Nugen Nugen S100PS User manual

PROMAC. LEADING THE WAY.
OPERATOR & MAINTENANCE
MANUAL

S100PS
GENERATING SET
OPERATOR & MAINTENANCE MANUAL
Edition B B
Date 2011-03-09

Table of Contents
1. Foreword.............................................................................................................. 1
2. Safety Information.............................................................................................. 2
2.1 General Safety Precautions......................................................................................3
2.2 Safety During Transportation ..................................................................................3
2.3 Safety During Installation & Initial Start-up ...........................................................4
2.4 Safety During Operation..........................................................................................4
2.5 Safety Around Diesel Engines.................................................................................5
2.6 Safety During Maintenance .....................................................................................5
2.7 Symbols and Their Meanings ..................................................................................6
3. Specifications and Parts Introduction ...........................................................10
3.1 Specifications.........................................................................................................10
3.1.1 Use ..............................................................................................................10
3.1.2 Main Specifications.....................................................................................10
3.1.3 Ambient Condition......................................................................................10
3.2 Generator Specifications........................................................................................11
3.3 Generator Layout and Main Components..............................................................12
3.4 Control Cabinet and Panel.....................................................................................14
3.4.1 Control Cabinet ...........................................................................................14
3.4.2 Control Panel...............................................................................................16
3.4.3 AMF25 Controller........................................................................................22
3.5 Generator Wiring Diagram ....................................................................................33
4. Installation .........................................................................................................33
4.1. Noise consideration...............................................................................................34
4.2. Acoustic Material consideration...........................................................................34
4.3 Fire protection........................................................................................................34
4.4 Mounting Arrangement..........................................................................................35
4.6 Indoor Installation..................................................................................................39
4.7 Mechanical Connections........................................................................................40
4.7.1 Fuel system .................................................................................................40
4.7.2 Lubrication system......................................................................................42
4.7.3 Exhaust system ...........................................................................................44
4.7.4 Ventilation and cooling system...................................................................44
4.8 Load Connections ..................................................................................................45
4.8.1 Sizing Load Cables .......................................................................................45
4.8.2 Connecting Load Cable................................................................................45
4.9 Earth Connections..................................................................................................46
4.10 Battery Connections.............................................................................................46

4.11 ATS Connections.................................................................................................47
5. Operation ...........................................................................................................48
5.1 General Pre-check Before Starting ........................................................................48
5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting.............................49
5.2.1 Engine oil.....................................................................................................49
5.2.2 Fuel..............................................................................................................50
5.2.3 Coolant........................................................................................................50
5.3 Manual Start-up .....................................................................................................51
5.4 Automatic Start-up.................................................................................................51
5.5 During Operation...................................................................................................52
5.6 Stopping Generator Under Manual Operation Mode.............................................53
5.7 Stopping Generator Under Automatic Operation Mode........................................53
5.8 Shutting Down Genset...........................................................................................53
5.9 Lifting and Transportation.....................................................................................54
5.10 Overnight Storage................................................................................................54
5.11 Long-term Storage ...............................................................................................54
6. Maintenance......................................................................................................54
6.1 Periodic Maintenance Schedule.............................................................................55
6.2 New Machines .......................................................................................................56
6.3 Air Cleaner.............................................................................................................56
6.3.1 Clean Air Filter Element ..............................................................................56
6.3.2 Change Air Filter Element ...........................................................................56
6.4 Engine Coolant.......................................................................................................56
6.4 Engine Coolant.......................................................................................................57
6.5 Engine Oil and Oil Filter........................................................................................58
6.5.1 Change Engine Oil .......................................................................................58
6.5.2 Change Oil Filter..........................................................................................58
6.6 Fuel Filter...............................................................................................................59
6.6.1 Drain Water / Sediment in the Fuel Filter ..................................................59
6.6.2 Change Fuel Filter .......................................................................................59
6.7 Troubleshooting.....................................................................................................59

OPERATOR & MAINTENANCE MANUAL
PAGE-1
1. Foreword
Thank you for purchasing your new Nugen soundproof diesel generator.
The Operator and Maintenance Manual must be read and understood prior to operating the
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 does not cover the diesel engine and alternator maintenance procedures. Please
consult the engine and the alternator operation and maintenance manuals if necessary.
This manual is not to be reproduced in any form or by any means without the express written
approval of Promac Sales Pty Ltd.
ENGINE EXHAUST can cause serious injury or even death!
Use only in open well ventilated areas or vent exhaust outside!
DISCLAIMER STATEMENT
Promac Sales Pty Ltd publishes the technical information in this manual as an aid to its
customers and to the public. The information included in this manual is based on sound
engineering principles, research, extensive field experience, and technical judgments.
This mater is subject to change in light of developments in technology and field
experience. U
se or adoption of the information contained in this manual is voluntary.
Promac Sales Pty Ltd reserves the right to change any portion of this information without
notice.

OPERATOR & MAINTENANCE MANUAL
PAGE-2
2. Safety Information
This manual contains important instruction that should be followed during installation and
maintenance of the generator and batteries
Before operating the machine, read the operator’s manual and become familiar with it and
the equipment. Safe and efficient operation can only be achieved if the equipment is
correctly operated and maintained. Many accidents are caused by failure to follow
fundamental rules and precautions.
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on
labels attached to the machine itself. It warns of the potential for personal injury. It is
essential that you carefully read the instructions and safety regulations before you attempt
to operate or maintain this machine.
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
PAGE-3
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 that the earth spike is connected to the earth point in front of the plant.
All service and maintenance personnel must be competent and adequately trained.
Always dispose of any rags used to clean up fuel or oil in appropriate bins.
Always disconnect the main battery before commencing maintenance operations.
Ensure that the appropriate Personal Protective Equipment (PPE) is worn while
working on generators.
Stay clear of any moving parts.
2.2 Safety During Transportation
Always shut the engine down before transporting.
Never transport the generator with any access doors open.
Ensure the 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 securely fixed.
When relocating the generator only lift from designated lift points.
Do not use the lifting points located over the engine, alternator or any other
components.
If the generator is damaged during transport, repairs should only be carried out by
an authorised service agent.
Unpacking must be carried out carefully, avoiding any damage to the goods –
particularly when using levers, saws or any other metallic tools.

OPERATOR & MAINTENANCE MANUAL
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2.3 Safety During Installation & Initial Start-up
All installation and repair procedures must be carried out by competent and
adequately trained personnel.
Installation of the generator must be in accordance with Clause 4.
Ensure all emergency procedures are adhered to.
Ensure that the appropriate PPE is worn while working on the generator.
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 part
of the electrical installation.
Take extreme caution to avoid risks of electrocution. Ensure that all earthing
installations have been fitted according to the Electrical Standards and all local
regulations.
Ensure all connections and wires are insulated. Do not leave any of the generator’s
electrical terminals 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 competent and adequately trained personnel are to access the operating area
of the generator.
Always wear ear protection when the generator is in operation.
Before operating the generator, make sure the earth spike is connected to the earth
point in front of the plant.
Before starting the engine, turn off any connected loads and set all circuit breakers

OPERATOR & MAINTENANCE MANUAL
PAGE-5
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 or any other 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 verified and corrected.
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 while 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.
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 while 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 competent and
adequately trained 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.

OPERATOR & MAINTENANCE MANUAL
PAGE-6
Do not remove the radiator cap while 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 is worn while working on the generator.
2.7 Symbols and Their Meanings
The following symbols are used on the product and throughout this manual.
TABLE 1: SAFETY LABELS
LABEL DESCRIPTION
1. Read the Operator 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. To prevent hearing loss, wear hearing protection.
2. Avoid spraying water into 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.

OPERATOR & MAINTENANCE MANUAL
PAGE-7
Warning
Always refuel with th
e engine stopped and in a
well-ventilated area. Do not smoke or allow open flames
or sparks in or near the area where refuelling is
performed or where fuel is stored.
Warning
Do not operate while transporting. Ensure panel latches
and caps are secure for transporting or relocating.
Warning
Read this label before lifting and transporting.
Only use designated lifting points on generator.
Warning
1. Disconnect the battery before servicing.
2. Read the Operator Manual for instructions.
Warning
Do not manipulate the generator with the switch on.
Warning
Engine exhaust can cause serious injury or even death.
Hot surfaces can burn skin.
Danger
High voltage.
Warning
Do not clean the alternator with water
Warning
High temperature.

OPERATOR & MAINTENANCE MANUAL
PAGE-8
Caution
Check the engine oil level before starting the engine.
Warning
High voltage
Note
1. Check the coolant level in the radiator
2. Check the coolant level in the overflow bottle
3. Check the engine oil level
Warning
Not a lifting point
Note
Lubrication oil inlet
Note
Fuel inlet
Note
Phase connection points.
Note
Earth connection points.
Note
Water inlet.

OPERATOR & MAINTENANCE MANUAL
PAGE-9
Note
Forklifting point
Note
Bottom drain bund
Diesel fuelling point
Coolant refill point and type of coolant
Main Isolator Switch
Off – On Switch
Circuit Breaker – Type & Size

OPERATOR & MAINTENANCE MANUAL
PAGE-10
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 services:
Continuous service – Used for the production of electrical energy for varied
purposes: motion force, lighting, heating, etc.
Emergency service –Used to rectify main supply interruptions or to face
consumption peaks.
3.1.2 Main Specifications
Reliable and powerful Perkins engine and Leroy Somer alternator.
Operation: Using the advanced Intelilite AMF 25 Controller, allows for simple
and convenient fingertip control through the front control panel or by PC
connection. The Intelilte AMF 25 Controller also monitors the engine and the
alternator displaying all warning alarms and performing automatic shutdowns on
fault signals.
50°C designed cooling system.
The engine and alternator have rubber av mounts installed to reduce vibration.
High anti-corrosion protection.
Easy maintenance: Wide doors are designed to allow easy access for
maintenance and cleaning.
Super quiet performance: Acoustic insulation installed inside all of the panels
and doors and an oversized muffler to minimise noise.
Engine and alternator can resist any direct impact stress.
Control cabinet can reach IP66 protection. Canopy can reach IP44 protection.
Double bunded fuel tank protection.
Leak proof base: All drain points are located on the inside.
Muffler with spark arrester.
3.1.3 Design Ambient Conditions
Installation: Outdoors and indoors in a well-ventilated area.
Temperature: -15°C to 50°C.
Relative humidity: Less than 80%.
Altitude: To a maximum of one thousand (1000) metres above sea level.

OPERATOR & MAINTENANCE MANUAL
PAGE-11
3.2 Generator Specifications
TABLE 2: GENERATOR SPECIFICATIONS
ITEM UNIT DATA
Model S100PS
Rated Output kVA 100
kW 80
Rated Voltage V 415 / 240
Power Factor 0.8
Rated Frequency Hz 50
Rated Speed rpm 1500
Phase / Wire 3-Phase / 5-Wire
Noise Level dB(A)@7m 68
ENGINE SPECIFICATIONS
Model Perkins (UK), 1104C-44TAG2
Number of Cylinders 4 vertical in-line
Bore mm 105 / 4.13
Stroke mm 127 / 4.99
Engine Speed rpm 1500
Prime Power kW 100
Standby Power kW 110
Compression Ratio 18.2:1
Displacement L 4.41
Cooling System Water-cooled
Battery Voltage V 12
Type of Oil 20W50-CF4 Upgrade
Type of Fuel 0# or –20# Light Diesel
Fuel Tank Capacity L 510
ALTERNATOR SPECIFICATIONS
Model Leroy Somer LSA42.2 L9
Exciter Brushless
Excitation System AREP
Insulation Type Class H
DIMENSION
Length mm 2830
Width mm 1060
Height mm 1890
Dry Weight kg 2080

OPERATOR & MAINTENANCE MANUAL
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3.3 Generator Layout and Major Components

OPERATOR & MAINTENANCE MANUAL
PAGE-13
TABLE 3: CONTROL CABINET
REF NAME DESCRIPTION
1 Canopy Size: 2630 x 1060 x 1490mm
2 Fire extinguisher bracket Designed for 9kg ABE fire extinguisher
3 Field wiring cabinet
4 Base Size: 2830 x 1060 x 400mm
5 Control cabinet assembly
6 Spark Arrestor Rating: 8m
3
/min
7 Alternator LSA42.2-L9
8 Diesel engine Perkins 1104C-44TAG2
9 Radiator 50°C
10 Muffler Rating: 12m
3
/min

OPERATOR & MAINTENANCE MANUAL
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3.4 Control Cabinet and Panel
3.4.1 Control Cabinet

OPERATOR & MAINTENANCE MANUAL
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TABLE 4: CONTROL CABINET
REF NAME DESCRIPTION
1 Terminals DC 12V
2 Relays DC 12V
3 Circuit Breaker 16A 1P
4 Circuit Breaker 32A 1P
5 Circuit Breaker 6A 1P
6 Relays DC 12V (start relay and fuel start relay)
7 Cable Duct
8 Battery Charger
9 DC Regulator Module
10 Terminals AC 240V
11 Earth Bar
12 Neutral Bar
13 AMF/Island Mode
Selector Switch
Refer to Note 1
14 Circuit Breaker 10A 3P
15 RCD/MCB Combo 10A 2P (Protects the battery charger)
16 Earth leakage relay Schneider Vigirex RH99P (Din mounted)
17 Double action RCD
bypass switch
Refer to Note 2
Note 1: With the switch in AMF mode, the controller will be in Automatic Mains Failure
function. With the switch in ISLAND mode, the generator can be remotely started by closing
the remote start terminals.
Both AMF and Remote Start require the Intelilite AMF 25 Controller to be in AUTO mode.
NOTE 2: The RCD bypass switch has a protective cap to prevent accidental operation. The
machines are delivered with the switch in the off position and the cap down. In this
configuration the adjustable earth leakage relay (16) will monitor any earth leakage current.
If a leakage current greater than the relay setting is detected the shunt trip will trip the Main
Circuit Breaker. When the RCD bypass switch is on and the cap is in the up position, the earth
leakage relay will be bypassed.
This operation must only be carried out by a licensed electrician.

OPERATOR & MAINTENANCE MANUAL
PAGE-16
3.4.2 Control Panel