Manual Operacao Amf25

OPERATOR & MAINTENANCE MANUAL
PROMAC. LEADING THE WAY.
S80PS GENERATING SET

Edition Date
BB 2011-06-07
Table of Contents
1. Foreword .................................................................................................. 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 ............................................................. 9

3.1 Specifications ........................................................................................................... 9 3.1.1 Use ................................................................................................................ 9 3.1.2 Main Specifications ..................................................................................... 10 3.1.3 Design Ambient Conditions ........................................................................ 10 3.2 Generator Specifications ........................................................................................ 11 3.3 Generator Layout and Major Components ............................................................ 13 3.4 Control Cabinet and Panel ..................................................................................... 15 3.4.1 Control Cabinet ........................................................................................... 15 3.4.2 Control Panel............................................................................................... 18 3.4.3 AMF 25 Controller ....................................................................................... 23 3.5 Generator Wiring Diagram .................................................................................... 34 4.1. Noise consideration ............................................................................................... 35 4.2. Acoustic Material consideration ........................................................................... 35 4.3 Fire protection ........................................................................................................ 35 4.4 Mounting Arrangement .......................................................................................... 36 4.6 Indoor Installation .................................................................................................. 40 4.7 MECHANICAL CONNECTIONS ........................................................................ 41 4.7.1 Fuel system ................................................................................................. 41 4.7.2 Lubrication system ...................................................................................... 43 4.7.3 Exhaust system ........................................................................................... 45 4.7.4 Ventilation and cooling system................................................................... 45 4.8 Load Connections .................................................................................................. 46 4.8.1 Sizing Load Cables ....................................................................................... 46 4.8.2 Connecting Load Cable................................................................................ 46 4.9 Earth Connections .................................................................................................. 47 4.10 Battery Connections ............................................................................................. 47 4.11 ATS Connections ................................................................................................. 48
5. Operation ........................................................................................................... 49
5.1 General Pre-check Before Starting ........................................................................ 49 5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting............................. 50 5.2.1 Engine oil ..................................................................................................... 50 5.2.2 Fuel .............................................................................................................. 51 5.2.3 Coolant ........................................................................................................ 51 5.3 Manual Start-up ..................................................................................................... 52 5.4 Automatic Start-up ................................................................................................. 52 5.5 During Operation ................................................................................................... 53 5.6 Stopping Generator Under Manual Operation Mode............................................. 54
5.7 Stopping Generator Under Automatic Operation Mode ........................................ 54 5.8 Shutting Down Genset ........................................................................................... 54 5.9 Lifting and Transportation ..................................................................................... 55 5.10 Overnight Storage ................................................................................................ 55 5.11 Long-term Storage ............................................................................................... 55
6. Maintenance ...................................................................................................... 55
6.1 Periodic Maintenance Schedule ............................................................................. 56 6.2 New Machines ....................................................................................................... 57 6.3 Air Cleaner ............................................................................................................. 57 6.3.1 Clean Air Filter Element .............................................................................. 57 6.3.2 Change Air Filter Element ........................................................................... 57 6.4 Engine Coolant....................................................................................................... 57 6.4 Engine Coolant....................................................................................................... 58 6.5 Engine Oil and Oil Filter........................................................................................ 59 6.5.1 Change Engine Oil ....................................................................................... 59 6.5.2 Change Oil Filter .......................................................................................... 59 6.6 Fuel Filter ............................................................................................................... 60 6.6.1 Drain Water / Sediment in the Fuel Filter .................................................. 60 6.6.2 Change Fuel Filter ....................................................................................... 60 6.7 Troubleshooting ..................................................................................................... 60 6.7 Troubleshooting ..................................................................................................... 61
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. 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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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 operators 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 industrys 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
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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 generators 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
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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.
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.
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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.
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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
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.
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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. 50C 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: -15C to 50C. Relative humidity: Less than 80%. Altitude: To a maximum of one thousand (1000) metres above sea level.
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3.2 Generator Specifications TABLE 2: GENERATOR SPECIFICATIONS

ITEM Model Rated Output Rated Voltage Power Factor Rated Frequency Rated Speed Phase / Wire Noise Level kVA kW V Hz rpm dB(A)@7m UNIT DATA S80PS 80 64 415 / 240 0.8 50 1500 3-Phase / 5-Wire 69.8
ENGINE SPECIFICATIONS
Model Number of Cylinders Bore Stroke Engine Speed Prime Power Standby Power Compression Ratio Displacement Cooling System Battery Voltage Type of Oil Type of Fuel Fuel Tank Capacity Perkins (UK), 1104C-44TAG1 4 vertical in-line 105 / 4.13 127 / 4.99 1500 80 88 18.2:1 4.4 Water-cooled 12 20W50-CF4 Upgrade 0# or 20# Light Diesel 510
mm mm rpm kW kW L V
ALTERNATOR SPECIFICATIONS
Model Exciter Excitation System Insulation Type Leroy Somer LSA43.2 L8 Brushless AREP Class H
DIMENSION
Length Width Height mm mm mm
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2830 1060 1890
Dry Weight
kg
1815
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3.3 Generator Layout and Major Components
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TABLE 3: CONTROL CABINET

REF 1 2 3 4 5 6 7 8 9 10 NAME Canopy Fire extinguisher bracket Field wiring cabinet Base Control cabinet assembly Spark Arrestor Alternator Diesel engine Radiator Muffler DESCRIPTION Size: 2630 x 1060 x 1490mm Designed for 9kg ABE fire extinguisher Size: 2830 x 1060 x 400mm Rating: 8m3/min LSA43.2 L8 Perkins 1104C-44TAG1 50C Rating: 12m3/min
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3.4 Control Cabinet and Panel

3.4.1 Control Cabinet
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TABLE 4: CONTROL CABINET

REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NAME Relays Circuit Breaker Circuit Breaker Circuit Breaker Relays Terminals Battery Charger DC Regulator Module Terminals RCD/MCB Combo Circuit Breaker AMF/Island Mode Selector Switch Double action RCD bypass switch Earth Bar Neutral Bar Neutral Bar Earth Bar MEN Bar Terminal Diode DESCRIPTION DC 12V 6A 1P 32A 1P 16A 1P DC 12V (start relay and fuel start relay) DC 12V
AC 240V 10A 2P (Protects the battery charger) 10A 3P Refer to Note 1 Refer to Note 2
Empty ZP5A
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. NOTE 3: The MEN connection terminals are provided to facilitate simple connection and disconnection of the MEN Link. The MEN Link (18) is connected on the alternator side of the toroids for the earth leakage protection. If the load side has another MEN Link connected, the generator side MEN Link must be disconnected. A spare terminal (9), is provided. The
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earth leakage relay must also be bypassed (in the control cabinet). This operation must only be done by a licensed electrician.
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3.4.2 Control Panel
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TABLE 5: CONTROL PANEL

REF NAME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Control Cabinet Lamp Switch Control Cabinet Lamp RCD Status Lamp RCD Status Lamp Globe Test Button Mains / ATS Battery Charging Lamp Mains / ATS Battery Charger Selector Switch Audible Alarm Master Control Switch Controller Earth leakage relay RCD Test Point Push Button Test Point Switch Circuit Breaker Circuit Breaker RCD Circuit Breaker GPO Switch Main Circuit Breaker RCD RCD/MCB Combo RCD/MCB Combo Door Lock DESCRIPTION
Intelilite AMF 25 Schneider Vigirex RH99P; Panel mounted 10A ,Test Point Mains connected, two pole RCD Test button 20A,Lockable 50A 3P,General purpose outlets 2A 2P, Test point 63A 4P,30mA 20A 3P,General purpose outlets 150A,Lockable 125A 3P 40A 4P, 30mA 20A 2P 16A 2P
1. Control Cabinet Lamp Switch The Control Cabinet lamp switch (1) is used to illuminate the control cabinet lamp (2). 2. Control cabinet lamp. The control cabinet lamp (2) is located above the controller.
3. RCD Status Lamp The RCD Status Lamp (3) indicates the status of the RCD. When the RCD Status
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Lamp is illuminated the earth leakage relay (ELR) is protecting the outlets and main field wiring terminals. If the RCD Status Lamp is not illuminated the ELR relay is bypassed. 4. RCD Status Lamp Globe Test Button The RCD Status Lamp Globe Test Button (4) is used to test the function of the globe of the RCD status lamp (3).
5. Main/ATS Battery Charging Indicator Lamp The indicator (5) will illuminate when the 12V main battery is being charged by either the mains inlet power or ATS power.
6. Mains/ATS Battery Charge Select Switch The switch (6) is used to select the source of the battery charging power, either Mains Inlet or ATS.
7. Audible Alarm IF the AMF controller senses a fault . The Audible Alarm (7) will sound.
8. Master Control Switch The switch (8) energises the control panel.
9. Controller (AMF 25) The generator controller AMF 25 (9) is a microprocessor-based control unit containing all of the necessary functions for the protection and control of the generator. It also monitors the three-phase AC voltage & current. The unit is equipped with a liquid crystal display, to present all values and alarms. 10. Earth Leakage Relay (ELR) The generator is equipped with an earth leakage relay (10). There are two different types of relays, the standard
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configuration is RH99P, which is panel mounted. The other is RH99M, din rail mounted, located in the control cabinet. 11. RCD Test Point The RCD Test Point (11) is used to test the earth leakage protection function. When an earth leakage greater than the adjustable ELRs setpoint occurs, the main circuit breaker (19) will shunt trip. 12. Mains RCD Test Pushbutton Depressing the Mains RCD Test Pushbutton (12) allows power to the RCD Test Point (11).
13.Test Point Switch The test point switch (13) is used to isolate the RCD Test Point (11)
14.Circuit Breaker (50A 3P) The three-phase circuit breaker (50A 3P) (14) is located on the control panel. When the electric current in the 5-pin socket circuit is above 50A, this breaker will turn to the OFF position automatically and interrupt power from the in the load side of RCD to the respective GPO in the field wiring cabinet. 15. RCD Test Point Circuit Breaker (2A,2P) The two pole RCD Test Point Circuit Breaker (15) is located on the control panel and protects the RCD Test Point (11).
16.Three Phase Earth leakage Residual Current Device (RCD) (63A,4P,30mA) The Three Phase Residual Current Device (16) is located on the control panel. When a residual current of greater value than 30mA is detected this device will automatically trip to the fault position. This will interrupt power from the load side of RCD to the respective GPO in the field wiring cabinet. Note: If a fault occurs, test accordingly before reinstating RCD.
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17. Three Pole Circuit Breaker Protecting 20A Three Phase Outlet The Three Phase Circuit Breaker (21) is located on the control panel. When the electric current in the three phase outlet circuit is above 20A, this breaker will automatically trip to the fault position. This will interrupt power from the the load side of RCD to the respective GPO in the field wiring cabinet. Note: If a fault occurs, test accordingly before reinstating circuit breaker
18. GPO Switch(150A) The GPO switch (18) is used to disconnect the power to all outlets.
19.Main Circuit Breaker (125A 3P) The lockable three-phase circuit breaker (125A 3P) (19) is located on the control panel. When the electric current exceeds 125A, it will automatically trip to the fault position and interrupt all power from the load side of the circuit breaker.When earth leakage fault occurs above 30mA, this breaker will turn to the OFF automatically and interrupt all power from the load side of breaker. Note: Generator will still supply power on the line side of breaker. 20.Three Phase Earth leakage Residual Current Device (RCD) (40A,4P,30mA) The Three Phase Residual Current Device (20) is located on the control panel. When a residual current of greater value than 30mA is detected this device will automatically trip to the fault position. This will interrupt power from the load side of RCD to the respective GPO in the field wiring cabinet. Note: If a fault occurs, test accordingly before reinstating RCD.
21. Single Phase RCD/MCB Combo Protecting 20A Single Phase Outlet The 20A Single Phase RCD/MCB Combo device (21) is located on the control panel. When the electric current is greater than 20A or a residual current of
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greater value than 30ma is detected, this device will automatically trip to the Fault position. This will interrupt power from the load side of the RCD/MCB to the 20A single phase GPO in the field wiring cabinet. RCD capability exists to protect the end user. Note: If a fault occurs, test accordingly before reinstating RCD/MCB.
22. Single Phase RCD/MCB Combo Protecting 16A Single Phase Outlet The 16A Single Phase RCD/MCB Combo device (22) is located on the control panel. When the electric current is greater than 20A or a residual current of greater value than 30ma is detected, this device will automatically trip to the Fault position. This will interrupt power from the load side of the RCD/MCB to the 16A single phase GPO in the field wiring cabinet. RCD capability exists to protect the end user. Note: If a fault occurs, test accordingly before reinstating RCD/MCB.
3.4.3 AMF 25 Controller
TABLE 5: PUSH BUTTONS

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REF
1
NAME
DESCRIPTION
START button. Works in MAN mode only. Press this button to initiate the start sequence of the engine. STOP button. Works in MAN mode only. Press this button
to initiate the stop sequence of the gen-set. Repeated pressing or holding the button for more than 2s will cancel the current phase of stop sequence (ramping the power down or cooling) and the next phase will continue. FAULT RESET button. Use this button to acknowledge
alarms and deactivate the horn output. Inactive alarms will disappear immediately and status of active alarms will be changed to "confirmed" this will allow the alarm to reset when the fault condition is alleviated.
HORN RESET button. Use this button to deactivate the horn output without acknowledging the alarms.
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MODE LEFT button. Use this button to change the mode. NOTE: 5 This button will not work if the controller mode is locked by one of the binary inputs: Remote OFF, Remote MAN, Remote AUT, Remote TEST. MODE RIGHT button. Use this button to change the mode. NOTE: 6 This button will not work if the controller mode is locked by one of the binary inputs: Remote OFF, Remote MAN, Remote AUT, Remote TEST. GCB button. Works in MAN mode only. Press this button to 7 open or close the GCB manually. NOTE: Certain conditions must be valid otherwise GCB closing is blocked. MCB button. Works in MAN mode only. Press this button to 8 open or close the MCB manually. CAUTION! Pressing this button can disconnect the load from the mains supply!
GEN-SET OPERATION INDICATORS

Gen-Set Failure. If a Gen-set failure fault is detected the Red LED will start 9 flashing. After pressing the Fault Reset button the LED will turn off if no alarm is active or will become constant if the alarm is still active. Gen-Set Voltage OK. If the generator voltage is within the preset limits the Green LED will be illuminated. NOTE: The limits for the generator voltage and frequency are given by set points in the Generator Protection Parameters. GCB ON. If the Generator Circuit Breaker (GCB) is closed the Green LED will be illuminated. It is driven by the GCB CLOSE/OPEN output (AMF 8/9) or by the GCB feedback signal (AMF 20/25). MCB ON. If the Mains Circuit Breaker (MCB) is closed the Green LED will be illuminated. It is driven by the MCB CLOSE/OPEN Output (AMF 8/9) or by MCB feedback signal (AMF 20/25). Mains Voltage OK. If a Mains Voltage is present and within limits the Green LED will be illuminated. Mains Failure. If a mains failure is detected the Red LED will start flashing. The 14 LED will be constantly illuminated after the gen-set has started and connected to the load.
10
11
12
13
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DISPLAY AND CONTROL BUTTONS

15 16 Graphic B/W display, 128 x 64 pixels PAGE button. Use this button to switch between display pages. See Display Screens and Pages Structure for more details. 17 UP button. Use this button to move up or increase a value.
18
DOWN button. Use this button to move down or decrease a value.
19
ENTER button. Use this button to finish editing a set point or moving right in the history page.
Display Screens and Pages Structure

The displayed information is structured into "pages" and "screens". Use the PAGE button to scroll through the pages. 1. The Measurement pages consist of screens which display the measured values, ie. voltages, current, oil pressure etc. The calculated, values i.e. gen-set power, statistical data & alarm list are displayed on the last screen. 2. The Set Points pages contain all the set points categorized by their groups and also a separate page for entering the password. 3. The History Log pages display the history log in chronological order with the most recent record displayed first.
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Alarms
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Browsing ECU Alarms
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3.4.5 Field Wiring Cabinet
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TABLE 7 OUTPUT TERMINAL ASSEMBLY

1. RE F
1 2 3 4 5 6 7 8 9
NAME
Emergency stop switch
DESCRIPTION
GPO manual switch

50A 5-pin GPO 20A 5-pin GPO 15A 3-pin GPO ATS connector Tie bar 20A 3-pin GPO 10A Male 3 flat pin mains inlet Single Phase Single Phase Three Phase Three Phase Single Phase
Emergency Stop Switch The generator is equipped with two red emergency stop switches. One switch (15) is located in the field wiring cabinet, the second is adjacent to the control cabinet. The two switches are wired in series. When activated, the emergency stop (activated by pushing the red button) will turn off the fuel solenoid, resulting in the engine shutting down. Rotate button to reset emergency stop. Note: The cabinet emergency stop has a protective cover, which has to be lifted to be activated.
WARNING: ONLY press emergency stop button in the case of an actual emergency. Note: Stopping the generator under load may cause mechanical damage! 2. GPO Manual Switch The lockable GPO Manual Switch is used to isolate the respective GPO. 3. General Purpose Outlet (GPO) (Manually switched 20A 5pin, three-phase) The generator is equipped with two 415V three-phase GPO (3) rated at 50A. The GPO connects through the main line circuit breaker. It is also protected by its own RCD & circuit breaker located in the control cabinet.
4.General Purpose Outlet (GPO) (Manually switched 20A 5pin, three-phase) The generator is equipped with one 240V three-phase GPO (4) rated at 20A. The GPO connects through the main line circuit breaker. It is protected by
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its own RCD/MCB combo breaker located in the control cabinet. 5.General Purpose Outlet (GPO) (15A, single-phase) The generator is equipped with two Auto switched 240V single-phase GPOs (5) rated at 15A. Both are connected through the main line circuit breaker. Each GPO is protected by its own RCD/MCB combo breakers located in the control cabinet.
6. ATS Connector The generator is equipped with an Automatic Transfer Switch (ATS) plug on the left side of the control panel. The customer can select an appropriate automatic transfer switch (ATS) and connect it to the generator
7.Tie Bar The Tie Bar is used to protect the wiring cables by tied them on it. 8.Safety Micro Switch The generator is equipped with one 240V single-phase GPO (8) rated at 20A. The GPO connects through the main line circuit breaker. It is protected by its own RCD/MCB combo breaker located in the control cabinet. 9.Mains Inlet for Battery Charging (10A male 3 flat pin, single phase) The generator is equipped with one 240V single phase 3 flat pin inlet, (14) rated at 10A. It connects to the battery charger through an RCD/MCB combo breaker, which is located in the control box. .
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3.5 Generator Wiring Diagram
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4. Installation
A diesel generator is a high-speed piece of rotating equipment. To ensure reliability and safety the installation must be given thorough attention. Before installing the unit, we must consider all environmental factors. Generator installation must comply with local building codes, fire regulations and environmental requirements. Use these instructions as a general guide only, the complete installation must comply with all local, state, and federal building codes, fire ordinances, and any other applicable regulations.
4.1. Noise consideration

Because noise eafects the surrounding environment, it is important to consider noise factors when installing a generator. The generator has been acoustically treated, but if more stringent local environmental specifications require additional noise attenuation, please consider adding noise barriers or the construction of special rooms, etc.
4.2. Acoustic Material consideration

Consider the following when selecting acoustic material: Foam is not recommended as an acoustic material, because of its low density it is a poor acoustic insulator. And not all foams are fire retardant. A concrete block enclosure is an excellent barrier in regards to noise reduction. The blocks may be filled with sand to make the wall denser. However, concrete housing tends to become hot and supplementary cooling methods will be required for correct engine performance.
4.3 Fire protection

Each country has its own rules and regulations controlling the design of buildings to prevent fires. Fire departments are reliable sources of information to determine installation compliance. The installation of generators, must comply with the provisions of the local fire department. Fire protection systems must be consistent with the requirements of the relevant authorities.
1. The genset room cannot be used for storage. 2. Because of the fuel used the genset room must be consdered as a key target area for fire prevention. 3. The generator must be treated as a high-temperature device, exhaust pipe temperatures can reach 500C.
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4.4 Mounting Arrangement

The base is used to support the unit and its accessories, its carrying capacity should be 2 to 5 times the total mass of the generator, but also able to absorb the unbalanced force generated by the machine. The generator is specially designed to minimize the vibration of the unit. If an installation requires greater noise and vibration attenuation, the generator should be installed in a manner that reduces the impact of vibration on buildings. The base height is calculated as follows: The depth H of base is calculated as the basis:
H= K G (mm) D W L
K: Safety factor, typically value is 2; G: Genset weight; D: Cement density, typically value is 2400; W: Base width; L: Base length; The Figure below shows a typical foundation installation.
TABLE 7 FOUNDATION
REF
1 2 3 4 5 6 7 8 Floor slab Sand or gravel Foundation Genset Sealant material Grout Anchor nut Foundation bolt
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DESCRIPTION
When designing the base, we need to pay specific attention to the following: The generator base must be isolated from the building foundation. Depth and width to meet the basic requirements. Foundation must be strong enough to take the impact and running force of the machine. Ensure that no vibration is transmitted to the building foundation when the unit starts. Ease of maintenance and servicability operations. When calculating the length L and width B of the base allow an additional 100-300mm on each side. The base should be higher than engine room floor by 20-300mm.
Incorrect installation or service can result in severe personal injury or death, and/or equipment damage. Only qualified service personnel should be allowed to perform electrical and mechanical component installation.
Mounting the Generator The generator is mounted on a steel-base tank that provides adequate support. Vibration isolators are recommended between the base tank and the foundation to provide stable operation and avoid installation damage. Bolting the generator directly to the floor or foundation can result in excessive noise and vibration, and possible damage to the generator and floor foundation. Mount the generator on a substantial and level base such as a concrete pad. Use 20mm anchored mounting bolts to secure the vibration isolators to the base tank using flat or bevel washers and a hexagonal nut for each bolt. The isolators should be located as shown on the generator outline drawing.
Never install the genset near combustible materials. Locate the genset such that combustible material can not accumulate under the machine. The possibility exists of fire or explosion, causing damage to the equipment and or severe bodily harm or even death!
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4.5 Outdoor Installation

Install the generator in an area that is free of debris, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust gases will not be discharged in the direction of nearby buildings. The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do so will result in deterioration of the insulation and will result in short circuits. Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.
Pay close attention to ventilation when operating the generator inside confined spaces and enclosed areas. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area. The canopy 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 the 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.
CAUTION:
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PAGE-39
4.6 Indoor Installation

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoor, the exhaust fumes must be vented to the outside. The engine should be installed at least 1000mm from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves. 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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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 it will not compromise reliability from any 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.
Note The generator can be used at temperatures between -15 to 50C, An ambient temperature that is outside these temperatures will cause damage to the equipment, when the temperature is too low, the metal will become very weak; when the temperature is too high, the engine temperature may rise to a point where damage is caused to the engine and other components such as piston rings. In order to protect the engine, when the ambient temperature is around 50C, or close to -15C, the equipment load must be reduced or engine life may be compromised.
4.7 MECHANICAL CONNECTIONS

After considering all applicable codes and laws and finding a suitable location for the generator set, the installer should consider the mechanical connections that will be necessary to make during installation. The four (4) systems that could require mechanical connections are the following: Fuel system Lubrication system Exhaust system Ventilation and cooling system 4.7.1 Fuel system The fuel system feeds fuel from the fuel tank to the combustion chamber. Its an important part of engine. The general fuel system of diesel engine is shown in the diagram below:
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Fuel from the tank flows in the fuel lines and is injected from the nozzle via the fuel injection pump. Overflow fuel returns to the tank. The system includes filters to protect it from entrance of air, water and dust. While the engine is running, fuel is fed into the pump by the fuel feed pump after passing through the fuel filter where any foreign matter is removed. The fuel camshaft actuates the injection pump and force feeds fuel to the injection nozzle through the injection pipe. Fuel is then sprayed through the nozzle into the combustion chamber. The fuel discharged after lubricating and cooling the injection nozzle is returned to the fuel tank through the over-flow pipe. Base Tank Base mounted fuel tanks are used to store fuel directly underneath the Genset, eliminating the need for a remote main fuel supply tank and/or auxiliary fuel transfer pumps. This mounting arrangement offers the convenience of having a fuel supply tank mounted at the generator. These tanks are designed to be contained in a rectangular base on which the engine-generator set is mounted. Generally, these tanks only increase the height of the generator set since the tank base is usually matched to the generator skid dimension. Remote tank Remote tanks are used when the engine fuel pump does not have the capacity to draw the fuel from the base tank; or the base tank is overhead and presents problems of high fuel head pressure for the system. In high ambient conditions, the day tank temperature might need to be considered. Warm fuel returning from the engine fuel injection pump should not be returned to the day tank if possible. As fuel temperature increases, fuel density and viscosity decrease, reducing maximum power output and lubrication of fuel handling parts such as pumps and injectors. This may be avoided by returning the fuel back to the supply tank rather than the day tank. Engines need to maintain some of the oil pump pressure and return oil pressure when the engine is working. When using a remote fuel tank, the height difference between the pump
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and the fuel tank generates a differential pressure, the differential pressure will affect the work of the engine. When the fuel tank is above the pump, correct fuel return may become an issue, and the tubing will have to be able to withstand a positive pressure. If the differential pressure is too large, fuel leaks may become a concern. When the fuel tank is below the pump, the fuel supply may become an issue, and the tubing will have to be able to withstand a negative pressure. If the differential pressure is too large, fuel supply may become a concern. Fuel Filter and Fuel/Water Separator The fuel filter located between the tank and the injection pump prevents foreign matter from entering the injection pump. A standard filter uses a paper element (filtration diameter less than 15). Normally filter elements or cartridges must be changed every 400 hours. Air trapped in the filter is purged by the vent plug. Fuel-water separator is a device designed to separate gross amounts of fuel and suspended solids from the wastewater effluents of fuel refineries, petrochemical plants, chemical plants, natural gas processing plants and other industrial sources. Three-way valves Valves used to switch between the base tank and a remote tank. Normally, the three-way valves are open to the base tank. When a remote tank is used simply open both of the valves to allow connection to the remote tank. The figure shown below shows the three-way valves in the default location connected to the base tank.
4.7.2 Lubrication system All moving parts of the engine must be lubricated to function correctly. For this purpose, the lubricating oil circulating through the engine has a number of functions. In addition to reducing friction, the oil cools the engine, controls expansion and dispersion of bearing areas, provides a sealing action, prevents rusting, seals out dust, and purifies products generated in the cylinders by incomplete combustion.
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Warning Poor quality oil will shorten engine life. Use only the specified lubricating oils. Important points regarding lubricating oil are described below. CLASSIFICATION OF ENGINE OIL SAE (Society of Automotive Engineers) Standards are generally used to classify engine oil viscosities. Viscosity is a principal property of oil, the higher the viscosity, the thicker the oil film formed over the metal surface will be and the lower the viscosity, the thinner the film thickness becomes. Viscosity varies with temperature. The higher the temperature, the lower the viscosity and vice versa. Engine oil should have the appropriate viscosity and have properties which are not affected by viscosity changes caused by temperature changes. In other words, engine oil must have a high viscosity index. Multi grade oils having relatively low viscosity (For example SAE 10W-30) can provide superior lubrication at both low and high temperatures. Such oils are available commercially for all-season use. Oil viscosity changes in cold temperature as crystallization of the wax element contained in oil proceeds, and fluidity is finally lost. Incorrect selection of oil cannot only increase resistance for cold starting but also affect lubrication of each part. Oils for low temperature, containing additives for lowering the pour point, should be used. The following diagram shows how to select lubricants.
Note
The use of synthetic oil is not recommended.
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4.7.3 Exhaust system Exhaust system components installed on any genset must be approved and correctly installed to meet the codes and regulations required by local government. A muffler and spark arrester have been installed in your genset. If a generator is used in a forest, on brush or grass covered unimproved land it must be equipped with a Spark Arrestor. It is the responsibility of the generator owner or operator to maintain the entire exhaust system in good working condition. Engine exhaust must be routed away from building intake vents, windows, doorways and other openings. Because the exhaust discharge is in a vertical position it may be possible for raim water to enter the muffler. A drain valve has been provided at the base of the muffler to remove any unwanted water. This process must be completed whilst the engine is shut down, as it may cause injury. 4.7.4 Ventilation and cooling system As the generator produces a high volume of heat, ventilation and heat dissipation must be carefully considered. The generator has been specially designed to operate in ambient temperatures to 50C. If the generator is used outdoors, ensure that no objects (such as plastic bags, etc.) are allowed to block the air inlet. The engine exhaust temperature is extremely high, do not vent towards any objects that cannot withstand high temperatures. The machine is provided with cabinet filters that must be cleaned regularly. In dusty environments, the cabinet filters must be cleaned daily. Remove the cabinet filters as the follow steps: Loosen the philips head screw at the top of the grille, remove the limit stop, and then slide the air filter out. If the generator is used indoors, make sure that there is adequate ventilation to the air inlets and outlets, and that the engine's exhaust is ducted out of room.
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4.8 Load Connections

4.8.1 Sizing Load Cables Selecting the load cables, number of cores and diameter, based on its allowable amperage and the distance between the generator and the load is critical. Correct selection should be carefully calculated. It is recommended that there is a maximum 5% marginal drop only for the rated voltage between the load and generator via the cables. This should be considered when selecting the cable.
DANGER If the load exceeds the allowable amperage overheating may cause damage to cables. If the cables are too long, there will be excessive voltage drop. It may result in fire, personal injury, reduced performance or damage to machinery.
4.8.2 Connecting Load Cable The generator is ready for field connections. The cables should be connected to the Main wiring terminals which are located inside the field wiring cabinet.
WARNING: Before connection, the following precautionary measures must be taken Connection must only be carried out by a licensed electrician. Battery must be disconnected. The control power switch must be set to the OFF position.
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4.9 Earth Connections

The generator and electrical components have their respective earth wires which are all connected to the main earth bar in the control cabinet. Multiple Earthed Neutral (MEN) is installed on this generator.
WARNING: If the terminal is not connected, it may result in injury or death. All the doors must be earthed. Main earth and earth spike should be installed and tested by a licensed electrician before running the generator.
4.10 Battery Connections

The battery cables should be disconnected when the generator is required to be transported or be stored for long periods. Reconnect the battery cables before running the machine. Connect the red cable to the positive (+) terminal post. Connect the black cable to the negative (-) terminal post.
WARNING: Do not dispose of the battery in a fire. The battery may explode. Battery electrolyte solution is caustic and can cause severe burns and blindness. If electrolyte contacts skin or eyes, immediately flush the area with water and urgently seek medical attention.
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4.11 ATS Connections

The generator is equipped with an Automatic Transfer Switch (ATS) plug on the left side of the control panel. The customer can select an appropriate automatic transfer switch (ATS) and connect it to the generator. Connect the wire between the generator set and ATS plug. Connect the wires between the generator main wiring terminals and the ATS wiring terminals. Connect the wires between the mains supply wiring terminals and the ATS wiring terminals. Connect the wires between the load wiring terminals and the ATS wiring terminals.
WARNING: Do not operate the generator before connection of the ATS.
The ATS is controlled by the PLC module which can monitor the incoming AC mains supply. If the mains supply is satisfactory the load is run through the ATS and the generator will not run. On the contrary the generator will run if the mains power is abnormal. THE ATS LOCATION IS IMPORTANT, THE FOLLOWING MUST BE OBSERVED: The ATS should be located inside the building near the main switchboard. Locate the ATS in a clean, dry, well ventilated location, away from excessive heat. When the ambient air is above 40C (104F), fuses and circuit breakers must be de-rated. Allow adequate working space around the transfer switch. Never install control wires in the same conduit with mains wiring. ATS and all equipment must be installed in accordance with relevant local and national codes and regulations. If the ATS is mounted outside, it must be protected from the environment. Do not mount the ATS on the generator. Do not mount the ATS where flammable liquids or vapours are present.
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5. Operation
5.1 General Pre-check Before Starting
Before starting the generator, check each item below: Check engine oil, fuel and coolant. Check for leakage at the hose connections.
WARNING: Do not use the machine when any leak is found. Repairs are to Be carried out by trained personnel and according to regulations.
Check to make sure there are no obstructions lodged in vents, near the radiator or around the cooling fan. Ensure that nothing is contacting the muffler or exhaust pipes. Check the generator is earthed and the earth spike is installed and tested as per local regulations. Make correct terminal connections. TEST accordingly. Check that all electrical connections were made in compliance with local regulations and standards. Make sure the fan belt and hoses on the engine have no loose connections or are fraying. Tighten or replace as required. Check the battery cables are firmly secured to the terminals. Tighten the clamps if necessary. Close and secure side panel access doors. Review and follow safety instructions at the front of this manual.
Warning: 1. Failure to follow the procedures listed in this manual may cause injury to personnel or damage to the generator. Ensure all persons setting up the generator are certified or fully trained on the installation of the generator. 2. Always wear protective gloves, clothes and other P.P.E. as required.
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5.2 Checking Engine Oil, Fuel and Coolant Level Before Starting
5.2.1 Engine oil Ensure that the generator is on level ground before checking engine oil level. Install the oil dipstick all the way in. The appropriate level should be between the lower limit and upper limit on the dipstick. Add engine oil if the level is below the lower limit. Select the appropriate engine oil. Open the access door, remove oil cap. Add engine oil to bring oil level NO higher than FULL mark on the dipstick. Tighten the oil inlet cap and close the access door.
CAUTION: If the generator is not level when checking the engine oil, you cannot obtain an accurate oil level reading. Do not overfill the engine oil. The level cannot exceed the upper limit. An excessive amount of engine oil may damage the engine. Do not smoke and extinguish any naked flames before adding engine oil.
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5.2.2 Fuel Remove the fuel inlet cap and check the fuel level in the tank. Adding Fuel: Select the correct fuel. Loosen the fuel inlet cap and remove it. Fill the fuel through the inlet until the fuel is slightly less than the full-tank level Tighten the fuel inlet cap.
CAUTION: 1. Do not smoke while you are refuelling an engine. 2. Do not refuel an engine near open flames or sparks. 3. Always stop the engine before refuelling.
5.2.3 Coolant Remove the radiator cap, check coolant level in the tank. Adding Coolant: Remove the coolant inlet cap. Remove the radiator cap. Fill coolant up to the radiator inlet top. Reinstall and tighten the coolant inlet and radiator caps.
WARNING: Avoid injury! The coolant will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed. Shut off engine and allow it to cool. Do not remove cap unless the radiator and the engine are cool to touch with bare hands. Slowly loosen the cap to the first stop to release all pressure, then remove cap.
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5.3 Manual Start-up

Carefully read the illustration on the control cabinet and control panel (PLC), then proceed according to the following operation steps: 1. Set every circuit breaker and load switch to the OFF position. 2. Turn the Main Circuit Breaker (19), Circuit Breaker (14, 15, 17), RCD/MCB (21, 22), RCD (16, 20),GPO Switch(18) to the OFF position. 3. Open the side access door and turn on the engine battery switch, then close the door. 4. Turn the Master Control Switch (8) to the ON position. 5. Select manual mode. 6. Press the START button (5), the fuel solenoid is energised and after a one-second delay the starter motor will crank the engine for the duration of the crank timer (preset on PLC, three attempts). 7. After the engine successfully starts, allow allow approximately five minutes for the engine to warm. 8. Turn the Circuit Breakers ON (19, 14, 17 ), turn the GPO Switch(18), RCD/MCB (21, 22), RCD (16, 20) ON. This will allow power to all of the respective outlets (GPOs & main terminals). The external load can now be switched on.
DANGER: Before turning the Main Circuit Breaker (19) to ON, make sure all load circuit breakers and switches are positioned to OFF. Failure to do so may cause an electric shock to the operator. Do not touch any wires or connections when the generator is running, this may result in serious injury or death.
5.4 Automatic Start-up

Follow steps 1 to 4 as described above (see 5.3). Select AUTO mode. Press the START button (5), the module will proceed with its normal auto start sequence. The module will monitor the incoming AC mains supply. If the mains supply is satisfactory, the ATS will carry the mains loads and the generator will not run. On the contrary the generator will run the supply power if the mains supply is unsatisfactory. The generator will operate up to 5 seconds (Warm up Mode). PLC will automatically switch (ATS) load circuit breaker to ON, generator will
PAGE-52
supply power. NOTE: Before operating the automatic start-up mode, connection of ATS is required.
5.5 During Operation

Check the LCD reading of voltage, current, frequency by scrolling the Display Buttons and . Check the LCD reading of engine oil, coolant and fuel levels. Check the LCD reading of engine oil pressure and coolant temperature. Check for any alarm signal on the LCD or audible alarm. Check for any leakage of coolant, oil or fuel. Check for any unusual vibration or noise. Check for any unusual colour from the exhaust. Under normal conditions the exhaust gas has no colour. If the engine cannot run because of low fuel, bleed the air from the fuel system. Loosen air release bleed bolt on the fuel filter. Bleed the air in the fuel system for about 30 seconds. Tighten the bolt.
CAUTION: 1. If a fault is detected, stop and isolate the machine immediately. 2. Generator to be repaired by certified or fully trained personnel (refer to troubleshooting guidelines 6.7).
PAGE-53
5.6 Stopping Generator Under Manual Operation Mode

1. Turn off every RCD/circuit breaker. 2. Turn the Main Circuit Breaker (19), Circuit Breaker (14, 15, 17), RCD/MCB (16, 18), RCD (21, 22), GPO Switch( 18)to the OFF position. 3. Press the Stop button (6). 4. Allow the engine to remain idle for approximately one minute to cool down. 5. Turn off the Master Control Switch (8). 6. Open the side access door and turn off the battery isolator switch, then close the door.
5.7 Stopping Generator Under Automatic Operation Mode

If the mains supply returns and the generator does not stop running, follow the steps listed below: Turn every switch and circuit breaker on the load to OFF position. Turn off the Master Control Switch (9). Open the side access door and turn off the engine battery switch, then close the door.
5.8 Shutting Down Genset

The generator is equipped with an automatic shutdown feature. The LCD will display the fault.
Warning: In the event of a shutdown alarm, turn off the engine. Generator must be repaired by certified or fully trained personnel according to the troubleshooting guidelines (see 6.7).
PAGE-54
5.9 Lifting and Transportation

Lifting: The top of the generator has two lifting lugs and the four chassis angles have four holes attached to the lifting frame inside the housing. Refer to the technical data for the weight of the generator. Make sure the lifting device has sufficient capacity to lift the unit safely. When lifting the generator, attach a hook or sling securely to the lifting lug. Transportation: When transporting the generator, it should be secured correctly with ropes tied to the roping lugs at the top of the generator.
5.10 Overnight Storage

When storing the generator overnight, make sure all access doors are closed and padlocked. CAUTION: Do not store generator in a low lying area, as large quantities of water can enter the generators electrical / mechanical systems and damage may result.
5.11 Long-term Storage

If the generator will not be used for more than two months, the following procedures need to be performed. Close and padlock all access doors. Remove the start key. Avoid storing generator in a dusty, humid environment. Refer to and follow the engine manufacturers recommendations for long-term storage. These procedures are designed to help minimize engine corrosion.
6. Maintenance
Before performing any checks or maintenance, stop the engine and remove the start key. For detailed maintenance procedures on the engine, refer to engine operator's manual.
PAGE-55
6.1 Periodic Maintenance Schedule

TWO YEARS OR AFTER 1000 HRS
SERVICE ITEMS
DAILY OR AFTER 8 HRS
WEEKLY OR AFTER 50 HRS
MONTHLY OR AFTER 100 HRS
SIX MONTHS OR AFTER 250 HRS
YEARLY OR AFTER 500 HRS
Check various meters and alarm lamps Check engine oil , fuel and coolant level Check for leaks (oil, fuel and coolant) Check air cleaner dust cap Check generator visually Check battery charging system Check drive belt tension Drain water/sediment from fuel filter Drain water/sediment from fuel tank Change engine oil and replace oil filter Change fuel filter element Clean or change air filter element Check cooling system Clean unit inside & outside Change coolant Pressure test cooling system Clean inside fuel tank
Change Change
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6.2 New Machines

Run the generator at least 60 100% of continuous load for the first 100 hours. Change engine oil and replace oil filter after the first 50 hours.
6.3 Air Cleaner

6.3.1 Clean Air Filter Element Loosen clips in the air cleaner and remove the dust cap. Remove the air filter element which contains a primary filter and a safety filter. Loosen the safety filter from the primary filter. Use compressed air to flush the safety filter and primary filter from inside. Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube. Reinstall the air cleaner in the reverse order.
6.3.2 Change Air Filter Element Loosen clips in the air cleaner and remove the dust cap. Remove the air filter element. Loosen the safety filter from the primary filter. Change the primary filter. Reinstall the air cleaner in the reverse order
Caution: Do not remove the air cleaner while operating the generator or immediately after stopping the machine. Do not start the engine after the air cleaner is removed. The backfire can cause serious burns. Change the primary filter every 250 hours or as required; and the safety filter every 500 hours or as required.
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6.4 Engine Coolant

Changing Coolant: Open the radiator drain ball valve, located on the top of the generator base tank, and drain coolant. After draining, close the drain ball valve. Remove the coolant inlet cap. Remove the radiator cap. Pour new coolant into the radiator up to the radiator inlet top. Close the radiator cap and coolant inlet cap.
WARNING: Avoid injury! The radiator will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed. Shut off engine and allow it to cool. Do not remove cap unless the radiator and the engine are cool to touch with bare hands. Slowly loosen the cap to the first stop to release all pressure, then remove cap.
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6.5 Engine Oil and Oil Filter

6.5.1 Change Engine Oil Open the oil drain ball valve. Open the access door. Open sump and oil ball valve which is under the oil pump. Use oil pump to drain engine oil. After draining, close the oil drain ball valve and oil ball valve. Loosen and remove the oil inlet cap; add oil to the oil inlet through an outside oil filter until the level is slightly less than the upper limit by checking the oil level on the oil gauge. Tighten the oil inlet cap and close the access door. 6.5.2 Change Oil Filter Drain engine oil completely, as described in 6.5.1. Loosen and remove the oil filter. Add engine oil into a new oil filter. Lubricate the new gasket with oil. Screw the new filter into place and tighten it until the gasket touches the seal surface. Tighten accordingly. Supply engine oil as described in 6.5.1.
WARNING: 1. If the generator is not level when checking the engine oil, you cannot obtain accurate oil level. 2. Do not overfill the engine oil. The level cannot exceed the upper limit because the excessive amount of engine oil may damage the engine. 3. Do not smoke or be near an open flame when adding engine oil.
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6.6 Fuel Filter

6.6.1 Drain Water / Sediment in the Fuel Filter Loosen the drain plug to drain water and sediment. Bleed the air and tighten plug. 6.6.2 Change Fuel Filter Loosen the drain plug and drain fuel and water. Loosen and remove fuel filter. Add fuel into a new fuel filter. Lubricate the new gasket will oil. Screw the new filter into place and tighten accordingly.
DANGER: Do not smoke while you are refuelling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refuelling. Wear protective gloves, goggles and clothing when changing the fuel filter.
6.7 Troubleshooting
When performing any troubleshooting, follow the guidelines. If further clarification is required please contact our authorised service agent. TROUBLE CAUSES 1. Lubricant oil is insufficient Low engine oil pressure 2. Oil hose has leak 3. Oil filter is clogged 4. Wrong oil is used 1. Coolant is insufficient 2. Coolant pipe has leak High coolant temperature 3. Fan belt is loose 4. Radiator core is clogged 5. Water temp sensor is defective 6. Engine thermostat is defective 1. Fuel is insufficient 2. Fuel hose has a leak Low fuel level 3. Fuel tank has a leak 4. Fuel filter is clogged SOLUTIONS 1. Add lubricant oil 2. Tighten or change oil hose 3. Change oil filter 4. Change to correct oil 1. Add coolant 2. Tighten or change coolant pipe 3. Tighten the belt 4. Clean radiator core 5. Repair or change the sensor 6. Repair or change the thermostat 1. Add fuel 2. Tighten or change fuel hose 3. Repair or change fuel tank 4. Drain water/sediment or change fuel filter
Cannot turn the breaker to on
5. Fuel level sensor is defective 5. Repair or change the sensor 1. The main breaker position is 1. Turn off and on. located between on and off 2. Replace breaker if faulty 2. Short circuit on the load 1. The controller cable is disconnected from the battery 2. The battery power is insufficient 3. The DV fuse is damaged 1. Loads total exceeds the rated current 2. Check and repair the load circuit 1. Connect the controller cable to the battery 2. Charge the battery with the utility power 3. Change the DV fuse 1. Decrease the loads to meet the rated output
Controller not working
Voltage drops when connecting to the load
2. Battery output is low 3. Battery is deteriorated 4. Battery terminal is loose 1. Fuel is insufficient Starter 2. Fuel hose has leak motor drives, but 3. Fuel filter is clogged engine cannot start 4. Gauze filter is clogged 5. Air is mixed in fuel line 1. Fuel hose has a leak 2. Fuel filter is clogged Engine starts but stalls 3. Gauze filter is clogged at once 4. Lubricant oil is insufficient 5. Air is mixed in fuel line 6. Air filter element is clogged 1. Wrong fuel is used Muffler releases black smoke 2. Air filter element is clogged
2. Charge the battery 3. Change the battery 4. Tighten the terminal 1. Add fuel 2. Tighten or change fuel hose 3. Drain water/sediment or change fuel filter 4. Clean or change gauze filter 5. Bleed the air 1. Tighten or change fuel hose 2. Drain water/sediment or Change fuel filter 3. Clean or change gauze filter 4. Add lubricant oil 5. Bleed the air 6. Clean or change air filter element 1. Change to correct fuel 2. Clean or change air filter element
Promac Sales
Email: sales@promac.net.au Phone: +61 8 6254 1800 Fax: +61 8 6254 1899 Office: 11 Poole Street, Welshpool, Western Australia, 6106 Postal Address: PO Box 538, Welshpool, Western Australia, 6986
PROMAC. LEADING THE WAY.

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OPERATOR & MAINTENANCE MANUAL

PROMAC. LEADING THE WAY.

S80PS GENERATING SET

1. Foreword .................................................................................................. 2. Safety Information .............................................................................................. 2

3. Specifications and Parts Introduction ............................................................. 9

OPERATOR & MAINTENANCE MANUAL

ENGINE EXHAUST can cause serious injury or even death!

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

2.1 General Safety Precautions

2.2 Safety During Transportation

OPERATOR & MAINTENANCE MANUAL

2.3 Safety During Installation & Initial Start-up

2.4 Safety During Operation

OPERATOR & MAINTENANCE MANUAL

2.5 Safety Around Diesel Engines

2.6 Safety During Maintenance

OPERATOR & MAINTENANCE MANUAL

2.7 Symbols and Their Meanings

TABLE 1: SAFETY LABELS

OPERATOR & MAINTENANCE MANUAL

Warning Do not manipulate the generator with the switch on.

Danger High voltage.

Warning Do not clean the alternator with water

Warning High temperature.

OPERATOR & MAINTENANCE MANUAL

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

Note Forklifting point

Note Bottom drain bund

Diesel fuelling point

Coolant refill point and type of coolant

Main Isolator Switch

Circuit Breaker Type & Size

3. Specifications and Parts Introduction

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

3.2 Generator Specifications TABLE 2: GENERATOR SPECIFICATIONS

2830 1060 1890

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

3.3 Generator Layout and Major Components

OPERATOR & MAINTENANCE MANUAL

TABLE 3: CONTROL CABINET

OPERATOR & MAINTENANCE MANUAL

3.4 Control Cabinet and Panel

OPERATOR & MAINTENANCE MANUAL

TABLE 4: CONTROL CABINET

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

3.4.2 Control Panel

OPERATOR & MAINTENANCE MANUAL

TABLE 5: CONTROL PANEL

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

OPERATOR & MAINTENANCE MANUAL

3.4.3 AMF 25 Controller

TABLE 5: PUSH BUTTONS