Kipor KDE16EA User manual

DIESEL
GENERATING SET
R
WUXI KIPOR POWER CO., LTD.
R
KDE16EA K DE16STA
KDE19EA K DE19STA
KDE16EA3 K DE16STA3
KDE19EA3 K DE19STA3
Single-phase:
Three-phase:

PREFACE
Thank you for purchasing a our generating set.
This manual covers the operation and maintenance of our generating
sets KDE16STA/KED19EA/KED19STA/ 3/KDE16STA3/
KED19EA3/KED19STA3 generating set. All information in this manual is based on
the latest product information available at the time of printing.
Read all labels and the owner's manual before operating this generator.
Operate only in well ventilated areas. Exhaust gas contains poisonous carbon
monoxide, and can be deadly. Always stop engine before refueling. Wait 5 minutes
before restarting.
Check for spilled fuel or leaks. Clean and/or repair before use.
Keep any sources of ignition away from engine.
KDE16EA/ KDE16EA
We reserves the right to make changes at any time without notice and without
incurring any obligation.
No part of this publication may be reproduced without written permission.
This manual should be considered an important part of the generating set, and
it must stay with the generating set if resold.
Check local laws and regulations before operating the generating set. If you
have any questions about compliance with local requirements governing
generating set use, consult a qualified electrician, electrical inspector, or licensed
contractor.
Read this manual careful. Pay special attention to these symbols and anyinst-
ruction that follow:
Failure to properly follow these precautions can result in
property damage, serious injury or DEATH!

If a problem should arise, or if you have any questions about your generating
set, consult our company or an authorized our agent.
Indicates a strong possibility of severe personal injury or
death if instructions are not followed.
Indicates that the equipment damage will result if the
instructgions are not followed.
Indicates that helpful information is provided.
To ensure the safety and durability, be sure to obey to this
manual. To ensure the safety of the operator and others, be
sure to correctly operate and carefully manage your
generating set.
Indicates that there is potential danger of severe personal
injury or death if carelessly operate or misuse the generat-ing
set. Be sure to read this manual before operation.
If a problem should arise, or if you have any questions about
your generating set, consult our company or an authorized
our agent.
[OPERATION NOTICE]
39

1. Safety Information
2. Parts Name and Control Unit
2.1 Generator fig
2.2 Control Panel
2.3 Breaker
2.4 Fuel Meter
2.5
2.6 AC Three-phase and Single-phase Output Terminals
3. Pre-running Check
3.1 Engine Oil
3.2 Fuel
3.3 Coolant
3.4 Fuel-water Separator
3.5 Battery
4. Start and shut off the engine
4.1 Break-in Period (initial 50 hours)
4.2 Start the Engine
4.3 Stop the Engine
The functions of the digital panel
1
2
2
3
4
4
5
6
7
8
9
11
12
13
14
14
14
16
CONTENTS
38
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

5. Handling the Generating Set
5.1 Connecting to a Building's Power Supply System
5.2 AC Application
5.3 Usage of the Receptacles and Terminals
6. Maintenance
6.1 Maintenance schedule
6.2 Replace Engine Oil
6.3 Service the Air Cleaner
6.4 Clean the Battery
6.5 Replace the Fuse
7. Transporting and Storage
7.1 Transporting
7.2 Storage
8. Troubleshooting
9. Technical Specifications and Data
10. Electrical wiring diagram
11. Appendix
17
17
18
22
23
23
24
25
26
27
28
28
29
30
31
33
37
37
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.
2
The application of the single-core insulating cable section mm
2
The application of the multi-core insulating cable section mm
1. The choice of the electric cable
Potential (v) = Current (A) 3
Length
Section area
1
58
50A
100A
200A
300A
Current
Length
beneath
75m 125m 200m150m50m 100m
8
22
60
100
14
30
60
100
38
60
125
200
22
38
60
100
22
50
80
125
30
50
100
150
50A
100A
200A
300A
Current
75m 125m 200m150m50m 100m
14
38
38 2
60 2
14
38
38 2
60 2
22
38
38 2
60 2
22
50
50 2
60 2
30
50
50 2
80 2
38
60
50 2
100 2
Length
beneath
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 cables of 2.5mm2
Caution:
!
1010
11. PPENDIX

1
Carbon monoxide hazards
Exhaust contains poisonous carbon monoxide, a colorless and odorless
gas.Inhaling exhaust can cause loss of consciousness and lead to death.
If you run the generating set in unventilated or confined place, the air you
breathe could contain a dangerous amount of exhaust gas. So, be sure to
keep the good ventilation to prevent the exhaust gas from building up.
Operator
Responsibility:
For the safety of the operator and others, be sure to operate the
generating set carefully.
Know how to stop the generating set quickly in case of emergency. Master
the usage and connection procedures of all generating set controllers,
output receptacles. Be sure that the operator must receive proper
instruction. The children or the pets are forbidden to close to the generator.
The operation including installation, running and maintenance should be
done by professional people who know well about the feature of generator.
Fire and burn hazards
The exhaust gets hot enough to ignite some materials. The gen-erating set
must be kept at least 1 meter away from buildings and other equipments.
Keep flammable materials away from the generating set. Be sure to service or
store the generating set in doors after the engine cooled.
The fuel is flammable and fuel vapor can explode. Refuel in a well-ventilated
place with the engine stopped. Keep the flames and sparks away, and do not
smoke in the area.
Fuel may spill and ignite if the generating set is tilted or overturned. Place the
generating set on a firm, level surface. Avoid loose sand or snow.
It is limited to use the generator in the high-hazard risk area.
Some parts of the explosive motor are very hot. Failure to operate could lead
to burn. Please note the warning stickers on the generator.
Operators should have self-protection awareness when operating generator,
please wear sound-proof ear shield, insulating boot and insulating gloves.
The key of door lock and electric door accessories for meter door and
maintenance door should be well kept by operators. Please lock the doors of
generator tightly to prevent somebody to operate (the children can not realize
the danger).
WARNING
WARNING
Electric shock hazards
The generating set will produce enough electric current to cause a serious
shock or electrocution if misused. Running the generating set in the wet
places such as rain, snow, swimming pool or sprinkler system, or when your
hands are wet, could result in electrocution. Do not connect to the building's
power system without installation of the isolation switch performed by a
qualified electrician.
WARNING
1. SAFETY INFORMATION
4. KDE16EA3, KDE19EA3Electrical wiring diagram of
36

Coolant drain outlet
2
2. PATS NAME AND CONTROL UNIT
2.1 Generator fig.
Cooling air outlet
Exhaust outlet
Lifting hook
Fuel filler cap
Emergent stop button
Operation panel
Grounding bolt
Connection pole
Fuel drain outlet
Engine oil drain outlet
Overflow pot
Engine oil drain bolt
Battery
Air filter
35
3. KDE16EA, KDE19EAElectrical wiring diagram of

3
2.2 Control panel
Fuel Meter Fuse Breaker
Smart Display Starter Switch
Starter switch
starter
starter
34
2. KDE16STA3, KDE19STA3Electrical wiring diagram of

4
Breaker can prevent the electric shock. If need to replace , please replace one
that has equal degree and performance.
Fuel
2.4 Fuel Meter
2.3 Circuit Breaker
Indicator Fuel meter
33
1. Electrical wiring diagram of KDE16STA, KDE19STA
1010
10. ELECTRICAL WIRING DIAGRAM

5
Knob function:
Screen Option: Switch the content of display, the content including: battery voltage,
running time, output frequency, output current, generator voltage.
Phase Sequence Switch: Switch the three-phase voltage and current.
Start/Back: Start the generator, press the knob for two minutes after the generator
started, the generator current specification will display automatically.
Stop/Clear: Stop the generator, it can stop the annunciator, trouble indicator light.
Indicator function:
Battery Voltage: Indicating battery voltage.
Running Time: Indicating generator total running time.
Frequency: Indicating generator frequency.
2.5 The functions of the digital panel
Voltage Current Frequency Running time Battery voltage
Generator running
Running trouble
Voltage Current Frequency Running time Battery voltage
Generator running
Running trouble
Code map list:
P-01 Low oil pressure
P-02 Underfrequency
P-03 Undervoltage
P-04 Generator overload
P-05 Start trouble
P-06 Emergency indicator
P-07 Charging trouble
P-08 Generator overheating
PRE-H Preheating indicator
START Start indicator
Code map list:
P-01 Low oil pressure
P-02 Underfrequency
P-03 Undervoltage
P-04 Generator overload
P-05 Start trouble
P-06 Emergency indicator
P-07 Charging trouble
P-08 Generator overheating
PRE-H Preheating indicator
START Start indicator
Screen option
Phase sequence
switching
Start/Back Stop/Clear
Screen option
Phase sequence
switching
Start/Back Stop/Clear
PVC Lable (Three-phase) PVC Lable (Single-phase)
32
Generating Set Model
Engine
Model
Type
Displacement(L)
BoreXStroke(mm)
Fuel
startomg system
lubricating system
Engine oil capacity(L)
Rated output (kW)
Rated frequency (Hz)
Rated voltage(V)
Rated current(A)
Max. output (kVA)
Phase
Power factor
Excitation method
Fuel tank capacity(L)
Structure
LxWxH(mm)
Net weight (kg)
Unit
Fuel consumption (g/kWh)
Generator unit
KM376AG KM376AG KM376AG KM376AG
Calibration power kw/r(r/min)
1.048
76X73
1.048
76X77
1.048
76X77
1.048
76X77
13.5/3000 15.5/3600 15.3/3000 17.5/3600 17.5/3600 17.5/3600 15.3/3000 15.3/3000
Light diesel oil
295 295 295 295
12V DC electric starter
Pressure and splashing
4.8
12
50
13
14
15.5KVA
13.5KVA
230/115
52.2/104.4
1714.4
19.0KVA 16.25KVA
60 60 60 6050 50 50
240/120
58.3/116.6
15 16.7 18.7
400/230
19.5
416/240
21.5
230/115
62.6/125
240/120
70.8/142
23.5 26.4
Single phase Three phase Single phase Three phase
1.0 0.9(Lag) 1.0
Self-excited stabilivolt (AVR)
38
Ultra silent generator
1210 800 855
400/230 416/240
300 300 320 320
0.9(Lag)
KDE16EA KDE16EA3
KDE19EA
KDE19EA3
15kVA 17kVA 18.75kVA
21kVA

6
Three-phase current: Indicating generator current.
Single phase power: Indicating generator power.
Generator voltage: Indicating generator voltage.
Generator running: Indicating the existence of electrical power.
Running trouble: Indicating running trouble, check it according to the code map list.
The indication lamp function of Code map list :
P-01 Low oil pressure: Indicating low oil pressure, the generator will self-braking.
P-02 Underfrequency: Indicating frequency higher (lower), the generator will self-
braking.
P-03 Undervoltage: Indicating voltage higher (lower), the generator will self-
braking.
P-04 Generator overload: indicate overload, the generator will self-braking.
P-05 Start trouble: Indicating failure start
P-06 Emergency indicator: Indicating stop generator according to emergency
measure.
P-07 Charging trouble: Charging system trouble.
P-08 Generator overheating: Water temperature of generator is overheated, the
engine will self-braking.
2.6 AC Three-phase and Single-phase Output Terminals
31
Specifications and technical of Ultra-silent generating set
the noise list indicates the noise emission level while not the safe working noise
level. Although the noise emission level is related to the sound exposure level, it is
not the judging standard for whether applying noise protection. Factors affect the
practical noise level include: the ambient condition and other noise source, such as
the quantity of working machine or the working hours in noisy condition. Furthermore,
the sound exposure level varies among different countries.
INSTRUCTION
!
Generating Set Model
Engine
Model
Type
Displacement(L)
BoreXStroke(mm)
Fuel
startomg system
lubricating system
Engine oil capacity(L)
Rated output (kW)
Rated frequency (Hz)
Rated voltage(V)
Rated current(A)
Max. output (kVA)
Phase
Power factor
Excitation method
Fuel tank capacity(L)
Structure
LxWxH(mm)
Net weight (kg)
Unit
Fuel consumption (g/kWh)
Generator unit
KDE16STA
KDE16STA3
KDE19STA KDE19STA3
KM376AG KM376AG KM376AG KM376AG
Calibration power kw/r(r/min)
1.047
76X77
1.047
76X77
1.047
76X77
1.047
76X77
15.3/3000 17.2/3600 15.3/3000 17.2/3600 17.5/3600 17.5/3900 15.3/3000 15.3/3000
Light diesel oil
320 320 320 320
12V DC electric starter
Pressure and splashing
5.2
12
50
13
14
15.5KVA
13.5KVA
230/115
52.2/104.4
1714.4
19.0KVA 16.25KVA
60 60 60 6050 50 50
240/120
58.3/116.6
15 15 17 16.7 18.7 18.7 21
400/230
19.5
416/240
21.5
230/115
62.6/125
240/120
70.8/142
23.5 26.4
Single phase Three phase Single phase Three phase
1.0 0.9(Lag) 1.0
Self-excited stabilivolt (AVR)
38
Ultra silent generator
1540X845X925
9. TECHNICAL SPECIFICATIONS AND DATA
400/230 416/240
420 420 442 442
0.9(Lag)

7
3. PRE-RUNNING CHECK
Maintenance door
30
Is the electric door lock on? Turn the electric door lock on?
8. TROUBLESHOOTING
ing.
agent.

8
3.1 Engine Oil
29
7.2 Storage
1. Clean each generating set component.
2.Check each part according to the maintenance schedule and repair/service the faulty
parts.
3. Replace the engine oil with fresh oil before operating the generating set after storage.
4.Fill the fuel tank with fresh diesel fuel.
5.Disconnect the battery ground cable from the terminal and tape it. While storing the
battery, fully charge teh battery once a month.
6.Cover the generating set and place it in a well ventilated and dry area. If the
generating set is still hot, wait until it cools down cover.
consult our authorized agent.

9
.
3.2 Fuel
28
7. TRANSPORTING AND STORAGE
7.1 Transporting
Handle
Handle
Lifting hook

10
The waste oil and water processing
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
law.
27
agent.
6.5 Replace the Fuse
Turn the key of electric door lock to OFF position and remove the key before
checking and replacing the fuses to prevent accidental short circuit.
20A
30A

11
Wait until the engine is cold, turn the radiator cap counterclockwise until stops.
Do not press down while turning the cap. After any remaining pressure has been
relieved, remove the cap by pressing down and again turning it counterclockwise.
Add enough coolant to fill the radiator, and reinstall the cap. Be sure to tighten it
securely. Fill the r up to the MAX mark with the engine cold.overflow pot
3. If there is no in the , check whether the cooling system has
leadage and service it if necessary. Be sure that there is coolant in the radiator
and the .
coolant overflow pot
overflow pot
3.3 Coolant
1. Open the maintenance
2. Check the level while the engine has the normal wording temperature. If
the level is approaching the "MIN" mark, refill to "MAX" mark.
door.
water
coolant
Filling coolant liquid outler
Radiator
26
6.4 Clean the Battery
Negative terninal (-)
Battery set plate
Battery

12
3.4 Fuel-water Separator
Drain water: there is water mixed in oil usually, the fuel-water separator can
separate the water, and settled the cup base. So need to change regularly. Loose
the drain water bolt, the water will drain form the rubber conduit and drain it up,
then tighten the bolt.
25
6.3 Service the Air Cleaner

13
3.5 Battery
The generator uses battery which dose not need maintenance and filling liquid.
Observe the status displays of battery:
Blue: the battery is in good condition
White: the electricity is not enough, need to charge.
Red: the electrolyte is not enough, need to change.
24
Oil drain bolt
6.2 Replace Engine Oil

14
2. Insert the key to electric door lock and turn to START position, the unit is
preheating and starting, then hands off , the key will back to ON position
automatically
3. Smart panel control can preheat automatically when start, the time can be set.
4. START AND SHUTOFF THE ENGINE
4.1 Break-in Period (initial 50 hours)
4.2 Start the Engine
OFF
ON
Breaker
23
The electric eye color of battery electric
6. MAINTENANCE
6.1 Maintenance schedule
our authorized agent unless the owner