Kipor KGE12E User manual

WUXI KIPOR POWER CO., LTD.
R
Single-phase:
KGE12E
KGE12EA
KGE13EA
GASOLINE
GENERATOR
Three-phase:
KGE12E3
KGE12EA3
KGE13EA3

Thank you for your purchase of our unit, our aim is to provide a high-quality
generator set to achieve customer satisfaction, and we are confident that your
choice will be justified.
This manual, dealing with the generator side of the unit, gives all the basic
information to ensure satisfactory and reliable operation of your unit.
Please use this manual as a companion to the other manual covering the engine
side.
1. This product is the gasoline generator set which is movable on the ground.
2. Please read the manual carefully before operation, to operate the generator
after fully understanding the contents of working, check and maintenance.
3. The explosive motor is adopted in the generator, so the parts of muffle, engine
and others are the high temperature parts, Failure to operate could lead to burn.
Please note the warning stickers on the generator.
4.Fuel and lube oil are inflammable which close to the fire, this may touch off fire
hazard or explosion. The extinguisher and first-aid kit should be set in the working
field.
1. Use SAE 10W-30, 15W-40 (above CD grade) lubrication oil. Please replace
the oil after the first 20 hrs operation. Afterwards, replace it each 50hrs.
2. Don't connect the generator to other power supplies. Such as main supply of
power company. In some special cases, please connect the stand-by power to
the electrical system by professional electrician who must know the difference
between public supply and generator circuit.
3. For information about the engine operation and maintenance, please see our
engine's manual.
4. Laymen especially the children can not realize the danger, they should keep
away from the generator.
5. Please wear suitable clothes and safety protective coverall.
This book is mainly about the universal instructions for the generator set, with the
continues improvement of our products, it may be slightly different from the actual
products, for this we will not announce again and we hope users would take
notice of that.
PREFACE
CAUTION
CAUTION

-25-
1
6
9
11
12
13
15
17
24
CONTENTS
1. Names of Main Parts and Components
2. Preparatory Steps for Operation
3. Start and Run the generator set
4. Stop Procedure
5. Lon-term Storage
6. Control panel Function
7. Periodic Maintenance and Service
8. Electric diagram
9. Appendix
The conditions of generator rated output:
Altitude: 0 m Ambient temperature: 25 Relative humidity: 30%
Ambient modified coefficient: C (Relative humidity 30%)
Note: When the relative humidity is 60%, the modified coefficient is C-0.01
When the relative humidity is 80%, the modified coefficient is C-0.02
When the relative humidity is 90%, the modified coefficient is C-0.03
When the relative humidity is 100%, the modified coefficient is C-0.04
Counting example:
When the rated power of generator is P =5KW, altitude is 1000m, ambient
N
temperature is 35 , relative humidity is 80%, the rated power of generator is:
P=P (C-0.02) = 5 (0.82-0.02) = 4KW
N
2. Modified coefficient table of ambient condition power
Ambient temperature ( )
Altitude
(m)
0
500
1000
2000
3000
4000
25
1
0.93
0.87
0.75
0.64
0.54
30
0.98
0.91
0.85
0.73
0.62
0.52
35
0.96
0.89
0.82
0.71
0.6
0.5
40
0.93
0.87
0.80
0.69
0.58
0.48
45
0.90
0.84
0.78
0.66
0.56
0.46
CAUTION
Electrical equipment (including electrical lines and plugs connection) could not
be defective. By the effect of mechanical stress, make sure to use the rubber
sheathed flexible cable or analog.
Limit length of electric line when using the extension line or distributed
network is: less than 60m for cables of 1.5mm2, and less than 100m for
2
cables of 2.5mm

-24-
1. Names of Main Parts and Components
1. Control panel
KGE12E control panel
KGE12E3 control panel
--
Starting Switch Timer Voltage Meter Breaker
Overload Protector
Single Receptacle Earthing
Starting Switch Timer Voltage Meter Breaker
Three-phase Receptace
Earthing
Single Receptacle
9. APPENDIX
Ambient temperature 25
1. The choice of the electric cable
The choice of the electric cable depends on the allowable current of the cable
and the distance between the load and the generator. And the cable section
should be big enough.
If the current in the cable is bigger than the allowable current, it will become over
hot and the cable will be burnt. If the cable is long and thin, the input voltage of
the electric appliance will be not enough, causing that the generator doesn't start.
In the following formula, you can calculate the value of the potential "e".
The relations among of the allowable current, and length, section of the Insulating
cable (single core, multi-core) are as follow:
(Presume that the use voltage is 220V and the potential is below 10V.
Potential (v) = Current (A) 3
Length
Section area
1
58
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
No. Copper
cables model
2
1.5mm
2
2.5mm
2
4mm
2
6mm
2
10mm
2
16mm
2
25mm
2
35mm
2
50mm
2
70mm
2
95mm
2
120mm
2
150mm
2
185mm
2
240mm
Voltage
Drop
mv/M
Single core
Current capacity
(25 )(A)
Voltage
Drop
mv/M
Three cores
Current capacity
(25 )(A)
Voltage
Drop
mv/M
Four cores
Current capacity
(25 )(A)
VV22
20
28
38
48
65
88
113
142
171
218
265
305
355
410
490
YJV22
25
35
50
60
85
110
157
192
232
294
355
410
478
550
660
30.86
18.9
11.76
7.86
4.67
2.95
1.87
1.35
1.01
0.71
0.52
0.43
0.36
0.3
0.25
VV22
13
18
24
32
45
61
85
105
124
160
201
235
275
323
381
YJV22
18
22
32
41
55
75
105
130
155
205
248
292
343
400
480
30.86
18.9
11.76
7.86
4.67
2.6
1.6
1.2
0.87
0.61
0.45
0.36
0.3
0.25
0.21
VV22
13
18
25
33
47
65
86
108
137
176
217
253
290
333
400
YJV22
13
30
32
42
56
80
108
130
165
220
265
310
360
415
495
VV22
20
28
38
48
65
88
113
142
171
218
265
305
355
410
490
Note: The variation of temperature and the laying of cables will influence the current capacity
of cables, the table above is just used for reference.

-23-
7. KGE12E3 ELECTRICAL WIRING DIAGRAM (Without Electric Governing)
-2-
KGE12EA/KGE13EA digital control panel
KGE12EA3/KGE13EA3 digital control panel
Control Panel Emergency Knob
Starting Switch Single Receptacle Overload Protector
Fuse Breaker
Control Panel Emergency Knob
Starting Switch Single Receptacle Overload Protector
Fuse Breaker

-22-
6. KGE12E3 ELECTRICAL WIRING DIAGRAM (Without Electric Governing)
(DOUBLE VOLTAGE OUTPUT)
-3-
2. Outline drawing of gen-set
Bracket Protecting Plate
Control Panel
Output Connection Box
Wheel

-2 -
5. KGE12EA3/13EA3 ELECTRICAL WIRING DIAGRAM
-4-
3. Main Technical Specification and Date
Model
HZ
kVA
kW
kVA
kW
V
A
r/min
COS
mm
ml
kW
L
V-kW
V-A
V-Ah
g/kW.h
dB(A)
L
h
mm
kg
KGE12E/EA KGE13EA
50
8.5
8.5
9.5
9.5
115/230
73.9/36.9
3000
12
60
9.5
9.5
10.5
10.5
120/240
79.2/39.6
3600
14
50
10
10
11
11
115/230
87/43.5
3000
12
60
11
11
12
12
120/240
91.7/45.8
3600
14
KT12
2
1.0
B
KG690
78 72
688
8.5:1
V type, two cylinder, 4-stroke, air-cooled, OHV
KT12
2
1.0
B
KG690
78 72
688
8.5:1
1.3
12V electric starter
12V 1.4KW
12V 8A
12V 36Ah
Automotive unleaded gasoline
370
77
25
5
910 600 620
E: 161 EA: 168
1.3
12V electric starter
12V 1.4KW
12V 8A
12V 36Ah
370
Digital panel
78
25
4.5
910 600 620
168
Open frame
E:General panel/EA Digital panel
Rated Frequency
Rated Power
Max. Power
Rated Voltage
Rated Current
Rated Rotation Speed
Alternator model
Pole
Phase
Excitation Mode
Power Factor
insulation grade
Engine Model
Cylinder Type
Bore × Stroke
Displacement
Compression Ratio
Rated Power
Ignition Model
Lubricating System
Lube Model
Lube capacity
Starting Mode
Starter Motor capacity
Battery Capacity x qty.
Fuel type
Fuel Consumption
Panel type
Noise Level 7m
Structure Mode
Fuel Tank Capacity
Overall Dimension
Dry Weight
Charging generator capacity
Continuous Running Time
Single Phase
Self excitation andconstant voltage (withAVR)
V type, two cylinder, 4-stroke, air-cooled, OHV
Inductance type (TCI)
Pressure splash combined type
Above CD grade or SAE 10W-30 15W-40
Unit Generator
Engine

-20-
4. KGE12E3 ELECTRICAL WIRING DIAGRAM (Without Electric Governing)
-5-
HZ
KVA
KW
KVA
KW
V
A
r/min
COS
mm
ml
KW
L
V-KW
V-A
V-Ah
g/KW.h
dB(A)
L
h
mm
kg
KGE12E3/EA3 KGE13EA3
50
9.5
7.6
10.5
8.4
400/230
13.7
3000
12
60
10.5
8.4
11.5
9.2
416/240
14.6
3600
14
50
12.5
10
13.8
11
400/230
18
3000
12
60
13.8
11
15
12
416/240
19.2
3600
14
KTS12
2
0.8 (lag)
B
KG690
78 72
688
8.5:1
V type, two cylinder, 4-stroke, air-cooled, OHV
KTS12
2
B
KG690
78 72
688
8.5:1
0.8 (lag)
1.3
12V electric starter
12V 1.4KW
12V 8A
12V 36Ah
Automotive unleaded gasoline
370
77
25
5
910 600 620
E3: 161 EA3: 168
1.3
12V electric starter
12V 1.4KW
12V 8A
12V 36Ah
370
Digital panel
78
25
4.5
910 600 620
168
E3:General panel EA3:Digital panel
Open frame
Rated Frequency
Rated Power
Max. Power
Rated Voltage
Rated Current
Rated Rotation Speed
Alternator model
Pole
Phase
Excitation Mode
Power Factor
insulation grade
Engine Model
Cylinder Type
Bore × Stroke
Displacement
Compression Ratio
Rated Power
Ignition Model
Lubricating System
Lube Model
Lube capacity
Starting Mode
Starter Motor capacity
Battery Capacity x qty.
Fuel type
Fuel Consumption
Panel type
Noise Level (7m)
Structure Mode
Fuel Tank Capacity
Overall Dimension
Dry Weight
Charging generator capacity
Continuous Running Time
Unit Generator
Engine
Model
Three-phase
Self excitation andconstant voltage (withAVR)
V type, two cylinder, 4-stroke, air-cooled, OHV
Inductance type (TCI)
Pressure splash combinedtype
Above CD gradeor SAE 10W-30 15W-40

--
3. KGE12EA/KGE13EA ELECTRICAL WIRING DIAGRAM
-6-
2. PREPARATORY STEPS FOR OPERATION
1. Environmental Requirements
1-1 Outdoors use
1) Install gasoline generator in a dry and dustless place.
2) Avoid the direct sunshine, place gasoline Generator in shade.
1-2 Indoor use
1) Use in well-ventilated areas, or vent exhaust outside and away from any
building air intakes. A large volume of air is required for the operation.
2) Keep the air inlet/outlet and the exhaust gas outlet 1.5m away from any
obstacle.
3) Use under 40 degrees temperature.
4) Install Generator on a lever surface.
2. Preparation for the engine
2-1 Initial start check
Check the each part of the generator before starting.
Keep away the fuel, matches, gunpowder, fuel wetting rags, hay and other
inflammable and explosive goods from the generator.
Make sure that nobody near the generator is warned, before starting the gasoline
generator.
Don't operate the generator set with wet hand or in rain, otherwise it will cause
serious electric shock accident.
Be care of these parts in the generator, such as rotary parts, hot parts, high-
voltage parts.
3. Initial start check
The rotary parts are dangerous!
The high-speed rotating parts are very dangerous when the generator is running.
Service the unit after its engine stops completely.
Check the following items for the initial start:
1) Check and refill oil
Please use the CD grade(above) or SAE 10W-30 15W-40 lubrication oil.
Fill the lubrication oil between the two scales, don't beyond the upper limit. If the
lube spurts from the vent hole, it may cause the engine fault.
DANGER
CAUTION

a. The engine must be at level state when filling lube.
b. Remove the filler cover (orange), refill the
recommendatory oil to the upper limit of the oil
scale.
c. Measure the oil mass with oil gauge. In
order to measure the accurate oil level, first
pull out the oil gauge, clean it and put it in,
then pull out and look at the oil mark, at the same time check if the lube is
contaminated.
d. Start and run the generator for 3-5minutes, then stop it and make sure.
2) Check and refill fuel
Open the fuel filler cover, check the fuel and refill if necessary. Fuel should be
unleaded gasoline.
Stop the generator set before filling fuel.
Do not smoke or allow flames when refilling fuel.
Be careful not to spill fuel when refueling. If any fuel is spilled, clean it with dry
cloth before starting generator.
3) Check the battery voltage
(1) Check battery
The battery of generator set adopts advanced technique without maintenance.
Observe the battery indicator light when check the battery.
Blue: the electricity is enough.
Red: the electricity is not enough, need to charge.
White: replace the battery.
The crankshaft speed is lower than normal when start the engine, it may cause
start failure. Then charge the battery, if can not start the generator, you should
replace the battery.
The electricity is not enough; please charge the battery in time.
Please check the battery voltage before start the generator which has not been
run for three months. Charge the battery with outer charger when the voltage
below 12V. If start at low voltage, the motor may be damaged or burnt out.
(2) Notice for charging battery:
Charge the battery in the well-ventilated place.
First remove the cathode(-) terminal wire, then remove the anode(+) terminal
wire. Connect battery anode then cathode (incorrect connection may produce
spark and ignite inflammable gas in the battery thus leading to explosion.)
--
2. KGE12E3 ELECTRICAL WIRING DIAGRAM
-7-
CAUTION

--
8. ELECTRIC WIRING DIAGRAM
-8-
Charge the battery in the well-ventilated place.
If charge the battery in the badly ventilated place, there is ignition or fire risk due
to inflammable gas.
If the battery is too hot(above 45 ), recharge after stopping for a while.
Stop charging quickly after the battery is fully charged.
If connect the battery anode and cathode against, the motor may be damaged.
4) Check the grounding protection
The generator frame and load frame should be installed grounding protection,
and make sure the grounding protection is ok.
5) Check fuel leakage
Inspect the wholly unit and check the fuel leakage. If fuel leak, check or contact
with your dealer for service.
6) Check the nuts and screws for looseness
Check the nuts and screws for looseness, if loose, tighten them. Specially check
the air filter, muffle and charging alternator.
Pay attention to the connection of the electric wire.
7) Clean the dirty and dusty in the unit
Check the inner of unit for dusty and dirty and clean it.
Check the muffle and the places near the engine for sundries and combustibles
<http://www.iciba.com/combustibles/> and clean them.
Check the intake and outtake for clog and clean it.
8) Load power connection
a) Make sure the generator is matched with load capacity, in order to connect the
power properly.
b) Connect output cable as per regulated wire diameter. c) The output cable as
short as better, the overlong cable will cause the voltage drop. So generator
should be closed to the loading center while installing.
1. KGE12E ELECTRICAL WIRING DIAGRAM

-- -9-
3. START AND RUN THE GENERATOR SET
1. According to the “Check before running”requirement, finish each check. Then
turn the fuel tank switch to “ON”.
2. Disconnect all the outer loads on the AC receptacle.
3. Turn the breaker to the “OFF”position, draw the chock handle, and turn off the
choke.
4. Turn the “starting switch”key to the “RUN”, the generator is in the standby
mode after the “digital control panel”display initial interface.
5. Turn the “starting switch”key to the “START”, loose the key after generator
started, and the key will return to “RUN”automatically. In the first time, if start fail,
restart it after 30seconds.
6. Run the generator set
Loose “starter switch”key after starting, push the throttle handle back to it's
position, then the generator will be in the automatic running state.
7. After making sure the generator voltage, frequency and other running state
meet the using require, close the main breaker, then it can supply output power to
load.
Preheat generator three minute without load after the set starting, then running
with load
The new generator set have a running-in period, the period is the initial 20
hours, only with 50% load during the running-in period, or it will shorten the set
life.
8. Checks during the running
1) Whether there is abnormal sound or vibration;
2) Whether the engine misfires or runs rough;
3) Check the color of the exhaust. (Is it black or too white?)
If you notice any of the above-mentioned phenomenon happened, stop the
engine and find out the fault cause or contact with our agents.
If the engine has been running, the muffler will be very hot. Be careful not to
touch the muffler.
CAUTION
CAUTION
2. Simple trouble judge and maintain
Immediately stop running generator for check and repair if any abnormality is
found. Restart after checking and maintain. Continue running abnormal generator
may cause unexpected serious accidents.
DANGER
Fault Reason Troubleshooting
Engine doesn t start
Starter motor
run, but not
start
Spark plug
Carburetor
Starter motor
doesn't start
Battery is low or no power
Battery unclamped or rut
Starting switch badness
Starter motor fault
No fuel
Fuel pipe walled up or flat
Air in the fuel pipe
Gap is not appropriate
carbon lay-down
Overflow
Walled up or damaged
throttle valve is abnormal
The battery and starter motor connection is disconnected.
Charge or replace
Repair or replace
Repair or replace
Repair or replace
Refill fuel
Clean or replace
Empty air
Regulate
Clean or replace
Regulate
Open and clean or replace
Check and regulate
Refill oil
Replace switch
Repair
Replace
Tighten
Repair
Replace
Drop to rated load
Contact with service
Check
Tighten
Replace
Open and clean
Replace
Clean or replace
Contact with dealer
Improve the rated speed
Install the terminal after cleaning or replace
Ignition system
is abnormal
Fuel system
is abnormal
Abnormal
noise
Overheat
Break
badness
Engine stops
because of low
oil pressure.
Higher Fuel
consumption
engine
Engine
deflagration
Cannot
reach
the rated
power
Oil is not enough
Oil pressure switch badness
Engine Abnormal voice
Bad bearing
Fasten bolt loose
Engine coverAbnormal voice
Check around
The lube is not appropriate
Overload
Bad breaker
Load circuit short
The tighten ordain bolt leakage
Carburetor damaged
Cylinder head gasket damaged
Air filter walled up
AVR badness
Low rotation speed
Cylinder head combustion chamber carbon laydown
Carburetor
Alternator
Move sundries from air outlet

--
7. PERIODIC MAINTENANCE AND SERVICE
Interval
Item
Each
time used
First used
or 20Hrs
Each three
months or
100Hrs
Each six
months or
500Hrs
Each
year or
1000Hrs
Check each two year, replace if the pipe is aged and transmutative.
First time
Replace
(2)
(2)
--
9. Load
Do not start 2 or more machines simultaneously. Start them one by
one.
Do not use floodlight together with other machines.
Open the breaker, observe the voltmeter on the control panel, the voltmeter
should point to 230V 5% (50Hz) for single-phase generating set; about 400V
(50Hz) for three-phase generating set, then the loading can be carried out.
Connect the equipment to the generating set in order. For the matter of the
motor load, firstly the heave-duty motor should be connected, and then the light-
duty motors. If the operation is false, the generating set will lag or stop suddenly.
It is necessary to unload the generating set immediately and turn off the main
switch and do checks.
Electrical equipment (including electrical lines and plugs connection) could not
be defective. By the effect of mechanical stress, make sure to use the rubber
sheathed flexible cable or analog (accord with IEC245-4).
Limit length of electric line when using the extension line or distributed network
is: less than 60m for cables of 1.5mm2, and less than 100m for cables of 2.5mm2.
CAUTION
CAUTION
Periodic maintenance and service are very important for keeping the engine in
good condition durable.
Stop the generator before performing any service. If the generator must be run,
make sure the area is well ventilated. The exhaust contains poisonous carbon
monoxide gas.
1. Periodic maintenance table
Oil
Battery
electrolyte
Air filter
Fuel filter cup
Spark plug
Valve clearance
Cylinder cover
Fuel tank
Fuel pipe
Check
Replace
Check
Refill
Check
Clean
Clean
Clean
regulate
Clean
regulate
Clean
Clean
Check
First: it is the first check time. After that, check according to the normal period.
The checking time is slightly different between the different engines, please refer
to the engine manual.
Note
1) It is necessary to shorten the maintenance interval when used in dirty areas..
2) This item maintained by Kipor agent.
3) Don't pour waste oil into the sewer or the river to prevent environment pollution.
The exhaust oil from generator must be stored in container. To deal with bad
matter, such as fuel, oil cooling water, solvent, filter and battery, according to the
local law.
Stop the engine before maintaining.
CAUTION

-- --
4. STOP PROCEDURE
First disconnect the unit and load, then stop the generator.
1. Normal stop
1) Cut off the load from the generator.
2) Turn the breaker to “OFF”position.
3) Turn the starter switch to “STOP”position after running for 1-3 minutes with
zero load.
4) Turn off the fuel switch after the generator stopped.
2. Emergence stop
a. When generator set is running, the operator should keep eyes on its running
state. If there is anything wrong, stop the generator according to the normal
procedure.
b. If there is any emergency which may cause serious damage to the generator
or person injuries, eg. short circuit, electric shock and so on. The operator should
immediately apply the emergency stop: pressing hard the “Emergency stop”
button could stop the generator at once. (Caution: there is no emergency stop on
the KGE12E/KGE12E3 generator, please turn the “Starting switch”to the “stop”
position.
c. When the problem has been solved after stopping the generator, you should
reset the “Emergency stop”button before restarting the machine, rotate the
“Emergency stop”in the arrow direction and the button will reset.
Reset the pressed “Emergency stop”, then the generator will run again. And
restart the generator according to the normal procedure.
Do not use “Emergency stop”when in non-emergency situations. If that,
“Emergency stop”may cause some damage to the generator.
CAUTION
CAUTION
CAUTION
Single phase Three-phase
3. Code indicator light function
P-01 Low oil pressure: indicating the generator oil pressure is too low, the
generator will auto-stop.
P-02 Over-frequency: indicating the frequency over-high or over-low, the
generator will auto-stop.
P-03 Over-voltage: indicating the voltage over-high or over-low, the generator will
auto-stop.
P-04 Generator set overload: indicating the generator overload, it will auto-stop.
P-05 Charging fault: indicating charging system fault.
START indicating generator set start
The control panel operation refer to the Simple-style Panel Manual.
CAUTION

--
5. LONG-TERM STORAGE
--
6. CONTROL PANEL FUNCTION
If store the generator sets for long periods, please store the gen-sets in the dry,
clean and ventilated places. Store as following:
1) Stop engine after engine been running for three minutes. Drain off oil
completely and refill the new oil during the engine is still hot.
2) In order to prevent condensation in the fuel tank, drain off fuel completely, and
remove the sediments.
3) Put lube on the supporting point and connection port of speed regulating
system.
4) Please clean mud, dust and oil remained on the machine surface. If there is
paint stripping place, then respray.
5) Disconnect cable of storage battery from (-) terminal. Please charge the
storage battery once per month to resolve intrinsic shelf depreciation during
machine storage.
6) Must finish periodic check prior to maintenance.
7) Please cover the unit with plastic housing, in order to prevent water or dust
into control box, radiator and muffle of exhaust pipe. And add safeguard for the
outdoor generator.
8) Store the machine in the place without moisture or dust and with good
ventilation.
9) After a long storage, refer to the “2 Pre-start preparations”before restart the
generator.
About the engine refer to the engine manual.
1. Button function
Setting of various electric parameters display in circle
1) When the generator set is out of trouble, press the “Function' button for one or
two seconds, and then the various electric parameters will be displayed in circle.
2) When the electric parameters display is cycling, press the “Function' button for
one or two seconds, the generator will quit this state.
Button functionsetting function
1) Press the “Function”button for five second when starting the generator, it
enters the parameter setting function.
2) Press the “Function”button to choose the setting you want among the four
kinds below:
(1) Phase setting
(2) Frequency setting
(3) Voltage setting
(4) Current setting
2. Indicator light function:
Battery voltage: indicating battery voltage.
Running time: indicating the total running time of generator.
Frequency: indicating the generator frequency.
Three-phase current: indicating the generator current.
Single-phase power: indicating the generator power.
Generator voltage: indicating generator voltage.
Generator set running: indicating: indicating whether the power exist.
Running fault: indicating the running fault of generator, and you can inquire fault
refer to code list.

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