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

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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

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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.

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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.

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Warning
Read this label before lifting and transporting. Only
use designated lifting points on generator.
Warning
1. Disconnect battery before servicing.
2. Read the Operator’s Manual for instructions.
Warning
Do not manipulate the generator with the switch on.
Warning
Do not clean the alternator with water.
Warning
High temperature.
Caution
Check the engine oil level before starting the engine.
Note
Water inlet.
Note
Fuel inlet.
Danger
High voltage.
Note
Phase connection points.
Note
Earth.

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3. Specifications and Parts Introduction
3.1 Specifications
3.1.1 Use
The generator can be used as a power supply for two main types of service.
①Continuous service: Used for the production of electrical energy for several purposes:
motion force, lighting, heating, etc.
②Emergency service: Used to rectify main supply interruptions or to face consumption
peaks.
3.1.2 Main Specifications
Reliable and powerful Perkins engine and Stamford alternator.
Operation: Uses the advanced control module-DEIF-PLC-1F, for convenience and
ease of operation via PC or front control panel. In addition, it will perform automatic
shutdowns on fault signals. Compatible with ATS systems.
55℃cooling system.
Engine and alternator has rubber mounts installed to reduce vibration.
High anti-corrosion performance.
Easy maintenance: Wide doors are designed to allow easy access for maintenance
and cleaning.
Super quiet performance: Oversized muffler and acoustic insulation installed inside all
panels and doors to minimize noise.
3.1.3 Ambient Condition
Installation: Indoors and outdoors in a well ventilated area.
Temperature: -15℃to 50℃
Humidity: Less than 80%
Altitude: Less than one thousand (1000) metres above sea level.
3.2 Generator Specifications
Item
Unit
Data
Generator
Model
S150PS
Rated Output
kVA
150
kW
120

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3.3 Appearance and Main Parts
Rated Voltage
V
415 / 240
Power Factor
%
80
Rated Frequency
Hz
50
Rated Speed
rpm
1500
Phase / Wire
3-Phase / 5-Wire
Noise Level
dB(A)@7m
69.7
Engine
Model
Perkins(UK), 1006TAG2
Number of Cylinders
6 vertical in-line
Bore
mm/in
100 / 3.94
Stroke
mm/in
127 / 5.0
Engine Speed
rpm
1500
Prime Power
kVA
150
Standby Power
kVA
165
Compression Ratio
17.0:1
Displacement
L
5.99
Cooling System
Water-cooled
Battery Voltage
V
12
Type of Oil
CF4 / SG15W-40
Type of Fuel
0#, ASTM2
Fuel Tank Capacity
L
570
Alternator
Model
Stamford, UCI274F
Exciter
Brushless
Excitation System
Self-exciting
Insulation Type
Class H
Dimension
Length
mm
3200
Width
mm
1060
Height
mm
1938
Dry Weight
kg
2262

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3.4 Control Cabinet and Panel
Control Cabinet
Control Panel
Ref.
Description
1
Control panel
2
ATS receptacle
3
Perspex
4
Hinge
5
Main wiring terminals
6
Earth wiring terminal
7
Three-phase main circuit breaker
Protecting wiring terminals(225A)
8
Door catch
9
Key switch
10
Control cabinet lamp switch
11
Charge indicator
12
Control cabinet lamp
a
Power OK indicator
b
Start engine push button
c
Stop engine push button
d
Running feedback present
e
U/F OK genset
f
Close genset circuit breaker
g
Open genset circuit breaker
h
Close main circuit breaker
i
Open main circuit breaker
j
Set ready to output
k
Manual mode selection
l
Auto mode selection
m
Lamp test
n
Activates the selected test in entered time
o
Charger AC failures
p
Low fuel level
q
Low oil pressures
r
High water temperature
s
Jumps from parameter settings to display
t
Enters value or acknowledges alarm
u
Resets horn relay
v
Normal display: Scrolls the display down.
Programming: Decreases set point
w
Normal display: Scrolls the display up
Programming: Increases set point
x
Flashing: Active, non-acknowledged
alarm(s) present
Steady: Active, acknowledged alarm(s)
present
y
LCD panel

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① Control Module
The generator controller PLC-1F (1) is a micro processor-based control unit
containing all necessary functions for protection and control of a diesel
engine. In addition, it contains a three-phase AC voltage measuring circuit.
The unit is equipped with a LCD screen presenting all values and alarms.
② Main Circuit Breaker
The three-phase main circuit breaker (2) is located below the control panel. If
the electrical current in the main circuit exceeds 225A, it will automatically
switch to the “OFF”position and interrupt power from the circuit breaker to the
main wiring terminals in the field wiring cabinet.
Warning:
Before shutting down the generator or performing any service, ensure the main
circuit breaker is in the “OFF”position.
③ Key Switch
Rotating the key switch (7) to the “ON”position, turns the control module on.
④ Control Cabinet Lamp & Switch
The lamp switch (8), once selected, will illuminate the lamp (10). Which
illuminates the PLC control panel.
⑤ Utility Power Charge Indicator
The indicator (9) will illuminate when the 12V main battery is being charged by
mains power. This is only applicable when the AMF/ATS (Automatic Mains
Failure/Automatic Transfer Switch) option applies.

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① Emergency Stop Switch
The generator is equipped with an emergency stop switch. The switch (E) is
located on the control cabinet. When activated, the emergency stop (switch
by pushing the red button in) will turn off the fuel solenoid, resulting in the
engine shutting down. Rotate button to reset emergency stop.
Warning:
ONLY press emergency stop button in the case of an actual emergency.
Note: Stopping the generator under load may cause mechanical damage!
② ATS Input Plug connector
The generator is equipped with an automatic transfer switch plug (F) which is
used for connecting the generator to the ATS. In the event of a supply
interruption connection of an optional ATS can automatically transfer the
mains supply to generator supply (and vice versa).
③ Main Wiring Terminals protected by circuit breaker.
Main wiring terminals (G) are provided for a licensed electrician to connect
field wiring to an outside load. All terminals are labelled.

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3.6 Generator Wiring Diagram

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4. Installation
4.1 External Installation
The generator should be installed in an area that is protected directly from harmful gases
liquids, dust, corrosive particles and vibration.
The weatherproof enclosure 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 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.
4.2 Internal Installation
① 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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② 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 will not compromise reliability from the
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.