OPERATOR & MAINTENANCE MANUAL 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 the generator. 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 written approval of Promac Sales Pty Ltd. ...
OPERATOR & MAINTENANCE MANUAL 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 operator’s 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. ...
OPERATOR & MAINTENANCE MANUAL 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 ...
OPERATOR & MAINTENANCE MANUAL 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. ...
OPERATOR & MAINTENANCE MANUAL 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 ...
OPERATOR & MAINTENANCE MANUAL 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. ...
Page 11
OPERATOR & MAINTENANCE MANUAL 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. ...
Page 12
OPERATOR & MAINTENANCE MANUAL 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. PAGE‐8...
Page 13
OPERATOR & MAINTENANCE MANUAL 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 PAGE‐9...
OPERATOR & MAINTENANCE MANUAL 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 varied purposes: motion force, lighting, heating, etc. Emergency service – Used to rectify main supply interruptions or to face consumption peaks. 3.1.2 Main Specifications ...
OPERATOR & MAINTENANCE MANUAL 3.3 Generator Layout and Major Components PAGE‐12...
Page 17
OPERATOR & MAINTENANCE MANUAL TABLE 3: CONTROL CABINET REF NAME DESCRIPTION 1 Canopy Size: 2130 x 1060 x 1070mm 2 Fire extinguisher bracket Designed for 9kg ABE fire extinguisher 3 Field wiring cabinet 4 Base Size: 2390 x 1080 x 400mm 5 Control cabinet assembly 6 Spark Arrestor Rating: 8m /min 7 Alternator LSA40 VS2/1P 8 Diesel engine Kubota D1105‐BG 9 ...
OPERATOR & MAINTENANCE MANUAL 3.4.2 Control Panel PAGE‐16...
Page 21
OPERATOR & MAINTENANCE MANUAL TABLE 5: CONTROL PANEL REF NAME DESCRIPTION 1 Control Cabinet Lamp Switch 2 Control Cabinet Lamp 3 RCD Status Lamp RCD Status Lamp Globe Test 4 Button Mains / ATS Battery Charging 5 Lamp 6 Cam Lock Mains / ATS Battery Charger 7 Selector Switch 8 Audible Alarm 9 Master Control Switch ...
Page 22
OPERATOR & MAINTENANCE MANUAL 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 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. 7. Mains/ATS Battery Charger Selector Switch The switch (7) is used to select the source of the battery charging power, either Mains Inlet or ATS. ...
Page 23
OPERATOR & MAINTENANCE MANUAL 10. Controller (AMF 25) The generator controller AMF 25 (10) 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. 11. Earth Leakage Relay (ELR) The generator is equipped with an earth leakage relay (11). There are two different types of relays, the standard configuration is RH99P, which is panel mounted. The other is RH99M, din rail mounted, located in the control cabinet. ...
Page 24
OPERATOR & MAINTENANCE MANUAL 17. Main Isolator (50A 2P) The lockable two‐pole Main Isolator (50A) (17) is located on the control panel. When the electric current exceeds 50A, it will automatically trip to the “fault” position and interrupt all power from the load side of the circuit breaker. Note: The generator will still supply power to the line side of breaker. WARNING: Before shutting down the generator or performing any service, make sure the Main Isolator is in the “OFF” position and locked. 18. Single Phase RCD/MCB Combo Protecting 20A Single Phase Outlet The 20A Single Phase RCD/MCB Combo device (18) is located on the control panel. When the electric current is greater than 20A or a residual ...
OPERATOR & MAINTENANCE MANUAL 3.4.3 AMF 25 Controller TABLE 5: PUSH BUTTONS REF NAME DESCRIPTION START button. Works in MAN mode only. Press this button to initiate the start sequence of the engine. STOP button. Works in MAN mode only. Press this button to initiate the stop sequence of the gen-set.
Page 26
OPERATOR & MAINTENANCE MANUAL MODE LEFT button. Use this button to change the mode. 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. MODE RIGHT button.
OPERATOR & MAINTENANCE MANUAL ISPLAY AND ONTROL UTTONS Graphic B/W display, 128 x 64 pixels PAGE button. Use this button to switch between display pages. See Display Screens and Pages Structure for more details. UP button. Use this button to move up or increase a value. DOWN button.
Page 33
OPERATOR & MAINTENANCE MANUAL TABLE 7 OUTPUT TERMINAL ASSEMBLY REF NAME DESCRIPTION 1 Earth wiring terminal Green/yellow 2 Neutral wiring terminal Black 3 L1 wiring terminal Red 4 Spare terminal MEN disconnected terminal 5 Earth wiring terminal MEN connection 6 Neutral wiring terminal MEN connection 7 Micro switch Stops generator if Perspex door is opened ...
Page 34
OPERATOR & MAINTENANCE MANUAL 10 & 11. G eneral Purpose Outlets (GPO) (15A, single‐phase) The generator is equipped with two Auto switched 240V single‐phase GPOs (10) & (11) rated at 15A. Both are connected through the Main Isolator. Each GPO is protected by it’s own RCD/MCB combo breakers located in the control cabinet. 12. 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. ...
OPERATOR & MAINTENANCE MANUAL 4. Installation A diesel generator is a piece of high‐speed rotating equipment. To ensure reliability and safety the installation must be given thorough attention. Before installing the unit all environmental factors must be considered. Generator installation must comply with local building codes, fire regulations and environmental requirements. Use these instructions as a general guide only, the complete installation must ...
OPERATOR & MAINTENANCE MANUAL 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: ...
Page 38
OPERATOR & MAINTENANCE MANUAL When building the foundation, specific attention needs to be paid 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. ...
Page 39
OPERATOR & MAINTENANCE MANUAL 4.5 Outdoor Installation Install 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. 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. ...
OPERATOR & MAINTENANCE MANUAL 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 for service access. Allow clearance between hot parts of the system (exhaust) and structural members of the building (see figure below). ...
OPERATOR & MAINTENANCE MANUAL 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. WARNING: The floor foundation load‐carrying capacity must be checked and must not exceed the weight of the generator and its associated equipment. ...
Page 43
OPERATOR & MAINTENANCE MANUAL 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 ...
OPERATOR & MAINTENANCE MANUAL 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 tubing will have to be able to withstand a negative pressure. If the differential pressure is too large, ...
Page 45
OPERATOR & MAINTENANCE MANUAL Warning Poor quality oil will shorten engine life. Use only the specified lubricating oils. Important points regarding lubricating oil are described below. 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 ...
OPERATOR & MAINTENANCE MANUAL 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 ...
OPERATOR & MAINTENANCE MANUAL 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. DANGER: If the load exceeds the allowable amperage overheating may cause damage to cables. ...
OPERATOR & MAINTENANCE MANUAL 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. WARNING: If the terminal 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. ...
OPERATOR & MAINTENANCE MANUAL 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. ...
OPERATOR & MAINTENANCE MANUAL 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. WARNING: Do not use the machine when any leak is found. Repairs are only to be carried out by trained personnel and according to regulations. 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. ...
OPERATOR & MAINTENANCE MANUAL 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. ...
OPERATOR & MAINTENANCE MANUAL 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. 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. 5.2.3 Coolant Remove the radiator cap, check coolant level in the tank. Adding Coolant: ...
OPERATOR & MAINTENANCE MANUAL 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 Isolator (17), Circuit Breaker (15), RCD/MCBs (18, 19 and 20), to the “OFF” position. 3. Open the side access door and turn on the engine battery isolator switch, then close the door. ...
OPERATOR & MAINTENANCE MANUAL 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. ...
OPERATOR & MAINTENANCE MANUAL 5.6 Stopping Generator Under Manual Operation Mode 1. Turn off every RCD/circuit breaker. 2. Turn the Main Isolator (17), Circuit Breaker (15), RCD/MCBs (18, 19 and 20), 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 (9). 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 the door. ...
OPERATOR & MAINTENANCE MANUAL 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 data for the weight of the generator. Make sure the lifting device ...
OPERATOR & MAINTENANCE MANUAL 6.1 Periodic Maintenance Schedule TWO SIX YEARLY DAILY WEEKLY MONTHLY YEARS MONTHS OR OR OR OR OR SERVICE ITEMS OR AFTER AFTER AFTER AFTER AFTER AFTER 500 8 HRS 50 HRS 100 HRS 1000 250 HRS HRS HRS Check various meters and ...
OPERATOR & MAINTENANCE MANUAL 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 ...
OPERATOR & MAINTENANCE MANUAL 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. ...
OPERATOR & MAINTENANCE MANUAL 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 ...
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 tighten accordingly. ...
6.7 Troubleshooting When performing any troubleshooting, follow the guidelines. If further clarification is required please contact our authorised service agent. TROUBLE CAUSES SOLUTIONS 1. Lubricant oil is insufficient 1. Add lubricant oil 2. Oil hose has leak 2. Tighten or change oil hose Low engine oil pressure 3. Oil filter is clogged 3. Change oil filter 4. Wrong oil is used 4. Change to correct oil 1. Coolant is insufficient 1. Add coolant 2. Tighten or change coolant 2. Coolant pipe has leak pipe 3. Fan belt is loose 3. Tighten the belt High coolant 4. Radiator core is clogged 4. Clean radiator core temperature 5. Water temp sensor is 5. Repair or change the sensor defective ...
Page 63
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 1. Fuel is insufficient 1. Add fuel Starter 2. Fuel hose has leak 2. Tighten or change fuel hose motor 3. Drain water/sediment or drives, but 3. Fuel filter is clogged change fuel filter engine 4. Gauze filter is clogged 4. Clean or change gauze filter cannot start 5. Air is mixed in fuel line 5. Bleed the air 1. Fuel hose has a leak 1. Tighten or change fuel hose 2. Drain water/sediment or 2. Fuel filter is clogged Change fuel filter Engine starts but stalls 3. Gauze filter is clogged 3. Clean or change gauze filter at once 4. Lubricant oil is insufficient 4. Add lubricant oil ...
Page 64
Promac Sales Email: sales@promac.net.au Phone: +61 8 6254 1800 Fax: +61 8 6254 1899 Office: 11 Poole Street, Welshpool, Western Australia, 6106 Postal Address: PO Box 538, Welshpool, Western Australia, 6986 PROMAC. LEADING THE WAY.
Need help?
Do you have a question about the S10KS and is the answer not in the manual?
Questions and answers