Nugen Nugen S150PS User manual

PROMAC. LEADING THE WAY.
OPERATOR & MAINTENANCE
MANUAL

S150PS
GENERATING SET
OPERATOR & MAINTENANCE
MANUAL

Content Table
1. Foreword ............................................................................................................ 4
2. Safety Information .......................................................................................... 5
2.1 General Safety Precautions.......................................................................................6
2.2 Safety During Transportation....................................................................................6
2.3 Safety During Installation and Initial Start-up..........................................................6
2.4 Safety During Operation...........................................................................................7
2.5 Safety Around Diesel Engines ..................................................................................8
2.6 Safety During Maintenance ......................................................................................8
2.7 Safety Labels.............................................................................................................9
3. Specifications and Parts Introduction .....................................................11
3.1 Specifications..........................................................................................................11
3.1.1 Use ..................................................................................................................................11
3.1.2 Main Specifications......................................................................................................... 11
3.1.3 Ambient Condition.......................................................................................................... 11
3.2 Generator Specifications.........................................................................................11
3.3 Appearance and Main Parts ....................................................................................13
3.4 Control Cabinet and Panel......................................................................................14
3.5 Generator Wiring Diagram .....................................................................................17
4. Installation .......................................................................................................18
4.1 External Installation................................................................................................18
4.2 Internal Installation.................................................................................................18
4.3 Main Power with Automatic Mains Failure (optional)...........................................20
4.4 Load Connections ...................................................................................................20
4.4.1 Sizing Load Cables .........................................................................................................20
4.4.2 Connecting Load Cable...................................................................................................21
4.5 Earthing Connections..............................................................................................21
4.6 ATS Connections.....................................................................................................21
4.7 Battery Connections................................................................................................23
5. Operation .........................................................................................................23
5.1 General Pre-check before Starting..........................................................................23
5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting..............................24
5.2.1 Engine oil........................................................................................................................24
5.2.2 Fuel..................................................................................................................................25

5.2.3 Coolant............................................................................................................................25
5.3 Manual Start-up.......................................................................................................26
5.4 Automatic Start-up..................................................................................................27
5.5 During Operation ....................................................................................................27
5.6 Stopping Generator under Manual Operation Mode...............................................28
5.7 Stopping Generator under Automatic Operation Mode..........................................28
5.8 Protection................................................................................................................28
5.8.1 Displaying alarm signals.................................................................................................28
5.8.2 Warnings.........................................................................................................................29
5.9 Shutting Down the Generator .................................................................................30
5.10 Lifting and Transporting .......................................................................................31
5.11 Overnight Storage .................................................................................................31
5.12 Long-term Storage ................................................................................................31
6. Maintenance....................................................................................................32
6.1 Periodic Maintenance Schedule..............................................................................32
6.2 New Machines ........................................................................................................32
6.3 Air Cleaner..............................................................................................................33
6.3.1 Clean air filter element....................................................................................................33
6.3.2 Change air filter element.................................................................................................33
6.4 Engine Coolant........................................................................................................33
6.5 Engine Oil and Oil Filter.........................................................................................34
6.5.1 Change engine oil............................................................................................................34
6.5.2 Change oil filter...............................................................................................................34
6.6 Fuel Filter................................................................................................................35
6.6.1 Drain water / sediment in the fuel filter ..........................................................................35
6.6.2 Change fuel filter.............................................................................................................35
6.7 Troubleshooting ......................................................................................................36

OPERATOR & MAINTENANCE MANUAL
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1. Foreword
Thank you for purchasing your new Nugen sound proof diesel 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 must be read and understood prior to operating the generator.
This manual does not cover the diesel engine and alternator maintenance procedures.
Please consult the engine and alternator operation and maintenance manuals if necessary.
The information contained in this manual was based on the generator in production at the
time of publication. Promac Sales Pty Ltd reserves the right to change any portion of this
information without notice.
This manual is not to be reproduced in any form or by any means without the express written
approval of Promac Sales Pty Ltd.

OPERATOR & MAINTENANCE MANUAL
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2. Safety Information
Before operating the machine, carefully read and fully understand the following safety
regulations and check all local requirements. This will reduce the possibility of personal
injury, damage to the equipment, or improper service.
The operation, maintenance and repairs must only be carried out by authorized and
competent personnel.
The owner is responsible for maintaining the Nugen generator in good safe working
condition.
Carefully read the safety symbols attached to the generator and follow all instructions to
avoid possible injury or death.
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

OPERATOR & MAINTENANCE MANUAL
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2.1 General Safety Precautions
Check that all necessary or available guards are correctly fitted. DO NOT dismantle
or disable any safety devices.
Check the generator is securely mounted.
Check all mechanical connections are satisfactory.
Check all electrical connections are correct, safely insulated and suitably earthed.
Ensure the earth spike is connected to the earth point at the front of the plant.
All service and maintenance personnel must be adequately trained and competent.
Always dispose of any rags used to clean up fuel or oil in appropriate bins.
Always disconnect main battery before commencing maintenance operations.
Ensure that the appropriate PPE (personal protective equipment) is worn while working
on generators.
Stay clear of any moving parts.
2.2 Safety During Transportation
Always shutdown engine before transporting.
Never transport the generator with air intake doors open.
Ensure 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 safely fixed.
When relocating the generator only lift from the designated lift points.
Do not use lifting points located over the engine, alternator or any other components.
If the generator is damaged while transporting, repairs should only be carried out by an
authorized service agent.
Unpacking must be carried out carefully, avoiding any damage to the goods,
particularly when using levers, saws or any other metallic tools.
2.3 Safety During Installation and Initial Start-up
All installation and repair procedures must be carried out by adequately trained and
competent personnel.
Installation of the generator must be in accordance with clause 4.1 and 4.2.
Ensure all emergency procedures are adhered to.
Ensure that the appropriate PPE (personal protective equipment) is worn while working
on generator.

OPERATOR & MAINTENANCE MANUAL
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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 parts
of the electrical installation.
Take extreme caution to avoid risks of electrocution. Ensure that all earthing
installations have been fitted according to the regulations.
Ensure all connections and wires are insulated. Do not leave any terminals of the
generator 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.
2.4 Safety During Operation
Only adequately trained and competent personnel are to access the operating area of
the generator.
Always wear ear protection when the generator is in operation.
Before operating the generator, ensure that the earth spike is connected to the earth
point at the front of the plant.
Before starting the engine, turn off any connected loads and switch all circuit breakers
to the “OFF” position.
Do not operate the generator in any poorly ventilated areas.
Do not handle any wires or connections when the generator is operating.
Do not touch any rotating machinery.
Do not move the generator when it is operating.
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 during operation or close to any 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 corrected and verified.

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2.5 Safety Around Diesel Engines
Do not operate the engine when the air cleaner is removed. Engine backfire can
cause serious burns.
Do not remove the radiator cap whilst the engine is running. Allow the coolant to
sufficiently cool before removing the radiator cap. Coolant that is hot and under
pressure can 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 whilst 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.
2.6 Safety During Maintenance
All checks or maintenance of the generator must be carried out by adequately trained
and competent 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.
Do not remove the radiator cap whilst 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 (personal protective equipment) is worn whilst
working on the generator.

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2.7 Safety Labels
Label
Description
1. Read the Operator’s 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. Wear hearing protection to prevent hearing loss.
2. Avoid spraying water into the 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.
Warning
Always refuel with the engine stopped and in a well
ventilated area. Do not smoke or allow naked
flames or sparks in or near the area where
refuelling is performed or where fuel is stored.
Warning
Do not operate whilst transporting. Ensure panel
latches and caps are secure for transporting or
relocating.