Nugen S10KS User manual

PROMAC. LEADING THE WAY.
OPERATOR & MAINTENANCE
MANUAL

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S10KS
GENERATINGSET
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OPERATOR&MAINTENANCEMANUAL
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EditionAA
Date5May,2011

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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........................................................................................21
3.5 Generator Wiring Diagram ....................................................................................31
4.Installation.........................................................................................................32
4.1. Noise consideration...............................................................................................32
4.2. Acoustic Material consideration ...........................................................................32
4.3 Fire protection........................................................................................................32
4.4 Mounting Arrangement..........................................................................................33
4.6 Indoor Installation..................................................................................................37
4.7 Mechanical Connections........................................................................................38
4.7.1Fuelsystem .................................................................................................38
4.7.2Lubricationsystem......................................................................................40
4.7.3Exhaustsystem ...........................................................................................42
4.7.4Ventilationandcoolingsystem...................................................................42
4.8 Load Connections ..................................................................................................43
4.8.1SizingLoadCables .......................................................................................43
4.8.2ConnectingLoadCable................................................................................43
4.9 Earth Connections..................................................................................................44
4.10 Battery Connections.............................................................................................44

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4.11 ATS Connections.................................................................................................45
5.Operation...........................................................................................................46
5.1 General Pre-check Before Starting ........................................................................46
5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting.............................47
5.2.1Engineoil.....................................................................................................47
5.2.2Fuel..............................................................................................................48
5.2.3Coolant........................................................................................................48
5.3 Manual Start-up .....................................................................................................49
5.4 Automatic Start-up.................................................................................................49
5.5 During Operation ...................................................................................................50
5.6 Stopping Generator Under Manual Operation Mode.............................................51
5.7 Stopping Generator Under Automatic Operation Mode........................................51
5.8 Shutting Down Genset...........................................................................................51
5.9 Lifting and Transportation.....................................................................................52
5.10 Overnight Storage................................................................................................52
5.11 Long-term Storage ...............................................................................................52
6.Maintenance......................................................................................................52
6.1 Periodic Maintenance Schedule.............................................................................53
6.2 New Machines .......................................................................................................54
6.3 Air Cleaner.............................................................................................................54
6.3.1CleanAirFilterElement ..............................................................................54
6.3.2ChangeAirFilterElement ...........................................................................54
6.4 Engine Coolant.......................................................................................................54
6.4 Engine Coolant.......................................................................................................55
6.5 Engine Oil and Oil Filter........................................................................................56
6.5.1ChangeEngineOil .......................................................................................56
6.5.2ChangeOilFilter..........................................................................................56
6.6 Fuel Filter...............................................................................................................57
6.6.1DrainWater/SedimentintheFuelFilter ..................................................57
6.6.2ChangeFuelFilter .......................................................................................57
6.7 Troubleshooting.....................................................................................................57

OPERATOR & MAINTENANCE MANUAL
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1.Foreword
ThankyouforpurchasingyournewNugensoundproofdieselgenerator.
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TheOperatorandMaintenanceManualmustbereadandunderstoodpriortooperatingthe
generator.
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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.
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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.
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Thismanualisnottobereproducedinanyformorbyanymeanswithouttheexpresswritten
approvalofPromacSalesPtyLtd.
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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.Use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.
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OPERATOR & MAINTENANCE MANUAL
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2.SafetyInformation
Thismanualcontainsimportantinstructionthatshouldbefollowedduringinstallationand
maintenanceofthegeneratorandbatteries
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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.
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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.
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Indicatespotentialpersonalinjuryhazards
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Indicatesahazardoussituationwhich,ifnotavoided,willresultin
seriousinjuryorevendeath
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Indicatesahazardoussituationwhich,ifnotavoided,couldresult
inseriousinjuryorevendeath
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Indicatesahazardoussituationwhich,ifnotavoided,couldresult
inminorormajorinjury
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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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.

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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
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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.

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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.
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TABLE1:SAFETYLABELS
LABELDESCRIPTION
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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the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.

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

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
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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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.

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
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
3.2GeneratorSpecifications
TABLE2:GENERATORSPECIFICATIONS
ITEMUNITDATA
ModelS10KS
RatedOutputkVA10.3
kW8.2
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66.2
ENGINESPECIFICATIONS
ModelKubota,D1105‐BG
NumberofCylinders 3
Boremm78
Strokemm78.4
EngineSpeed rpm1500
PrimePower kW8.0
StandbyPower kW8.8
CompressionRatio24:1
Displacement L1.123
CoolingSystemWater‐cooled
BatteryVoltageV12
TypeofOil20W‐50CF
TypeofFuelNo.2‐D(ASTMD975)
FuelTankCapacityL186
ALTERNATORSPECIFICATIONS
ModelLeroySomerLSA40VS2/1P
ExciterBrushless
ExcitationSystemAREP
InsulationType
Class H
DIMENSION
Lengthmm2390
Widthmm1080
Heightmm1490
DryWeightkg950

OPERATOR & MAINTENANCE MANUAL
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
3.3GeneratorLayoutandMajorComponents





OPERATOR & MAINTENANCE MANUAL

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
TABLE3:CONTROLCABINET
REFNAMEDESCRIPTION
1Canopy Size:2130x1060x1070mm
2FireextinguisherbracketDesignedfor9kgABEfireextinguisher
3Fieldwiringcabinet
4Base Size:2390x1080x400mm
5Controlcabinetassembly
6SparkArrestor Rating:8m3/min
7Alternator LSA40VS2/1P
8Dieselengine KubotaD1105‐BG
9Radiator 50°C
10Muffler Rating:12m3/min


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

OPERATOR & MAINTENANCE MANUAL

PAGE‐15



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RCDTestPoint
12EarthBar
13NeutralBar
14AMF/IslandMode
SelectorSwitch
RefertoNote1
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.


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
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
3.4.2ControlPanel

