Kipor KGE12E User manual

WUXI KIPOR POWER CO., LTD.
KGE12E
KGE12E3
GASOLINE
GENERATOR

PREFACE
Congratulation and 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.
CAUTION
1. Use SAE 10W-30 Lubrication oil. After the first oil change at 10
hours operation.
2. Do not connect the generator output to commercial AC outlets.
3. For information about the engine operation and maintenance,
please see our engine's manual.

1. NAMES OF IMPORTANT PARTS AND COMPONENTS
KGE12E Control Panel
Voltmeter
Fre. meter
Main switch
Ammeter Engine switch
Single phase receptacle (25A)
Hour counter
AC Output terminals
--
1. Names of Important Parts and Components
2. Preparatory Steps for Operation
3. Safety Precations for Servicing
4. Warm-up Procedure
5. Starting-up Procedure
6. Stop Procedure
7. Simplified Troubleshooting Guide
8. Malfunction and Countermeasures
9. Electrical Skeleton Diagram
10. APPENDIX
CONTENTS
1
4
5
6
7
7
8
9
10
12

Specification
50Hz
Rated output
Type
Cylinder Volume
No. of Cylinder
Starting System
Fuel Consumption
Fuel Tank Capacity
Noise Lever (7m/dB)
Net Dimensions
(with wheels)
length width height
MODEL
*230V
KGE12E
8.5kVA
9.5kVA
Single/Two line
1.0
KGE12E3
10.5kVA
11.5kVA
Three/Four line
0.8
*400V
2
KG690
910 600 620 mm
(910 785 710mm)
12.0kW/3000rpm, 14.0kW/3600rpm
688cc
2
370g /kWh
26L
72dB/50Hz, 78dB/60Hz
152(159) kg
Generator Engine
AC
OUTPUT Standby
Prime
Phase
Power Factor
Voltage
Excitation System
Pole
Drive System
Voltages Regulation
Self-excited
Directly coupled to engine
1.5%( Rated Speed)
MODEL
Net weight (with wheels)
Air-forced four-stroke OHV gasoline Engine
Electric (recoil)
Engine
Muffler Lift hook Cover
Engine switch
Ammeter
Main switch
Hour meter
Single-phase receptacle
Fre. meter
Voltmeter
Output terminals
-- --

2. PREPARATORY STEPS FOR OPERATION
1) Environmental Requirements
1-1) Outdoor use
A) Install your unit in a dry and dustless place.
B) Avoid the direct sunshine. Place your unit in shade.
C) Keep your unit on a lever ground so that the unit will not move by itself . For
safely, Fix the unit on the ground by pegging.
1-2) Indoor use
A) 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.
B) Keep the air inlet /outlet and the exhaust gas outlet 1.5m away from any
obstacle.
C) Use under 40 degrees temperature.
D) Install your unit on a level surface.
2) Preparation for the engine
A) Check level of fuel gasoline, Lubrication oil. Add any of those fluids if is below
the sufficient level specified in the Engine Owner's Manual.
B) Check all major bolts and nuts on the engine. Tighten any loose bolts and nuts.
3) Electrical connection with load
A) Make sure that the load does not exceed the power capacity of your unit.
Connect electrical connections properly.
3. SAFETY PRECATIONS FOR SERVICING
A). Only qualified persons should test, maintain., and repair this unit.
B). Always wear a face shield, rubber gloves and protective clothing
when working on the unit.
C). Do not touch the generator unit or any part of load with your bare
hands or wet hands
D). Keep hands, hair, loose clothing, and tools away from moving pars
such as fans, belts and rotors.
E). Do not breathe exhaust fumes.
D). Stop engine and let it cool off before checking or adding fuel.
G). Do not add fuel while smoking or unit is near any sparks or open
flames.
H). Observe correct polarity ( & ) on batteries.
I). Do not tip battery.
J). Use equipment of adequate capacity to lift and support unit and
components.
--
--

4. WARM-UP PROCEDURE
A) Check all fluids daily. (The unit is shipped without lubricating oil.)
B) Turn the fuel cock to ON position.
C) Set the main switch to OFF.
D) Pull out the Chock lever.
E) Turn the engine start key to START position.
F) Warm-up time is about 3-5 minutes.
5. STARTING-UP PROCEDURE
A) Return speed control level to left position.
B) Ensure voltmeter indicates normal.
C) Set the main switch to ON.
D) Observe the voltage is in the normal loaded range.
6. STOP PROCEDURE
A). Set the main switch to OFF.
B). Turn the engine start key to STOP position.
C). Close the fuel cock if the unit is in storage or transportation.
-- --

7. SIMPLIFIED TROUBLESHOOTING GUIDE
This guide is intended to give brief information for troubleshooting with
no testing or measuring instruments to check the unit.
However, testing and measuring instruments are required to diagnose
parts and components in many trouble cases.
If you cannot determine the cause by visual inspection, you should
consult your dealer whom you purchased this unit from.
-- --
8. MALFUNCTION AND COUNTERMEASURES
Complaint
1. Speed up engine until rated
voltage is reached.
2. Replace diode
3. Repair or replace
4. Repair or replace
5. Replace switch
6. Replace VAR
1. Speed up engine until rated
voltage is reached.
2. Relocate the unit as close
as possible to the load
3. Reduce the load to and below
the capacity limit of the unit.
Possible cause Remedy
No power or
Insufficient power
1. Engine speed too low
2. Rotor diode breakage
3. Rotor wiring breakage
4. Rotor wiring breakage
5. Main switch breakage
6. AVR failure
Ammeter doesn't function
Power is available
but falls upon
loading
Loading trips
off the main
switch instantly
Noise from bearing
Voltmeter doesn't function
1. Engine speed too low
2. Too long a line is used
between generator and
load
3. The load is too large.
1. Overloading
2. Fault on the load side
Ammeter failure
Bearing worn out
Voltmeter failure
1. Reduce the load
2. Check to locate the faulted
circuit, and repair it.
Replace Ammeter
Replace bearing
Replace Voltmeter

9. ELECTRICAL SKELETON DIAGRAM
KGE12E ELECTRICAL SKELETON DIAGRAM
-- --
KGE12E3 ELECTRICAL SKELETON DIAGRAM

--
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
Potential (v) = Current (A) 3
Length
Section area
1
58
50A
100A
200A
300A
Current
Length
beneath
75m 125 20015050m 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 125 20015050m 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
1. The choice of the electric cable
--
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
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
2. Modified coefficient table of ambient condition power
10. APPENDIX