OPERATOR & MAINTENANCE MANUAL
Edition B
Date 2011-10-17
.............................................................................................................. 1
.............................................................................................. 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 ..................................................................................... 5
2.7 Symbols and Their Meanings .................................................................................. 6
........................................................... 10
3.1 Specifications ......................................................................................................... 10
3.1.1 Use .............................................................................................................. 10
3.1.2 Main Specifications ..................................................................................... 10
3.1.3 Design Ambient Conditions ........................................................................ 10
3.2 Generator Specifications ........................................................................................ 11
3.3 Generator Layout and Major Components ............................................................ 12
3.4 Control Cabinet and Panel ..................................................................................... 14
3.4.1 Control Cabinet ........................................................................................... 14
3.4.2 Control Panel ............................................................................................... 16
3.4.3 MRS15 Controller ........................................................................................ 22
3.4.4 Field Wiring Cabinet .................................................................................... 28
3.5 Generator Wiring Diagram .................................................................................... 32
......................................................................................................... 33
4.1. Noise consideration ............................................................................................... 33
4.2. Acoustic Material consideration ........................................................................... 33
4.3 Fire protection ........................................................................................................ 33
4.4 Mounting Arrangement .......................................................................................... 34
4.5 Outdoor Installation ............................................................................................... 36
4.6 Indoor Installation .................................................................................................. 38
4.7 Mechanical Connections ........................................................................................ 39
4.7.1 Fuel system ................................................................................................. 39
4.7.2 Lubrication system ...................................................................................... 41
4.7.3 Exhaust system ........................................................................................... 43
4.7.4 Ventilation and cooling system ................................................................... 43
4.8 Load Connections .................................................................................................. 44

OPERATOR & MAINTENANCE MANUAL
4.8.1 Sizing Load Cables ....................................................................................... 44
4.8.2 Connecting Load Cable ................................................................................ 44
4.9 Earth Connections .................................................................................................. 45
4.10 Battery Connections ............................................................................................. 45
........................................................................................................... 46
5.1 General Pre-check Before Starting ........................................................................ 46
5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting ............................. 47
5.2.1 Engine oil ..................................................................................................... 47
5.2.2 Fuel .............................................................................................................. 48
5.2.3 Coolant ........................................................................................................ 48
5.3 Manual Start-up ..................................................................................................... 49
5.4 Automatic Start-up ................................................................................................. 49
5.5 During Operation ................................................................................................... 50
5.6 Stopping Generator Under Manual Operation Mode ............................................. 51
5.7 Stopping Generator Under Automatic Operation Mode ........................................ 51
5.8 Shutting Down Genset ........................................................................................... 51
5.9 Lifting and Transportation ..................................................................................... 52
5.10 Overnight Storage ................................................................................................ 52
5.11 Long-term Storage ............................................................................................... 52
...................................................................................................... 52
6.1 Periodic Maintenance Schedule ............................................................................. 53
6.2 New Machines ....................................................................................................... 54
6.3 Air Cleaner ............................................................................................................. 54
6.3.1 Clean Air Filter Element .............................................................................. 54
6.3.2 Change Air Filter Element ........................................................................... 54
6.4 Engine Coolant ....................................................................................................... 55
6.5 Engine Oil and Oil Filter ........................................................................................ 56
6.5.1 Change Engine Oil ....................................................................................... 56
6.5.2 Change Oil Filter .......................................................................................... 56
6.6 Fuel Filter ............................................................................................................... 57
6.6.1 Drain Water / Sediment in the Fuel Filter .................................................. 57
6.6.2 Change Fuel Filter ....................................................................................... 57
6.7 Troubleshooting ..................................................................................................... 58

OPERATOR & MAINTENANCE MANUAL
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.
can cause serious injury or even death!
Use only in open well ventilated areas or vent exhaust outside!
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.
This mater is subject to change in light of developments in technology and field experience. Use or adoption of the information contained in this manual is voluntary.
Promac Sales Pty Ltd reserves the right to change any portion of this information without notice.
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OPERATOR & MAINTENANCE MANUAL
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.
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels attached to the machine itself. It warns of the potential for personal injury. It is essential that you carefully read the instructions and safety regulations before you attempt to operate or maintain this machine.
Indicates potential personal injury hazards
Indicates a hazardous situation which, if not avoided, will result in serious injury or even death
Indicates a hazardous situation which, if not avoided, could result in serious injury or even death
Indicates a hazardous situation which, if not avoided, could result in minor or major injury
Indicates additional information important to a procedure
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OPERATOR & MAINTENANCE MANUAL
 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.
 Always shut the engine down before transporting.
 Never transport the generator with any access doors open.
 Ensure the fuel tank cap is securely tightened.
 Drain fuel when transporting the generator over long distances or rough terrain.
 In order to lift and transport the generator, lifting machines of the appropriate capacity must be used. All loose and pivoting parts must be securely fixed.
 When relocating the generator only lift from designated lift points.
 Do not use the lifting points located over the engine, alternator or any other components.
 If the generator is damaged during transport, repairs should only be carried out by an authorised service agent.
 Unpacking must be carried out carefully, avoiding any damage to the goods – particularly when using levers, saws or any other metallic tools.
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OPERATOR & MAINTENANCE MANUAL
 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.
 Do not leave any flammable liquids or materials near the generator or any other part of the electrical installation.
 Take extreme caution to avoid risks of electrocution. Ensure that all earthing installations have been fitted according to the Electrical Standards and all local regulations.
 Ensure all connections and wires are insulated. Do not leave any of the generator’s electrical terminals unprotected.
 Ensure all connection points and their accessories have been correctly earthed.
 Verify and ensure that all electrical power connections and auxiliary service connections are correct.
 Check that the phase rotation matches the power supply.
 Ensure the correct ventilation of the premises so that all exhaust gases are released to the atmosphere and verify that they are in a safe position away from all doors, windows and air intakes.
 Make sure there are no leaks in the oil and fuel pipes.
 Never stand under or close to any object that is being hoisted or lifted into position.
 Only competent and adequately trained personnel are to access the operating area of the generator.
 Always wear ear protection when the generator is in operation.
 Before operating the generator, make sure the earth spike is connected to the earth point in front of the plant.
 Before starting the engine, turn off any connected loads and set all circuit breakers to
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OPERATOR & MAINTENANCE MANUAL 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.
 Do not operate the engine when the air cleaner is removed. Engine backfire can cause serious burns.
 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.
 Do not add coolant, oil or fuel to a hot engine. Allow the engine to sufficiently cool first.
 Do not touch the engine and muffler while the engine is running. Allow the engine to sufficiently cool before any maintenance is performed.
 Do not smoke in the vicinity of the generator.
 Consistently monitor the exhaust system for leaks. In the event of a leak, repair immediately.
 All checks or maintenance of the generator must be carried out by competent and adequately trained personnel.
 Ensure that the engine has fully stopped before performing any maintenance.
 Disconnect the terminals from the battery before operating any components of the electrical installation.
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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.
 Ensure that the appropriate PPE is worn while working on the generator.
The following symbols are used on the product and throughout this manual.
LABEL
DESCRIPTION
1. Read the Operator 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. To prevent hearing loss, wear hearing protection.
2. Avoid spraying water into generator.
3. Avoid hand injury in rotating belts and pulleys.
4. Mechanical moving parts can cause severe injury.
Safety Instructions
Read the Safety Instructions before operation.
Warning
Electric shock will cause serious injury or death.
Warning
Escaping steam can cause severe burns.
Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.
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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.
Only use designated lifting points on generator.
Warning
1. Disconnect the battery before servicing.
2. Read the Operator Manual for instructions.
Warning
Do not manipulate the generator with the switch on.
Warning
Engine exhaust can cause serious injury or even death.
Hot surfaces can burn skin.
Danger
High voltage.
Warning
Do not clean the alternator with water
Warning
High temperature.
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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.
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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
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OPERATOR & MAINTENANCE MANUAL
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
 Reliable and powerful Perkins engine and Leroy Somer alternator.
 Operation: Using the advanced Intelilite MRS 15 Controller, allows for simple and convenient fingertip control through the front control panel or by PC connection.
The Intelilte MRS 15 Controller also monitors the engine and the alternator displaying all warning alarms and performing automatic shutdowns on fault signals.
 50°C designed cooling system.
 The engine and alternator have rubber av mounts installed to reduce vibration.
 High anti-corrosion protection.
 Easy maintenance: Wide doors are designed to allow easy access for maintenance and cleaning.
 Super quiet performance: Acoustic insulation installed inside all of the panels and doors and an oversized muffler to minimise noise.
 Engine and alternator can resist any direct impact stress.
 Control cabinet can reach IP66 protection. Canopy can reach IP44 protection.
 Double bunded fuel tank protection.
 Leak proof base: All drain points are located on the inside.
 Muffler with spark arrester.
3.1.3 Design Ambient Conditions
 Installation: Outdoors and indoors in a well-ventilated area.
 Temperature: -15°C to 50°C.
 Relative humidity: Less than 80%.
 Altitude: To a maximum of one thousand (1000) metres above sea level.
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OPERATOR & MAINTENANCE MANUAL
Model
Rated Output
ITEM
Rated Voltage
Power Factor
Rated Frequency
Rated Speed
Phase / Wire
Noise Level
UNIT kVA kW
V
Hz rpm dB(A)@7m
DATA
S135PS
135
108
415 / 240
0.8
50
1500
3-Phase / 5-Wire
72
Model
Number of Cylinders
Bore
Stroke
Engine Speed
Prime Power
Standby Power
Compression Ratio
Displacement
Cooling System
Battery Voltage
Type of Oil
Type of Fuel
Fuel Tank Capacity
mm mm rpm kW kW
L
V
L
Perkins (UK), 1006TAG
6 vertical in-line
100 / 3.93
127 / 4.99
1500
135
150
17.1:1
5.99
Water-cooled
12
20W50-CF4 Upgrade
0# or –20# Light Diesel
650
Model
Exciter
Excitation System
Insulation Type
Length
Width
Height
Dry Weight
Leroy Somer LSA44.2
VS45
Brushless
AREP
Class H
mm mm mm kg
3540
1140
1800
2284
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OPERATOR & MAINTENANCE MANUAL
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OPERATOR & MAINTENANCE MANUAL
REF NAME DESCRIPTION
1 Canopy
2 Base
3 Field wiring cabinet
Size: 3300 x 1140 x 1400mm
Size: 3540 x 1140 x 400mm
4 Control cabinet assembly
5 Alternator LSA44.2 S75
6 Diesel engine
7 Radiator
8 Muffler
9 Spark Arrestor
Perkins 1006TAG
50°C
Rating: 12m
3
Rating: 8m 3
/min
/min
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OPERATOR & MAINTENANCE MANUAL
3.4.1 Control Cabinet
DESCRIPTION REF NAME
A DC Regulator Module DC 12V
B Terminals
C Relays
DC 12V
DC 12V
D Circuit Breaker
E Circuit Breaker
F Circuit Breaker
G Circuit Breaker
H Retainer
16A 1P
32A 1P
6A 1P
2A 1P
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OPERATOR & MAINTENANCE MANUAL
I Terminals AC 240V
J Three-pin socket
K Circuit Breaker
L RCCB
M MCB
10A, RCD1 test point
2A 2P
40A/0.03A/4P
10A 3 P
N RCD bypass switch Refer to Note 1
O MEN Terminal
P MEN Terminal
Q MEN Link
R MEN Terminal
S Earth Bar
T Neutral Bar
U C Phase
V B Phase
W A Phase
X Earth Bar
Y Neutral Bar
Z a b c d e
A Phase
B Phase
C Phase
Diode
Battery Charger
Relays
Spare Terminal
Earth
Refer to Note 2
Neutral
Copper Bar,Customer connect
Copper Bar,Customer connect
Copper Bar,Customer connect
Copper Bar,Connect to the Generator
Copper Bar,Connect to the Generator
Copper Bar,Connect to the Generator
ZP5A
AC240V/12V
DC 12V (start relay and fuel relay)
Note 1: The RCD bypass switch has a protective cap to prevent accidental operation. The machines are delivered with the switch in the off position and the cap down. In this configuration the adjustable earth leakage relay will monitor any earth leakage current. If a leakage current greater than the relay setting is detected the shunt trip will trip the Main Circuit
Breaker. When the RCD bypass switch is on and the cap is in the up position, the earth leakage relay will be bypassed.
This operation must only be carried out by a licensed electrician.
Note 2: The MEN connection terminals (O,P,R) are provided to facilitate simple connection and disconnection of the MEN Link (Q) . The MEN Link is connected on the alternator side of the toroids for the earth leakage protection. If the load side has another MEN Link connected, the generator side MEN Link must be disconnected. A spare terminal (O) , is provided. The earth leakage relay must also be bypassed (in the control cabinet).
This operation must only be done by a licensed electrician.
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3.4.2 Control Panel
OPERATOR & MAINTENANCE MANUAL
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OPERATOR & MAINTENANCE MANUAL
REF NAME DESCRIPTION
1 Control Cabinet Lamp Switch
2 Control Cabinet Lamp
3 RCD Status Lamp
4
RCD Status Lamp Globe Test
Button
5 Battery Charging Indicator Lamp
6 Master Control Switch
7 Alarm Buzzer
8 Battery Charge Switch
9 Earth Leakage Relay
10 Controller
11 Test Point Switch
12 Push Button
13 RCD Test Point
14 Circuit Breaker
15 RCD
16 Circuit Breaker
Schneider Vigirex RH99P; Panel mounted
MRS 15
20A,Lockable
Mains connected, two pole RCD Test button
10A ,Test Point
2A 2P, Test point
40A 4P, 30mA
20A 3P,General purpose outlet
17 Circuit Breaker
18 Circuit Breaker
19 Circuit Breaker
20 GPO Switch
21 Main Circuit Breaker
22 RCD
23 RCD
24 RCD
25 RCD/MCB Combo
26 RCD/MCB Combo
27 RCD/MCB Combo
50A 3P,General purpose outlet
50A 3P,General purpose outlet
63A 3P,General purpose outlet
250A,Lockable
250A 3P
63A 4P,30mA
63A 4P,30mA
63A 4P,30mA
20A 2P
16A 2P
16A 2P
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.
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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.
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.
Battery Charging Indicator Lamp
The indicator (5) will illuminate when the 12V main battery is being charged by the mains inlet power.
6.
Master Control Switch
The switch (6) energises the control panel
7.
Alarm Buzzer
IF the MRS 15 controller senses a fault . The Audible Alarm (7) will sound.
8.
Battery Charge Switch
The switch (8) is used to charge the battery from the Mains Inlet.
9.
Earth Leakage Relay (ELR)
The generator is equipped with an earth leakage relay
(9). 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.
10.
Controller (MRS 15)
The generator controller MRS 15 (10) is a microprocessor-based control unit containing all of the necessary functions for the protection and control of the
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OPERATOR & MAINTENANCE MANUAL 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.
Test Point Switch
The test point switch (11) is used to isolate the RCD Test Point (13)
12.
Mains RCD Test Pushbutton
Depressing the Mains RCD Test Pushbutton (12) allows power to the RCD Test
Point (13) .
13.
RCD Test Point
The RCD Test Point (13) is used to test the earth leakage protection function.
When an earth leakage greater than the adjustable ELR’s setpoint occurs, the main circuit breaker (21) will shunt trip.
14.
RCD Test Point Circuit Breaker (2A,2P)
The two pole RCD Test Point Circuit Breaker (14) is located on the control panel and protects the RCD Test Point (13).
15.
Three Phase Earth leakage Residual Current Device (RCD) (40A,4P,30mA)
The Three Phase Residual Current Device (14) is located on the control panel.
When a residual current of greater value than 30mA is detected this device will automatically trip to the “fault” position. This will interrupt power from the load side of RCD to the respective GPO in the field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating RCD.
16.
Three Pole Circuit Breaker Protecting 20A Three Phase Outlet
The Three Phase Circuit Breaker (15) is located on the control panel. When the electric current in the three phase outlet circuit is above 20A, 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.
Note: If a fault occurs, test accordingly before reinstating circuit breaker
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OPERATOR & MAINTENANCE MANUAL
17.
Circuit Breaker (50A 3P)
The three-phase circuit breaker (50A 3P) (17) is located on the control panel.
When the electric current in the 5-pin socket circuit is above 50A, this breaker will turn to the “OFF” position automatically and interrupt power from the in the load side of RCD to the respective GPO in the field wiring cabinet.
18.
Circuit Breaker (50A 3P)
The three-phase circuit breaker (50A 3P) (18) is located on the control panel. When the electric current in the 5-pin socket circuit is above 50A, this breaker will turn to the “OFF” position automatically and interrupt power from the in the load side of RCD to the respective GPO in the field wiring cabinet.
19.
Circuit Breaker (63A 3P)
The three-phase circuit breaker (63A 3P) (19) is located on the control panel. When the electric current in the 5-pin socket circuit is above 63A, this breaker will turn to the “OFF” position automatically and interrupt power from the in the load side of RCD to the respective GPO in the field wiring cabinet.
20.
GPO Switch(250A)
The GPO switch (20) is used to disconnect the power to all outlets.
21.
Main Circuit Breaker (250A 3P)
The lockable three-phase circuit breaker (250A 3P) (21) is located on the control panel. When the electric current exceeds 250A, it will automatically trip to the “fault” position and interrupt all power from the load side of the circuit breaker.When earth leakage fault occurs above 30mA, this breaker will turn to the “OFF” automatically and interrupt all power from the load side of breaker. Note: Generator will still supply power on the line side of breaker.
22.
Three Phase Earth leakage Residual Current Device (RCD) (63A,4P,30mA)
The Three Phase Residual Current Device (22) is located on the control panel.
When a residual current of greater value than 30mA is detected this device will automatically trip to the “fault” position. This will interrupt power from the load side of RCD to the respective GPO in the field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating RCD.
23.
Three Phase Earth leakage Residual Current Device (RCD) (63A,4P,30mA)
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OPERATOR & MAINTENANCE MANUAL
The Three Phase Residual Current Device (23) is located on the control panel.
When a residual current of greater value than 30mA is detected this device will automatically trip to the “fault” position. This will interrupt power from the load side of RCD to the respective GPO in the field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating RCD.
24.
Three Phase Earth leakage Residual Current Device (RCD) (63A,4P,30mA)
The Three Phase Residual Current Device (24) is located on the control panel.
When a residual current of greater value than 30mA is detected this device will automatically trip to the “fault” position. This will interrupt power from the load side of RCD to the respective GPO in the field wiring cabinet.
Note: If a fault occurs, test accordingly before reinstating RCD.
25.
Single Phase RCD/MCB Combo Protecting 20A Single Phase Outlet
The 20A Single Phase RCD/MCB Combo device (25) is located on the control panel. When the electric current is greater than 20A or a residual current of greater value than 30ma is detected, this device will automatically trip to the
“Fault” position. This will interrupt power from the load side of the
RCD/MCB to the 20A single phase GPO in the field wiring cabinet. RCD capability exists to protect the end user.
Note: If a fault occurs, test accordingly before reinstating RCD/MCB.
26.
Single Phase RCD/MCB Combo Protecting 15A Single Phase Outlet
The 16A Single Phase RCD/MCB Combo device (26&27) are located on the control panel. When the electric current is greater than 20A or a residual current of greater value than 30ma is detected, this device will automatically trip to the “Fault” position. This will interrupt power from the load side of the
RCD/MCB to the 16A single phase GPO in the field wiring cabinet. RCD capability exists to protect the end user.
Note: If a fault occurs, test accordingly before reinstating RCD/MCB.
WARNING:
Before shutting down the generator or performing any service, make sure the main circuit breaker is in the “OFF” position and locked.
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3.4.3 MRS15 Controller
OPERATOR & MAINTENANCE MANUAL
GEN-SET CONTROL BUTTONS
P OSITION B UTTON D ESCRIPTION
1
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
2 stop sequence of the gen-set. Repeated pressing or holding the button for more than 2s will cancel current phase of stop sequence (like ramping the power down or cooling) and next phase will continue.
3
4
FAULT RESET button. Use this button to acknowledge alarms and deactivate the horn output. Inactive alarms will disappear immediately and status of active alarms will be changed to "confirmed" so they will disappear as soon as their reasons dismiss.
HORN RESET button. Use this button to deactivate the horn output without acknowledging the alarms.
5
MODE LEFT button. Use this button to change the mode. The button works only if the main screen with the indicator of currently selected mode is displayed.
NOTE:
This button will not work if the controller mode is forced by one of binary inputs Remote OFF, Remote MAN, Remote AUT.
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OPERATOR & MAINTENANCE MANUAL
6
MODE RIGHT button. Use this button to change the mode. The button works only if the main screen with the indicator of currently selected mode is displayed.
NOTE:
This button will not work if the controller mode is forced by one of binary inputs Remote OFF, Remote MAN, Remote AUT.
GEN-SET OPERATION INDICATORS
P OSITION I NDICATOR D ESCRIPTION
Gen-set failure . Red LED starts flashing when gen-set failure occurs. After FAULT
7
RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active).
8
Gen-set voltage OK within limits.
. Green LED is on if the generator voltage is present and
NOTE:
The limits for the generator voltage and frequency are given by setpoints in the
Generator Protect group.
DISPLAY AND CONTROL BUTTONS
P OSITION B UTTON D ESCRIPTION
12
13
9
10
11
Graphic B/W display, 128x64 pixels
ENTER button. Use this button to finish editing a setpoint or moving right in the history page.
PAGE button. Use this button to switch over display pages. See Display
Screens and Pages Structure chapter below this table for more details.
UP button. Use this button to move up or increase a value.
DOWN button. Use this button to move down or decrease a value.
The displayed information is structured into "pages" and "screens". Use the PAGE button to scroll through the pages.
1. The Measurement pages consist of screens which display the measured values, ie. voltages, current, oil pressure etc. The calculated, values i.e. gen-set power, statistical data & alarm list are displayed on the last screen.
2. The Set Points pages contain all the set points categorized by their groups and also a separate page for entering the password.
3. The History Log pages display the history log in chronological order with the most recent record displayed first.
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OPERATOR & MAINTENANCE MANUAL
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OPERATOR & MAINTENANCE MANUAL
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OPERATOR & MAINTENANCE MANUAL
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OPERATOR & MAINTENANCE MANUAL
OFF MAN AUT TEST !
0 kW
Not ready
MainsFlt
PF 0.00
RPM 0
No Timer
0
Enter + Page
InteliLite NT ComAp
2007-2008
IL-NT-x.y
Serial:12345678
SW ver: x.y, x.y
Appl : MRS15
Branch: Standard
Page
Languages
>English
Chinese
Enter
Page
User interface:
User
>Engineer
Serial: 12345678
Pwd. dec.: 1234567890
Enter
Page
OFF
0 kW
Not ready
MainsFlt
PF
RPM 0
No Timer
0
Enter +
Enter
+
AUT
0 kW
Not ready
MainsFlt
PF
RPM 0
No Timer
0
0 kW
Not ready
Mains Flt
PF
RPM 0
No Timer
0
PAGE-27

3.4.4 Field Wiring Cabinet
OPERATOR & MAINTENANCE MANUAL
PAGE-28

OPERATOR & MAINTENANCE MANUAL
REF
NAME DESCRIPTION
A Emergency stop switch
B
C
GPO manual switch
GPO manual switch
D 50A 5-pin GPO
E 50A 5-pin GPO
F
G
GPO manual switch
GPO manual switch
H 20A 3-pin GPO
I One grid base
J 63A GPO
K 20A 5-pin GPO
L 15A 3-pin GPO
Lockable
Lockable
Three Phase
Three Phase
Lockable
Lockable
Single Phase
Remote start terminal
Three Phase
Single Phase
M 15A 3-pin GPO Single Phase
N 10A Male 3 flat pin mains inlet Single Phase
1.
Emergency Stop Switch
The generator is equipped with two red emergency stop switches. One switch (A) 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.
2.
GPO Manual Switch
The lockable GPO Manual Switch (B,C,F&G) are used to isolate the respective
GPO
3.
General Purpose Outlet (GPO) (Manually switched 50A 5pin, three-phase)
The generator is equipped with two 415V three-phase GPO (D&E) rated at
50A. The GPO connects through the main line circuit breaker. It is also protected by its own RCD & circuit breaker 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 (H) rated at
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OPERATOR & MAINTENANCE MANUAL
20A. The GPO connects through the main line circuit breaker. It is protected by its own RCD/MCB combo breaker located in the control cabinet.
5.
Remote Start Terminal
The remote start terminal is located in the one-grid base box (I) .The user can start the generator by connect it to a start switch.
6.
General Purpose Outlet (GPO) (Manually switched 63A 5pin, three-phase)
The generator is equipped with one 415V three-phase GPO (J) rated at
63A. The GPO connects through the main line circuit breaker. It is also protected by its own RCD & circuit breaker located in the control cabinet.
7.
General Purpose Outlet (GPO) (Manually switched 20A 5pin, three-phase)
The generator is equipped with one 415V three-phase GPO (K) rated at 20A.
The GPO connects through the main line circuit breaker. It is protected by its own RCD & circuit breaker located in the control cabinet.
8.
General Purpose Outlets (GPO) (15A, single-phase)
The generator is equipped with two Auto switched 240V single-phase GPOs
(L) & (M) rated at 15A. Both are connected through the main line circuit breaker. Each GPO is protected by it’s own RCD/MCB combo breakers located in the control cabinet.
9.
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, (N) rated at 10A. It connects to the battery charger through an RCD/MCB combo breaker, which is located in the control box.
Note: The cabinet emergency stop has a protective cover, which has to be lifted to be activated.
WARNING:
ONLY press emergency stop button in the case of an actual emergency.
Note: Stopping the generator under load may cause mechanical damage!
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OPERATOR & MAINTENANCE MANUAL
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. Use these instructions as a general guide only, the complete installation must comply with all local, state, and federal building codes, fire ordinances, and any other applicable regulations.
Because noise eafects the surrounding environment, it is important to consider noise factors when installing a generator. The generator has been acoustically treated, but if more stringent local environmental specifications require additional noise attenuation, please consider adding noise barriers or the construction of special rooms, etc.
Consider the following when selecting acoustic material:
 Foam is not recommended as an acoustic material, because of it’s low density it is a poor acoustic insulator. And not all foams are fire retardant.
 A concrete block enclosure is an excellent barrier in regards to noise reduction. The blocks may be filled with sand to make the wall denser. However, concrete housing tends to become hot and supplementary cooling methods will be required for correct engine performance.
Each country has its own rules and regulations controlling the design of buildings to prevent fires. Fire departments are reliable sources of information to determine installation compliance. The installation of generators, must comply with the provisions of the local fire department. Fire protection systems must be consistent with the requirements of the relevant authorities.
1.
The genset room cannot be used for storage.
2.
Because of the fuel used the genset room must be consdered as a key target area for fire prevention.
3.
The generator must be treated as a high-temperature device, exhaust pipe temperatures can reach 500°C.
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OPERATOR & MAINTENANCE MANUAL
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:
The depth H of base is calculated as the basis:
H

D
K


G
W

L
( mm )
K: Safety factor, typically value is 2;
G: Genset weight;
D: Cement density, typically value is 2400;
W: Base width;
L: Base length;
The Figure below shows a typical foundation installation.
REF
4
5
6
7
8
1
2
3
DESCRIPTION
Floor slab
Sand or gravel
Foundation
Genset
Sealant material
Grout
Anchor nut
Foundation bolt
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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.
 Ensure that no vibration is transmitted to the building foundation when the unit starts.
 Ease of maintenance and servicability operations.
 When calculating the length L and width B of the base allow an additional
100-300mm on each side.
 The base should be higher than engine room floor by 20-300mm.
Incorrect installation or service can result in severe personal injury or death, and/or equipment damage. Only qualified service personnel should be allowed to perform electrical and mechanical component installation.
Mounting the Generator
The generator is mounted on a steel-base tank that provides adequate 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.
Mount the generator on a substantial and level base such as a concrete pad. Use 20mm anchored mounting bolts to secure the vibration isolators to the base tank using flat or bevel washers and a hexagonal nut for each bolt. The isolators should be located as shown on the generator outline drawing.
Never install the genset near combustible materials. Locate the genset such that combustible material can not accumulate under the machine. The possibility exists of fire or explosion, causing damage to the equipment and or severe bodily harm or even death!
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OPERATOR & MAINTENANCE MANUAL
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.
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.
The canopy is designed to provide cooling and ventilation for the generator. Several factors should be carefully considered when selecting a location for installation.
 For effective cooling and maintenance, the generator should be mounted on a hard, flat, non-combustible, level surface. A concrete pad is ideal and provides a secure installation.
 The installation area should be well ventilated.
 Drainage must be adequate to ensure the concrete pad is free from standing water.
 Installation should prevent build-up of leaves, grass, sand, snow etc.
 Serviceable access should be provided to allow the opening or removal of access panels/doors for service and maintenance.
 Keep the generator at least one metre away from buildings and other structures.
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OPERATOR & MAINTENANCE MANUAL
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OPERATOR & MAINTENANCE MANUAL
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).
 On the generator end of the engine, allow a space equal to the length of the generator.
 The generator installation must comply with all of the current relevant standards and local authority requirements.
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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.
Note
The generator can be used at temperatures between -15 to 50°C, An ambient temperature that is outside these temperatures will cause damage to the equipment, when the temperature is too low, the metal will become very weak; when the temperature is too high, the engine temperature may rise to a point where damage is caused to the engine and other components such as piston rings. In order to protect the engine, when the ambient temperature is around 50°C, or close to -15°C, the equipment load must be reduced or engine life may be compromised.
After considering all applicable codes and laws and finding a suitable location for the generator set, the installer should consider the mechanical connections that will be necessary to make during installation. The four (4) systems that could require mechanical connections are the following:
 Fuel system
 Lubrication system
 Exhaust system
 Ventilation and cooling system
4.7.1 Fuel system
The fuel system feeds fuel from the fuel tank to the combustion chamber. It’s an important part of engine.
The general fuel system of diesel engine is shown in the diagram below:
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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 the injection pipe. Fuel is then sprayed through the nozzle into the combustion chamber. The fuel discharged after lubricating and cooling the injection nozzle is returned to the fuel tank through the over-flow pipe.
Base Tank
Base mounted fuel tanks are used to store fuel directly underneath the Genset, eliminating the need for a remote main fuel supply tank and/or auxiliary fuel transfer pumps. This mounting arrangement offers the convenience of having a fuel supply tank mounted at the generator. These tanks are designed to be contained in a rectangular base on which the engine-generator set is mounted. Generally, these tanks only increase the height of the generator set since the tank base is usually matched to the generator skid dimension.
Remote tank
Remote tanks are used when the engine fuel pump does not have the capacity to draw the fuel from the base tank; or the base tank is overhead and presents problems of high fuel head pressure for the system. In high ambient conditions, the day tank temperature might need to be considered. Warm fuel returning from the engine fuel injection pump should not be returned to the day tank if possible. As fuel temperature increases, fuel density and viscosity decrease, reducing maximum power output and lubrication of fuel handling parts such as pumps and injectors. This may be avoided by returning the fuel back to the supply tank rather than the day tank.
Engines need to maintain some of the oil pump pressure and return oil pressure when the engine is working. When using a remote fuel tank, the height difference between the pump
PAGE-40

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, fuel supply may become a concern.
Fuel Filter and Fuel/Water Separator
The fuel filter located between the tank and the injection pump prevents foreign matter from entering the injection pump. A standard filter uses a paper element (filtration diameter less than 15µ). Normally filter elements or cartridges must be changed every 400 hours. Air trapped in the filter is purged by the vent plug.
Fuel-water separator is a device designed to separate gross amounts of fuel and suspended solids from the wastewater effluents of fuel refineries, petrochemical plants, chemical plants, natural gas processing plants and other industrial sources.
Three-way valves
Valves used to switch between the base tank and a remote tank. Normally, the three-way valves are open to the base tank.
When a remote tank is used simply open both of the valves to allow connection to the remote tank. The figure shown below shows the three-way valves in the default location connected to the base tank.
4.7.2 Lubrication system
All moving parts of the engine must be lubricated to function correctly. For this purpose, the lubricating oil circulating through the engine has a number of functions. In addition to reducing friction, the oil cools the engine, controls expansion and dispersion of bearing areas, provides a sealing action, prevents rusting, seals out dust, and purifies products generated in the cylinders by incomplete combustion.
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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 must have a high viscosity index. Multi grade oils having relatively low viscosity (For example
SAE 10W-30) can provide superior lubrication at both low and high temperatures. Such oils are available commercially for all-season use.
Oil viscosity changes in cold temperature as crystallization of the wax element contained in oil proceeds, and fluidity is finally lost. Incorrect selection of oil cannot only increase resistance for cold starting but also affect lubrication of each part. Oils for low temperature, containing additives for lowering the pour point, should be used. The following diagram shows how to select lubricants.
：
The use of synthetic oil is not recommended.
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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. It is the responsibility of the generator owner or operator to maintain the entire exhaust system in good working condition.
Engine exhaust must be routed away from building intake vents, windows, doorways and other openings.
Because the exhaust discharge is in a vertical position it may be possible for raim water to enter the muffler. A drain valve has been provided at the base of the muffler to remove any unwanted water. This process must be completed whilst the engine is shut down, as it may cause injury.
4.7.4 Ventilation and cooling system
As the generator produces a high volume of heat, ventilation and heat dissipation must be carefully considered. The generator has been specially designed to operate in ambient temperatures to
50°C.
If the generator is used outdoors, ensure that no objects (such as plastic bags, etc.) are allowed to block the air inlet. The engine exhaust temperature is extremely high, do not vent towards any objects that cannot withstand high temperatures.
The machine is provided with cabinet filters that must be cleaned regularly. In dusty environments, the cabinet filters must be cleaned daily. Remove the cabinet filters as the follow steps: Loosen the philips head screw at the top of the grille, remove the limit stop, and then slide the air filter out.
If the generator is used indoors, make sure that there is adequate ventilation to the air inlets and outlets, and that the engine's exhaust is ducted out of room.
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OPERATOR & MAINTENANCE MANUAL
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.
If the cables are too long, there will be excessive voltage drop. It may result in fire, personal injury, reduced performance or damage to machinery.
4.8.2 Connecting Load Cable
The generator is ready for 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 only be carried out by a licensed electrician.
 Battery must be disconnected.
 The control power switch must be set to the “OFF” position.
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OPERATOR & MAINTENANCE MANUAL
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.
The battery cables should be disconnected when the generator is required to be transported or be stored for long periods. Reconnect the battery cables before running the machine.
Connect the red cable to the positive (+) terminal post.
Connect the black cable to the negative (-) terminal post.
WARNING:
Do not dispose of the battery in a fire. The battery may explode. Battery electrolyte solution is caustic and can cause severe burns and blindness. If electrolyte contacts skin or eyes, immediately flush the area with water and urgently seek medical attention.
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OPERATOR & MAINTENANCE MANUAL
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.
 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.
 Make correct terminal connections. TEST accordingly.
 Check that all electrical connections were made in compliance with local regulations and standards.
 Make sure the fan belt and hoses on the engine have no loose connections or are fraying. Tighten or replace as required.
 Check the battery cables are firmly secured to the terminals. Tighten the clamps if necessary.
 Close and secure side panel access doors.
 Review and follow safety instructions at the front of this manual.
Warning:
1.
Failure to follow the procedures listed in this manual may cause injury to personnel or damage to the generator. Ensure all persons setting up the generator are certified or fully trained on the installation of the generator.
2.
Always wear protective gloves, clothes and other P.P.E. as required.
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OPERATOR & MAINTENANCE MANUAL
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.
CAUTION:
 If the generator is not level when checking the engine oil, you cannot obtain an accurate oil level reading.
 Do not overfill the engine oil. The level cannot exceed the upper limit. An excessive amount of engine oil may damage the engine.
 Do not smoke and extinguish any naked flames before adding engine oil.
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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:
 Remove the coolant inlet cap.
 Remove the radiator cap.
 Fill coolant up to the radiator inlet top.
 Reinstall and tighten the coolant inlet and radiator caps.
WARNING:
Avoid injury! The coolant 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 it to cool. Do not remove cap unless the radiator and the engine are cool to touch with bare hands. Slowly loosen the cap to the first stop to release all pressure, then remove cap.
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OPERATOR & MAINTENANCE MANUAL
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 (21) , Circuit Breaker (14, 16, 17, 18, 19) , RCD/MCB
(25, 26, 27) , RCD (15, 22, 23, 24) , GPO Switch (20) to the “OFF” position.
3.
Open the side access door and turn on the engine battery switch, then close the door.
4.
Turn the Master Control Switch (6) to the “ON” position.
5.
Select manual mode.
6.
Press the START button, the fuel solenoid is energised and after a one-second delay the starter motor will crank the engine for the duration of the crank timer (preset on PLC, three attempts).
7.
After the engine successfully starts, allow allow approximately five minutes for the engine to warm.
8.
Turn the Main Circuit Breaker (21) " ON",turn the GPO Switch (20) , Circuit Breaker
(14, 16,17,18,19) , RCD/MCB (25, 26,27) , RCD (15, 22, 23, 24) " ON". This will allow power to all of the respective outlets (GPO’s & main terminals). The external load can now be switched on.
DANGER:
 Before turning the Main Circuit Breaker (21) to “ON”, make sure all load circuit breakers and switches are positioned to “OFF”. Failure to do so may cause an electric shock to the operator.
 Do not touch any wires or connections when the generator is running, this may result in serious injury or death.
 Follow steps 1 to 4 as described above (see 5.3).
 Select AUTO mode.
 Press the START button, the module will proceed with its normal auto start sequence.
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OPERATOR & MAINTENANCE MANUAL
 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.
 If the engine cannot run because of low fuel, bleed the air from the fuel system.
 Loosen air release bleed bolt on the fuel filter.
 Bleed the air in the fuel system for about 30 seconds.
 Tighten the bolt.
CAUTION:
1.
If a fault is detected, stop and isolate the machine immediately.
2.
Generator to be repaired by certified or fully trained personnel (refer to troubleshooting guidelines 6.7).
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OPERATOR & MAINTENANCE MANUAL
1.
Turn off every RCD/circuit breaker.
2.
Turn the Main Circuit Breaker (21), Circuit Breaker (14, 16, 21, 23), RCD/MCB
(17, 18, 19), RCD (20, 22) , to the “OFF” position.
3.
Press the Stop button.
4.
Allow the engine to remain idle for approximately one minute to cool down.
5.
Turn off the Master Control Switch (6).
6.
Open the side access door and turn off the battery isolator switch, then close the door.
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 (6) .
 Open the side access door and turn off the engine battery switch, then close the door.
The generator is equipped with an automatic shutdown feature. The LCD will display the fault.
Warning:
In the event of a shutdown alarm, turn off the engine. Generator must be repaired by certified or fully trained personnel according to the troubleshooting guidelines (see
6.7).
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OPERATOR & MAINTENANCE MANUAL
 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 has sufficient capacity to lift the unit safely. When lifting the generator, attach a hook or sling securely to the lifting lug.
 Transportation: When transporting the generator, it should be secured correctly with ropes tied to the roping lugs at the top of the generator.
When storing the generator overnight, make sure all access doors are closed and padlocked.
CAUTION:
 Do not store generator in a low lying area, as large quantities of water can enter the generators electrical / mechanical systems and damage may result .
If the generator will not be used for more than two months, the following procedures need to be performed.
 Close and padlock all access doors. Remove the start key.
 Avoid storing generator in a dusty, humid environment.
 Refer to and follow the engine manufacturer’s recommendations for long-term storage.
These procedures are designed to help minimize engine corrosion.
 Before performing any checks or maintenance, stop the engine and remove the start key.
 For detailed maintenance procedures on the engine, refer to engine operator's manual.
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OPERATOR & MAINTENANCE MANUAL
SERVICE ITEMS
Check various meters and alarm lamps
Check engine oil , fuel and coolant level
Check for leaks (oil, fuel and coolant)
●
●
●
Check air cleaner dust cap ●
DAILY
OR
AFTER
8 HRS
WEEKLY
OR
AFTER
50 HRS
MONTHLY
OR
AFTER
100 HRS
SIX
MONTHS
OR
AFTER
250 HRS
YEARLY
YEARS
OR
OR
AFTER
500
AFTER
1000
HRS
HRS
Check battery charging system
Check drive belt tension
Drain water/sediment from fuel filter
Drain water/sediment from fuel tank
Change engine oil and replace oil filter
Change fuel filter element
Clean or change air filter element
Check cooling system
Clean unit inside & outside
Change coolant
Pressure test cooling system
Clean inside fuel tank
●
●
 ●
●
●
●
Change
●
●
●
Change
●
●
●
●

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OPERATOR & MAINTENANCE MANUAL
 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.
6.3.1 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
 Loosen clips in the air cleaner and remove the dust cap.
 Remove the air filter element.
 Loosen the safety filter from the primary filter.
 Change the primary filter.
 Reinstall the air cleaner in the reverse order
Caution:
Do not remove the air cleaner while operating the generator or immediately after stopping the machine.
Do not start the engine after the air cleaner is removed. The backfire can cause serious burns.
Change the primary filter every 250 hours or as required; and the safety filter every
500 hours or as required.
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OPERATOR & MAINTENANCE MANUAL
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.
 Close the radiator cap and coolant inlet cap.
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 it to cool. Do not remove cap unless the radiator and the engine are cool to touch with bare hands. Slowly loosen the cap to the first stop to release all pressure, then remove cap.
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OPERATOR & MAINTENANCE MANUAL
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
 Drain engine oil completely, as described in 6.5.1.
 Loosen and remove the oil filter.
 Add engine oil into a new oil filter.
 Lubricate the new gasket with oil.
 Screw the new filter into place and tighten it until the gasket touches the seal surface. Tighten accordingly.
 Supply engine oil as described in 6.5.1.
WARNING:
1.
If the generator is not level when checking the engine oil, you cannot obtain accurate oil level.
2.
Do not overfill the engine oil. The level cannot exceed the upper limit because the excessive amount of engine oil may damage the engine.
3.
Do not smoke or be near an open flame when adding engine oil.
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OPERATOR & MAINTENANCE MANUAL
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.
DANGER:
 Do not smoke while you are refuelling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refuelling.
Wear protective gloves, goggles and clothing when changing the fuel filter.
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OPERATOR & MAINTENANCE MANUAL
When performing any troubleshooting, follow the guidelines. If further clarification is required please contact our authorised service agent.
TROUBLE CAUSES SOLUTIONS
Low engine oil pressure
High coolant temperature
Low fuel level
Cannot turn the breaker to on
Controller not working
Voltage drops when connecting to the load
1.
Lubricant oil is insufficient 1.
Add lubricant oil
2.
Oil hose has leak
3.
Oil filter is clogged
4.
Wrong oil is used
2.
3.
4.
Tighten or change oil hose
Change oil filter
Change to correct oil
1.
Coolant is insufficient
2.
Coolant pipe has leak
1.
Add coolant
2.
Tighten or change coolant pipe
3.
Tighten the belt
4.
Clean radiator core
3.
Fan belt is loose
4.
Radiator core is clogged
5.
Water temp sensor is defective
6.
Engine thermostat is defective
1.
Fuel is insufficient
2.
Fuel hose has a leak
3.
Fuel tank has a leak
4.
Fuel filter is clogged
5.
6.
1.
Repair or change the sensor
Repair or change the thermostat
Add fuel
2.
Tighten or change fuel hose
3.
Repair or change fuel tank
4.
Drain water/sediment or change fuel filter
5.
Fuel level sensor is defective
1.
The main breaker position is located between on and off
2.
Short circuit on the load
5.
1.
2.
Repair or change the sensor
Turn off and on.
Replace breaker if faulty
2.
Check and repair the load circuit
1.
The controller cable is disconnected from the battery
2.
The battery power is insufficient
3.
The DV fuse is damaged
1.
to the battery
2.
3.
Connect the controller cable
Charge the battery with the utility power
Change the DV fuse
1.Loads total exceeds the rated current
1.Decrease the loads to meet the rated output
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OPERATOR & MAINTENANCE MANUAL
2.Loads sharing to each terminal is unbalanced
Engine cannot start
Trouble Causes
Starter motor cannot drive or speed is low
1.Battery switch is off
2.Battery output is low
3.Battery is deteriorated
4.Battery terminal is loose
1.
Fuel is insufficient
2.
Fuel hose has leak Starter motor drives, but engine cannot start
3.
Fuel filter is clogged
4.
Gauze filter is clogged
5.
Air is mixed in fuel line
2.Balance the loads sharing to each terminal
Solutions
1.Turn the switch to on
2.Charge the battery
3.Change the battery
4.Tighten the terminal
1.
Add fuel
2.
Tighten or change fuel hose
3.
Drain water/sediment or change fuel filter
4.
Clean or change gauze filter
5.
Bleed the air
1.
Fuel hose has a leak 1.
Tighten or change fuel hose
Engine starts but stalls at once
Muffler releases black smoke
2.
Fuel filter is clogged
3.
Gauze filter is clogged
2.
Drain water/sediment or
Change fuel filter
3.
Clean or change gauze filter
4.
Lubricant oil is insufficient 4.
Add lubricant oil
5.
Air is mixed in fuel line
6.
Air filter element is clogged
5.
Bleed the air
6.
Clean or change air filter element
1.
Wrong fuel is used
2.
Air filter element is clogged
1.
Change to correct fuel
2.
Clean or change air filter element
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OPERATOR & MAINTENANCE MANUAL
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