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Nugen S100PS Operator's Maintenance Manual

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OPERATOR & MAINTENANCE
MANUAL
PROMAC. LEADING THE WAY.

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  • Page 1 OPERATOR & MAINTENANCE MANUAL PROMAC. LEADING THE WAY.
  • Page 2 S100PS GENERATING SET OPERATOR & MAINTENANCE MANUAL Edition Date 2011-03-09...

  • Page 3: Table Of Contents

    Table of Contents 1. Foreword ......................1 2. Safety Information ....................2 2.1 General Safety Precautions ..................3 2.2 Safety During Transportation .................. 3 2.3 Safety During Installation & Initial Start-up ............4 2.4 Safety During Operation ..................4 2.5 Safety Around Diesel Engines ................. 5 2.6 Safety During Maintenance ..................
  • Page 4 4.11 ATS Connections ....................47 5. Operation ......................48 5.1 General Pre-check Before Starting ................ 48 5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting ......49 5.2.1 Engine oil ..................... 49 5.2.2 Fuel ......................50 5.2.3 Coolant ......................50 5.3 Manual Start-up .....................

  • Page 5: Foreword

    Use only in open well ventilated areas or vent exhaust outside! DISCLAIMER STATEMENT Promac Sales Pty Ltd publishes the technical information in this manual as an aid to its customers and to the public. The information included in this manual is based on sound engineering principles, research, extensive field experience, and technical judgments.

  • Page 6: Safety Information

    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.

  • 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 Installation & Initial Start-Up

    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. ...

  • Page 9: Safety Around Diesel Engines

    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. ...

  • Page 10: Symbols And Their Meanings

    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. ...
  • 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.
  • 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...
  • 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...

  • Page 14: 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 services:  Continuous service – Used for the production of electrical energy for varied purposes: motion force, lighting, heating, etc.

  • Page 15: Generator Specifications

    OPERATOR & MAINTENANCE MANUAL 3.2 Generator Specifications TABLE 2: GENERATOR SPECIFICATIONS ITEM UNIT DATA Model S100PS Rated Output Rated Voltage 415 / 240 Power Factor Rated Frequency Rated Speed 1500 Phase / Wire 3-Phase / 5-Wire Noise Level dB(A)@7m ENGINE SPECIFICATIONS Model Perkins (UK), 1104C-44TAG2 Number of Cylinders...

  • Page 16: Generator Layout And Main Components

    OPERATOR & MAINTENANCE MANUAL 3.3 Generator Layout and Major Components PAGE-12...
  • Page 17 OPERATOR & MAINTENANCE MANUAL TABLE 3: CONTROL CABINET NAME DESCRIPTION Canopy Size: 2630 x 1060 x 1490mm Fire extinguisher bracket Designed for 9kg ABE fire extinguisher Field wiring cabinet Base Size: 2830 x 1060 x 400mm Control cabinet assembly Spark Arrestor Rating: 8m /min Alternator...

  • Page 18: Control Cabinet And Panel

    OPERATOR & MAINTENANCE MANUAL 3.4 Control Cabinet and Panel 3.4.1 Control Cabinet PAGE-14...
  • Page 19 OPERATOR & MAINTENANCE MANUAL TABLE 4: CONTROL CABINET NAME DESCRIPTION Terminals DC 12V Relays DC 12V Circuit Breaker 16A 1P Circuit Breaker 32A 1P Circuit Breaker 6A 1P Relays DC 12V (start relay and fuel start relay) Cable Duct Battery Charger DC Regulator Module Terminals AC 240V...

  • Page 20: Control Panel

    OPERATOR & MAINTENANCE MANUAL 3.4.2 Control Panel PAGE-16...
  • Page 21 OPERATOR & MAINTENANCE MANUAL TABLE 5: CONTROL PANEL REF NAME DESCRIPTION Control Cabinet Lamp Switch Control Cabinet Lamp RCD Status Lamp RCD Status Lamp Globe Test Button Mains / ATS Battery Charging Lamp Earth Leakage Relay (ELR) Schneider Vigirex RH99P; Panel mounted Mains / ATS Battery Charger Selector Switch Audible Alarm...
  • Page 22 OPERATOR & MAINTENANCE MANUAL 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.
  • Page 23 OPERATOR & MAINTENANCE MANUAL 10. Mains RCD Test Pushbutton Depressing the Mains RCD Test Pushbutton (10) allows power to the RCD Test Point (11). 11. RCD Test Point The RCD Test Point (11) is used to test the earth leakage protection function.
  • Page 24 OPERATOR & MAINTENANCE MANUAL 16. RCD Test Point Circuit Breaker (2A,2P) The lockable two pole RCD Test Point Circuit Breaker (16) is located on the control panel and protects the RCD Test Point (11). 17 & 18. Single Phase RCD/MCB Combo Protecting 15A Single Phase Outlets The 16A Single-phase RCD/MCB Combo devices (17) and (18) are located on the control panel.
  • Page 25 OPERATOR & MAINTENANCE MANUAL 23. Three Pole Circuit Breaker Protecting 50A Three Phase Outlet The Three Phase Circuit Breaker (23) is located on the control panel. When the electric current in the three phase outlet circuit is above 50A, this breaker will automatically trip to the “fault” position. This will interrupt power from the the load side of RCD to the respective GPO in the field wiring cabinet.

  • Page 26: Amf25 Controller

    OPERATOR & MAINTENANCE MANUAL 3.4.3 AMF 25 Controller TABLE 5: PUSH BUTTONS 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 27 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. 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.

  • Page 28: Display Screens And Pages Structure

    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 29 OPERATOR & MAINTENANCE MANUAL Alarms PAGE-25...
  • Page 30 OPERATOR & MAINTENANCE MANUAL Browsing ECU Alarms PAGE-26...
  • Page 31 OPERATOR & MAINTENANCE MANUAL PAGE-27...
  • Page 32 OPERATOR & MAINTENANCE MANUAL PAGE-28...
  • Page 33 OPERATOR & MAINTENANCE MANUAL 3.4.5 Field Wiring Cabinet PAGE-29...
  • Page 34 OPERATOR & MAINTENANCE MANUAL TABLE 7 OUTPUT TERMINAL ASSEMBLY DESCRIPTION NAME Neutral wiring terminal MEN connection Earth wiring terminal MEN connection Spare terminal MEN disconnected terminal L1 wiring terminal Red Phase L2 wiring terminal White Phase L3 wiring terminal Blue Phase Neutral wiring terminal Black Earth wiring terminal...
  • Page 35 OPERATOR & MAINTENANCE MANUAL breaker. Each GPO is protected by it’s own RCD/MCB combo breakers located in the control cabinet. 4. General Purpose Outlet (GPO) (Manually switched 20A, single-phase) The generator is equipped with one 240V single-phase GPO (13) rated at 20A.
  • Page 36 OPERATOR & MAINTENANCE MANUAL 7. Mains Inlet for Battery Charging (10A male 3 flat pin, single phase) The generator is equipped with one 240V single phase 3 flat pin inlet, (14) rated at 10A. It connects to the battery charger through an RCD/MCB combo breaker, which is located in the control box.

  • Page 37: Generator Wiring Diagram

    OPERATOR & MAINTENANCE MANUAL 3.5 Generator Wiring Diagram PAGE-33...

  • Page 38: Installation

    OPERATOR & MAINTENANCE MANUAL 4. Installation A diesel generator is a high-speed piece of rotating equipment. To ensure reliability and safety the installation must be given thorough attention. Before installing the unit, we must consider all environmental factors. Generator installation must comply with local building codes, fire regulations and environmental requirements.

  • Page 39: Mounting Arrangement

    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.
  • Page 40 OPERATOR & MAINTENANCE MANUAL When designing the base, we need to pay specific attention 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.

  • Page 41: Outdoor Installation

    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.
  • Page 42 OPERATOR & MAINTENANCE MANUAL PAGE-38...

  • Page 43: Indoor Installation

    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.

  • Page 44: Mechanical Connections

    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.
  • Page 45 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.

  • Page 46: Lubrication System

    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.
  • Page 47 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.

  • Page 48: Exhaust System

    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 land it must be equipped with a Spark Arrestor.

  • Page 49: Load Connections

    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.

  • Page 50: Earth Connections

    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.

  • Page 51: Ats Connections

    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. ...

  • Page 52: Operation

    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 to Be carried out by trained personnel and according to regulations.

  • Page 53: Checking Engine Oil, Fuel And Coolant Level Before Starting

    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.

  • Page 54: 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 55: Manual Start-Up

    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 Circuit Breaker (13), Circuit Breaker (15, 16, 21, 23), RCD/MCB (17, 18, 19), RCD (20, 22), to the “OFF”...

  • Page 56: During Operation

    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. ...

  • Page 57: Stopping Generator Under Manual Operation Mode

    OPERATOR & MAINTENANCE MANUAL 5.6 Stopping Generator Under Manual Operation Mode 1. Turn off every RCD/circuit breaker. 2. Turn the Main Circuit Breaker (13), Circuit Breaker (15, 16, 21, 23), RCD/MCB (17, 18, 19), RCD (20, 22), to the “OFF” position. 3.

  • Page 58: Lifting And Transportation

    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.

  • Page 59: Periodic Maintenance Schedule

    OPERATOR & MAINTENANCE MANUAL 6.1 Periodic Maintenance Schedule YEARLY DAILY WEEKLY MONTHLY YEARS MONTHS SERVICE ITEMS AFTER AFTER AFTER AFTER AFTER AFTER 8 HRS 50 HRS 100 HRS 1000 250 HRS Check various meters and ● alarm lamps Check engine oil , fuel and ●...

  • Page 60: New Machines

    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 ...

  • Page 61: Engine Coolant

    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. ...

  • Page 62: Engine Oil And Oil Filter

    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. ...

  • Page 63: Fuel 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. ...

  • Page 64: Troubleshooting

    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.
  • Page 65 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.
  • Page 66 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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