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Nugen S150PS Operator's Maintenance Manual

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OPERATOR & MAINTENANCE
MANUAL
PROMAC. LEADING THE WAY.

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Summary of Contents for Nugen Nugen S150PS

  • Page 1 OPERATOR & MAINTENANCE MANUAL PROMAC. LEADING THE WAY.
  • Page 2 S150PS GENERATING SET OPERATOR & MAINTENANCE MANUAL...

  • Page 3: Table Of Contents

    Content Table 1. Foreword ......................4 2. Safety Information ..................5 2.1 General Safety Precautions ..................6 2.2 Safety During Transportation ..................6 2.3 Safety During Installation and Initial Start-up ............6 2.4 Safety During Operation ................... 7 2.5 Safety Around Diesel Engines .................. 8 2.6 Safety During Maintenance ..................
  • Page 4 5.2.3 Coolant ..........................25 5.3 Manual Start-up....................... 26 5.4 Automatic Start-up ....................27 5.5 During Operation ....................27 5.6 Stopping Generator under Manual Operation Mode ..........28 5.7 Stopping Generator under Automatic Operation Mode .......... 28 5.8 Protection ........................ 28 5.8.1 Displaying alarm signals ....................

  • Page 5: Foreword

    Please consult the engine and alternator operation and maintenance manuals if necessary. The information contained in this manual was based on the generator in production at the time of publication. Promac Sales Pty Ltd reserves the right to change any portion of this information without notice.

  • Page 6: Safety Information

    OPERATOR & MAINTENANCE MANUAL 2. Safety Information Before operating the machine, carefully read and fully understand the following safety regulations and check all local requirements. This will reduce the possibility of personal injury, damage to the equipment, or improper service. The operation, maintenance and repairs must only be carried out by authorized and competent personnel.

  • Page 7: General Safety 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. ...

  • Page 8: Safety During Operation

    OPERATOR & MAINTENANCE MANUAL  Under no circumstances are any guards, panels or insulating materials to be tampered with.  Do not leave any flammable liquids or materials near the generator or any other parts of the electrical installation.  Take extreme caution to avoid risks of electrocution. Ensure that all earthing installations have been fitted according to the regulations.

  • Page 9: Safety Around Diesel Engines

    OPERATOR & MAINTENANCE MANUAL 2.5 Safety Around Diesel Engines  Do not operate the engine when the air cleaner is removed. Engine backfire can cause serious burns.  Do not remove the radiator cap whilst the engine is running. Allow the coolant to sufficiently cool before removing the radiator cap.

  • Page 10: Safety Labels

    OPERATOR & MAINTENANCE MANUAL 2.7 Safety Labels Label Description 1. Read the Operator’s Manual. 2. No sparks or naked flames near the machine. 3. Press the emergency stop switch when an emergency occurs. 4. Do not disassemble the machine. Warning 1.
  • Page 11 OPERATOR & MAINTENANCE MANUAL Warning Read this label before lifting and transporting. Only use designated lifting points on generator. Warning 1. Disconnect battery before servicing. 2. Read the Operator’s Manual for instructions. Warning Do not manipulate the generator with the switch on. Warning Do not clean the alternator with water.

  • Page 12: Specifications And Parts Introduction

    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 service. ① Continuous service: Used for the production of electrical energy for several purposes: motion force, lighting, heating, etc.

  • Page 13: Appearance And Main Parts

    OPERATOR & MAINTENANCE MANUAL Rated Voltage 415 / 240 Power Factor Rated Frequency Rated Speed 1500 Phase / Wire 3-Phase / 5-Wire Noise Level dB(A)@7m 69.7 Engine Model Perkins(UK), 1006TAG2 Number of Cylinders 6 vertical in-line Bore mm/in 100 / 3.94 Stroke mm/in 127 / 5.0...
  • Page 14 OPERATOR & MAINTENANCE MANUAL...

  • Page 15: Control Cabinet And Panel

    OPERATOR & MAINTENANCE MANUAL 3.4 Control Cabinet and Panel Ref. Description Control panel ATS receptacle Perspex Hinge Main wiring terminals Earth wiring terminal Three-phase main circuit breaker Protecting wiring terminals(225A) Door catch Key switch Control cabinet lamp switch Charge indicator Control cabinet lamp Power OK indicator Start engine push button...
  • Page 16 OPERATOR & MAINTENANCE MANUAL ① Control Module The generator controller PLC-1F (1) is a micro processor-based control unit containing all necessary functions for protection and control of a diesel engine. In addition, it contains a three-phase AC voltage measuring circuit. The unit is equipped with a LCD screen presenting all values and alarms.
  • Page 17 OPERATOR & MAINTENANCE MANUAL ① Emergency Stop Switch The generator is equipped with an emergency stop switch. The switch (E) is located on the control cabinet. When activated, the emergency stop (switch by pushing the red button in) will turn off the fuel solenoid, resulting in the engine shutting down.

  • Page 18: Generator Wiring Diagram

    OPERATOR & MAINTENANCE MANUAL 3.6 Generator Wiring Diagram...

  • Page 19: Installation

    OPERATOR & MAINTENANCE MANUAL 4. Installation 4.1 External Installation The generator should be installed in an area that is protected directly from harmful gases liquids, dust, corrosive particles and vibration. The weatherproof enclosure is designed to provide cooling and ventilation for the generator. Several factors should be carefully considered when selecting a location for installation.
  • Page 20 OPERATOR & MAINTENANCE MANUAL ② 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 will not compromise reliability from the ...

  • Page 21: Main Power With Automatic Mains Failure (Optional)

    OPERATOR & MAINTENANCE MANUAL ③ Mounting the Generator The generator is mounted on a steel base tank that provides correct support. Vibration isolators are recommended between the base tank and the foundation to provide stable operation and avoid installation damage. Bolting the generator directly to the floor or foundation can result in excessive noise and vibration, and possible damage to the generator and floor foundation.

  • Page 22: Connecting Load Cable

    OPERATOR & MAINTENANCE MANUAL 4.4.2 Connecting Load Cable The generator is supplied with field connections. The cables should be connected to the main wiring terminals which are located inside the field wiring cabinet. Warning: Before connection, the following precautionary measures must be taken. Connection must be only be carried out by a licensed electrician.
  • Page 23 OPERATOR & MAINTENANCE MANUAL ③ Connect the wires between the mains supply wiring terminals and the ATS wiring terminals. ④ Connect the wires between the load wiring terminals and the ATS wiring terminals. Warning: Do not operate the generator before connection of the ATS. The ATS is controlled by the PLC module which can monitor the incoming AC mains supply.

  • Page 24: Battery Connections

    OPERATOR & MAINTENANCE MANUAL 4.7 Battery Connections The battery cables should be disconnected when the generator is required to be transported or stored for long periods. Before running the machine, reconnect the battery cables. Connect the red cable to the positive (+) post. Connect the black cable to the negative (-) post.

  • Page 25: Checking Engine Oil, Fuel And Coolant Level Before Starting

    OPERATOR & MAINTENANCE MANUAL  Ensure that the battery cables are firmly secured to the terminals. Tighten the clamps if necessary.  Close and secure side panel access doors.  Review and follow the safety instructions in the front of this manual. Warning: Failure to follow the listed procedures may cause injury to personnel or damage to ...

  • Page 26: Fuel

    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. ...

  • Page 27: Manual Start-Up

    OPERATOR & MAINTENANCE MANUAL 5.3 Manual Start-up Carefully read the illustration on the control cabinet and control panel (PLC). Then follow the operation steps. ① Switch all loads to the “OFF” position. ② Turn the Main Circuit Breaker (2) , to the “OFF” position. ③...

  • Page 28: Automatic Start-Up

    OPERATOR & MAINTENANCE MANUAL 5.4 Automatic Start-up ① Follow steps ① to ④ as described in section 5.3. ② Turn the ATS (automatic transfer switch) to “AUTO” position. ③ Press the Auto button (l) , then the LED above the button will illuminate. The module will proceed with its normal auto start sequence.

  • Page 29: Stopping Generator Under Manual Operation Mode

    OPERATOR & MAINTENANCE MANUAL 5.6 Stopping Generator under Manual Operation Mode ① Turn off every Circuit Breaker. ② Turn the Main Circuit Breaker (2) to “OFF” position. ③ Press the OFF button (c) ④ Allow the engine to idle for approximately one minute to cool down. ⑤...

  • Page 30: Warnings

    OPERATOR & MAINTENANCE MANUAL 5.8.2 Warnings The warnings listed below are non-critical alarm conditions and do not affect the operation of the generator, they serve to draw the operators attention to an undesirable condition. Battery Charge Failure: If the PLC does not detect a voltage from the warning light ...

  • Page 31: Shutting Down The Generator

    OPERATOR & MAINTENANCE MANUAL 5.9 Shutting Down the Generator The generator is equipped with an automatic shutdown feature. The LCD will display the fault and the Alarm LED will flash. Warning: In the event of a shutdown alarm, turn off the engine. Generator to be repaired by certified or fully trained personnel according to the troubleshooting guidelines (see 6.7).

  • Page 32: Lifting And Transporting

    OPERATOR & MAINTENANCE MANUAL Generator Reverse Power: If the PLC detects a generator reverse power current in  excess of the pre-set trip, a shutdown is initiated. The LCD will indicate ‘Reverse Power’ and the Alarm LED will flash. Generator Over Current: If the PLC detects a generator output current in excess of ...

  • Page 33: Maintenance

    OPERATOR & MAINTENANCE MANUAL 6. Maintenance  Before performing any check or maintenance, stop the engine and remove the start key  For detailed maintenance procedures on the engine, refer to engine operator's manual. 6.1 Periodic Maintenance Schedule Daily Weekly Monthly Yearly Months...

  • Page 34: Air Cleaner

    OPERATOR & MAINTENANCE MANUAL 6.3 Air Cleaner 6.3.1 Clean air filter element ① Loosen clips in the air cleaner and remove the dust cap. ② Remove the air filter element containing a primary filter and a safety filter. ③ Loosen the safety filter from the primary filter. ④...

  • Page 35: Engine Oil And Oil Filter

    OPERATOR & MAINTENANCE MANUAL Warning: Avoid injury! The radiator will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed. Shut off engine and allow to cool. Do not remove cap unless the radiator and the engine are cool to touch with bare hands.

  • Page 36: Fuel Filter

    OPERATOR & MAINTENANCE MANUAL Warning: To obtain an accurate reading, ensure the generator is level before checking the oil  level. Do not overfill the engine oil. The level is not to exceed the upper limit. Excessive  engine oil may damage the engine. Extinguish all naked flames and cigarettes before adding engine oil.

  • Page 37: Troubleshooting

    OPERATOR & MAINTENANCE MANUAL 6.7 Troubleshooting When performing any troubleshooting, follow the guidelines. If further clarification is required please contact our authorized service agent. Trouble Causes Solutions 1. Insufficient oil Add lubricant oil 2. Oil hose has leak Tighten or change oil hose Low engine oil pressure 3.
  • Page 38 OPERATOR & MAINTENANCE MANUAL Trouble Causes Solutions 1. Battery switch is off Turn the switch to on Starter motor 2. Battery output is low Charge the battery will not drive or speed is 3. Battery is deteriorated Change the battery 4.
  • Page 39 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.

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