► 1. By pressing the arrow buttons you can cycle between the categories on the screen. Status Engine Generator...

  • 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 round terminal affixed cables for connection and securely fasten them. (See 2.4)  After checking phase number and voltage of the 3 Phase output terminal required load, make sure to connect them correctly.

  • Page 24: Output Terminal Connections

    3. Operation 3.2.1 Output Terminal connections  Voltage is selected with the voltage selector switch. Voltage Selector Switch Output terminals 3φ INV 480V 3φ 480V A240160 A040153-1 Voltage Selector Switch Output terminals Output terminals Output terminals 3φ 240V/139V 3φ 240V 1φ...

  • Page 25: Inverter Output

    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. Total output Usage example 40HP...
  • Page 26 3. Operation 3.2.3 Auxiliary AC Power 120V GFCI RECEPTACLES CIRCUIT BREAKER AUX. RECEPTACLES BREAKER Auxiliary AC Power Auxiliary AC Power will be will be available, available only when the independent of the voltage selector switch is position of voltage turned to 240/120V. selector switch.
  • 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 and three phase settings. Values shown in the left column give the maximum current available at the 120V-20A GFCI receptacles for a single receptacle as 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 (delivery condition)
  • 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 overheating from poor coolant flow.

  • Page 30: Before Starting The Unit

    3. Operation 3.4 Before Starting the Unit Before starting the unit, be sure to perform the pre-start inspection. If you find any abnormalities, be sure to repair them before operating the unit. Neglecting inspection or failing to correct any abnormalities prior to starting and operating the unit is a potential fire hazard and may melt internal components.

  • Page 31: Check Coolant Level

    3. Operation 3.4.2 Check Coolant Level  Verify the coolant level in the reserve tank is above [MIN].  If the coolant level is lower than [MIN], remove the cap and supply coolant up to the center between [MIN] and [MAX]. If too much coolant is poured into the reserve tank, it may overflow during operation.

  • Page 32: Check Fuel

    3. Operation 3.4.4 Check Fuel Prior to operating the unit, ensure there is sufficient fuel remaining to prevent shortage during operation. If necessary, drain condensate accumulated at the bottom of the fuel tank.  Refueling should be done outdoors or in a 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 Belt Tension

    3. Operation 3.4.7 Check Belt Tension Adjust the alternator belt by the following procedure: Unfasten the mounting bolts and nuts of the alternator to adjust the alternator belt. <Procedures> Press the center 1. Visually check there are no cracks or wear or other damage to the belt.
  • Page 35 3. Operation 3.4.8 Check Thermo-Label of Stator Thermo-label on the stator irreversibly changes its color from white to brown when reaching or exceeding 212°F (100℃), that color change signals an overload during operation. If it has discolored, there is a possibility that an abnormality has already occurred in the generator end, immediately reduce the load, and contact your nearest dealer.

  • Page 36: Operating Procedure

    3. Operation 3.5 Operating Procedure Make sure that all enclosure doors are closed before starting. 3.5.1 Starting and Stopping Procedure To start, please follow the procedure below. Manual Mode [When using the 3-phase 240V, single-phase 240V output] <Procedures> 1. Set the circuit breaker [A] on the instrument panel to [OFF] position. 2.
  • Page 37 3. Operation Check frequency and voltage <Procedure> ▲▼ 1. After warm up, on the Generator display screen press to show [Generator Frequency]. Check that the frequency of the generator is at 60Hz after warm up. (See 3-2) Display Screen ▲▼ 2.
  • Page 38 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 39 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 40 3. Operation Auto Mode 1.Cable connection method for a remote control switch.  Connect the cable to the remote control terminal [A1-A2] of the remote operation terminal block [J] and install the remote operation switch between [A1-A2]. Prior to connecting this cable be sure the (－) battery cable is disconnected.
  • Page 41 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 42 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 43 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 44 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 Lamps Frequency...
  • Page 45 3. Operation  Do not under any circumstance, open the valves below during operation. Coolant condensate drain valve  Engine oil condensate 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 during operation.
  • Page 46 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. A240156 <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 47: 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 A240142...

  • Page 48: Failure And Troubleshooting

    4. Failures 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 49: Circuit Breaker

    4. Failures 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 50 4. Failures 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 51: Troubleshooting

    4. Failures 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 the problem and solution.
  • Page 52 4. Failures and Troubleshooting Symptom Cause Counter measures Circuit breaker trips. (1) Overloaded Reduce the load (2) Load side short-circuit. Get rid of cause of short-circuiting. No voltage or too low (1) Terminal connections are loose Check/tightening voltage generated when (2) Broken or shorted to the exciter field Repair operated at rated...
  • Page 53 4. Failures 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 54: Periodic Inspection

    5. Periodic Inspection 5.1 Important Items at Periodic Inspection and Maintenance This manual shows the inspection and maintenance intervals under normal operating conditions, not the warranty period. When using under severe environmental conditions or operating conditions, shorten the maintenance interval. ...

  • Page 55: 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 56: Periodic Replacement Of Parts

    5. Periodic Inspection Every Every Every Maintenance Daily 1,000 Ref. Remarks hours hours hours Check interior 3-13 ○ Check oil fence drain 3-15 ○ Check terminal and wirings 5-13 Every 4 months ○ Check, clean and change of dustproof 5-15 ○...

  • Page 57: 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. <Procedures> 1. Remove the engine oil filler port cap [A], remove the drain plug [B] located outside, and then open the drain valve [C] located inside to drain oil.

  • Page 58: Check Battery

    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 thinly coating the oil on the new oil filter element [A] packing [B], screw it in. (For the part number, see 5.3.) 3.
  • Page 59 5. Periodic Inspection 5.4.4 Maintenance of Battery Battery may generate hydrogen gas and can explode. Therefore, recharging should be done in a well-ventilated place.  Do not check the battery by short-circuiting the positive and negative terminals with a piece of metal.

  • Page 60: Check And Clean Air Filter Elements

    5. Periodic Inspection [How to use booster cable] <Procedure> To engine block 1. Stop the engine. Booster 2. Connect one end of the (+) booster cable to the (+) 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 61: Check Accumulations In Exhaust System

    5. Periodic Inspection 5.4.6 Check Carbon 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 62 5. Periodic Inspection 5.4.8 Check Insulation Resistance Every 2 months or 250 Hours <Procedure> 3 Phase output terminal 1. Voltage selector switch to 3φ240V/139V or 1φ 240V/120V. 2. Remove the load side cable from the output terminal board. To Bonnet 3.
  • Page 63 5. Periodic Inspection  When measuring insulation resistance, make sure to turn the voltage selector switch to 3φ240V/139V or 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.

  • Page 64: Drain Fuel Tank

    5. Periodic Inspection 5.4.9 Check Bearing Thermo Label on the Generator Every 2 months or 250 Hours Thermo-label on the rotor bearing irreversibly changes its color from white to blue by reaching or exceeding 176°F (80°C). If discoloration has occurred, check the bearing for abnormal noise or vibration, and contact the dealer immediately.

  • Page 65: Clean Outside Of Radiator And Intercooler

    5. Periodic Inspection 5.4.12 Clean Outside of Radiator and Intercooler Every 500 hours  If the fins and tubes [C] of the radiator [A] and intercooler [B] are clogged with dust and dirt, the heat exchange rate will decrease and the temperature of the coolant will rise, regardless of inspection and maintenance schedule.

  • Page 66: Check And Cleaning Of The Supply Pump Strainer

    5. Periodic Inspection 5.4.15 Check and Cleaning of the Supply Pump Strainer Every 500 hours  Loosen the supply pump strainer [A] (joint bolt integrated type) and remove it. After washing it with diesel oil, blow dust and dirt off with compressed air. Replace the gaskets [B] and [C] as well.

  • Page 67: Check Exhaust Flexible Pipe

    5. Periodic Inspection 5.4.17 Check Flexible Exhaust Pipe Every 4 months or 500 Hours  Check the engine exhaust outlet coupler to flexible Crack Flexible exhaust pipe pipe for leaks and check for any cracks in the flexible piping.  If any leak is found, take care to avoid getting burned by exhaust gas.
  • Page 68 5. Periodic Inspection 5.4.19 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 69 5. Periodic Inspection 5.4.21 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 70: Change Coolant (Llc)

    5. Periodic Inspection 5.4.23 Change Coolant Every 2 years Be sure to stop the engine and let the coolant water sufficiently cool down before changing it. <Procedures> 1. Remove the radiator cap [A] on the top of the radiator [D] and the drain plug [F], then open the drain valve [B] to drain the coolant.

  • Page 71: Storage And Disposal

    6. Storage and Disposal 6.1 Preparation for Long-term Storage When storing for more than half a year without using the machine, perform the following measures and store it in a dry place with little dust.  Put the machine in an enclosure if it is stored outside. Avoid leaving the machine outside with a sheet directly on the paint for a long period of time, as this may cause rusting.

  • Page 72: Specifications

    7. Specifications 7.1 Specifications Model SDG45SV-8E2 Exciting system Brushless Armature Connection Double star Parallel zig-zag Single Phase Phase number 3-phase 4 wires 3-phase 3 wires 3 wire Power Factor Frequency Rated Output kVA (kW) 37.5(30) 45(36) 28.3(28.3) Voltage 240/120 Amps Model ISUZU BP-4LE2X Type...
  • Page 73 ＭＥＭＯ ...
  • Page 74 7.Specifications 7.2 Outline drawing [Unit : in.] A240169...
  • Page 75 7.Specifications [Unit : mm] A240169...

  • Page 76: Generator Wiring Diagram

    7.Specifications 7.3 Generator Wiring Diagram A240153E...

  • Page 77: Engine Wiring Diagram

    7.Specifications 7.4 Engine Wiring Diagram A240154E...
  • Page 78 7.Specifications A180870E...

  • Page 79: Piping Diagram

    7.Specifications 7.5 Piping Diagram A180872E...
  • Page 80 ＭＥＭＯ...
  • Page 83 发行者 总公司 工厂 新泻县燕市下粟生津 3074 TEL 0256-93-5571 FAX 0256-94-7567 （禁止擅自复印以及转载） 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)2024 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved. 39600 69950 Printed AUG.2024...

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