Operation Manual
Contents
1. BUNDU POWER OPERATIONS amp CONTROLLER MANUAL 1500 RPM D E Weg 8 gege T 27 0 11 397 7373 F 27 0 11 397 7404 E support bundupower co za 2 Bravo Road Jetpark Johannesburg www BunduPower co za WARNING Read and understand all safety precautions and warnings before operating or performing maintenance on the generator Failure to follow instructions procedures and safety precautions in this manual may increase the possibility of accidents or injuries Do not alter or adjust any part of the generator set without prior approval as Bundu Power will not be held responsible for faults or accidents caused by modifications or alterations It is very important to regularly carry out checks suggested in this manual to maximise the generators lifespan and prevent accidents from occurring Never start the generator unless all foreign items are removed from inside the sound attenuated canopy and the doors are securely closed Do not attempt to operate the generator in unsafe conditions If the generator set is unsafe to operate disconnect the battery negative lead to prevent starting the generator until the problem has been rectified Disconnect the generators negative battery lead prior to attempting any repairs or cleaning the inside of the sound attenuated canopy Install and operate this generator within the local and national legislation applicable to your territory I2. JOB DONE BY NOTES 39 NOTES YOUR LOCAL AGENT IS 40
3. 14 Replace Oil Filter 15 Replace Fuel Filter Bs 16 Replace Clean Air Filter 17 Check Belts and tension 18 Replace Cam Belt BP19 Only DATE DEALER STAMP JOB DONE BY NOTES 2750 HOURS OF OPERATION MAINTENANCE PERFORMED 11 Replace Engine Oil 12 Replace Oil Filter 13 Replace Fuel Filter 14 Replace Clean Air Filter 15 Check Belts and tension DEALER STAMP NO OF HOURS DATE JOB DONE BY NOTES 37 3000 HOURS OF OPERATION MAINTENANCE PERFORMED 19 Replace Engine Oil 20 Replace Oil Filter 21 Replace Fuel Filter Bs 22 Replace Clean Air Filter 23 Check Belts and tension 24 Replace Cam Belt BP19 Only DATE DEALER STAMP JOB DONE BY NOTES 3250 HOURS OF OPERATION MAINTENANCE PERFORMED 16 Replace Engine Oil 17 Replace Oil Filter 18 Replace Fuel Filter 19 Replace Clean Air Filter 20 Check Belts and tension DEALER STAMP NO OF HOURS DATE JOB DONE BY NOTES 38 3500 HOURS OF OPERATION MAINTENANCE PERFORMED 25 Replace Engine Oil 26 Replace Oil Filter 27 Replace Fuel Filter Bs 28 Replace Clean Air Filter 29 Check Belts and tension 30 Replace Cam Belt BP19 Only DATE DEALER STAMP JOB DONE BY NOTES 3750 HOURS OF OPERATION MAINTENANCE PERFORMED 21 Replace Engine Oil 22 Replace Oil Filter 23 Replace Fuel Filter 24 Replace Clean Air Filter 25 Check Belts and tension DEALER STAMP NO OF HOURS DATE
4. 5 Check Belts and tension 1 6 Replace Cam Belt BP19 Only DATE NOTES DEALER STAMP 1250 HOURS OF OPERATION MAINTENANCE PERFORMED 1 Replace Engine Oil 2 Replace Oil Filter 3 Replace Fuel Filter 4 Replace Clean Air Filter 5 Check Belts and tension DEALER STAMP NO OF HOURS DATE JOB DONE BY NOTES 34 1500 HOURS OF OPERATION MAINTENANCE PERFORMED 2 Replace Oil Filter J 3 ReplaceFuelFiler Le 4 Replace Clean Air Filter 1 5 Check Belts and tension 1 6 Replace Cam Belt BP19 Only DATE NOTES DEALER STAMP 1750 HOURS OF OPERATION MAINTENANCE PERFORMED 1 Replace Engine Oil 2 Replace Oil Filter 3 Replace Fuel Filter 4 Replace Clean Air Filter 5 Check Belts and tension DEALER STAMP NO OF HOURS DATE JOB DONE BY NOTES 35 2000 HOURS OF OPERATION MAINTENANCE PERFORMED 8 Replace Oil Filter Jooo H RepaceFuelFiler J o oo o 10 Replace Clean Air Fiter 1 11 Check Belts and tension SS o 12 Replace Cam Belt BP19 Only DEALER STAMP DATE NOTES 2250 HOURS OF OPERATION MAINTENANCE PERFORMED 6 Replace Engine Oil 7 Replace Oil Filter 8 Replace Fuel Filter 9 Replace Clean Air Filter 10 Check Belts and tension DEALER STAMP NO OF HOURS DATE JOB DONE BY NOTES 36 2500 HOURS OF OPERATION MAINTENANCE PERFORMED 13 Replace Engine Oil
5. if possible or pull the plug or cable away from the victim as quickly and safely as possible If this is not possible stand on dry insulating material and pull victim clear of the conductor preferably using non conductive material such as dry wood Immediately contact a hospital to treat patients who have been injured 4 STARTER BATTERY Ensure that the battery is installed correctly in the battery cradle within the generator and that the terminals are correctly connected and tightened Batteries should not be placed too far from the generator if not placed in the battery cradle as the increased resistance from the extended cable will decrease the likelihood of the generator starting on the reduced current 5 ELECTRICAL CONNECTION The cables connecting the generator with the distribution system should be protected by means of a circuit breaker fuses or other means to disconnect the generator in case of overload or short circuit 5 1 LOADING When planning your distribution system it is important to ensure that a balanced load is placed on the generator If 3 phase generator If loading on one phase is excessive in comparison to the other two phases this will cause overheating in the alternator windings imbalance in the phase to phase voltage output and possible damage to sensitive 3 phase equipment connected to the system Ensure that no phase current exceeds that of the current rating of the generator It may be necessary to r
6. 12 define code as 8 8 0 12 define code as 8 8 43 Configurable T F 12 0 12 define code as input 3 iz 8 8 E ddl 4 Input 1 delay Input 2 delay 4 47 Configurable 0 80 define code as relay 1 i 4g Configurable 0 80 define code as relay 2 i 8 9 Mains Parameters ITEMS PRESET VALUE RANGE NO 5 1 Low Mains E 90 20 200 0 not voltage set 55 High Mains e 115 20 200 9999 not voltage set requency 29 55 MCB opening 1 9999 S delay Mains On 1 9999 S Delay Calibration Menu NO ITEMS PRESET VALUE RANGE Current l1 6 2 offset Current 12 let mite Current 13 MAINS V1 o MAINS V2 410 096 offset MAINS V3 410 096 offset Pressure 10 0 offset Temperature 10 0 offset 2 Batt Voltage l dad q 10 0 offset mE WARNING ALARM 30 The optional items for P T sensor CODE The brand model of The brand model of HET sensor LOP sensor 0 nousd Lngtueed _ 6 Muphy7ba Muphy 8 Preset2 QPreseti 9 Prest3 Lrese 12 Leoongpoured by user WARRANTY Bundu Power offers warranty on all generators as per the table below TYPE PERIOD OR TIME 1500 RPM 1 Year or 1000 Hours of operation Whichever occurs first 3000 RPM 6 Months or 500 Hours of operation Whichever occurs first PLEASE NOTE Warranty is on a Carry In basis If a technician is dispatched to site by Bun
7. flash The LCD screen will display Aux Warning icon on the left of the screen Controller continuously detects battery voltage during standby and Battery Low High Voltage pre alarms are active Battery Low Voltage pre alarm is inactive during cranking 16 SHUTDOWN ALARMS PRE ALARM DESCRIPTION LCD DISPLAY START FAILURE If the generator does not start after the pre defined number of start attempts The Shutdown Alarm LED will be lit The LCD screen will display the Start Failure icon in the bottom left corner STOP FAILURE If the generator does not shut down after the shutdown sequence The Shutdown LED will be lit The LCD screen will display the Stop Failure icon in the bottom left corner 24 EMERGENCY STOP If the emergency stop button is pushed The generator will be shut down immediately The shutdown alarm LED will be lit The LCD screen will display the emergency stop icon LOW OIL PRESS If the controller detects low oil pressure below the warning threshold The generator will shut down automatically and the Shutdown LED will be lit The LCD screen will display the low oil pressure icon ENGINE HIGH TEMP If the controller detects engine high temperature above the high temperature warning threshold the generator will shut down automatically and the Shutdown LED will be lit The LCD screen will display the High Temperature icon OVER SPEED If the controller detects engine over speed
8. the coolant has cooled Then loosen the cap slowly to relieve any excess pressure before removing the cap completely 2 3 CHEMICAL All fuels oils coolants acids and lubricants should be handled with care and any spills in and around the generator should be cleaned up immediately Do not swallow or allow skin contact with fuel oil battery acid or lubricants If swallowed seek medical treatment immediately Do not induce vomiting For skin contact wash with soap and water thoroughly Do not wear clothing contaminated with fuels or other chemical products as they may cause skin irritation or ignite Wear an acid resistant apron and face shield or goggles when servicing the battery If acid gets onto the skin or clothing flush immediately with large quantities of water 6 2 4 ELECTRICAL Ensure all electrical equipment and components are correctly installed to prevent damage to the components and the operator In addition ensure that these items are correctly and regularly maintained The generator must be connected to the load only by trained and qualified electricians who are authorised to do so Connections should be in compliance with relevant electrical codes standards and other regulations in your country When required their work should be inspected and accepted by the inspection agency prior to operating the generator or a certificate of compliance COC should be issued Ensure the generator is effectively grounded
9. well as the operation of the generator controller In addition it outlines the general safety precautions whilst utilizing the generator All relevant chapters should be read before attempting to install lift move or perform maintenance on the generator Installation should always be performed by a qualified electrician who will supply you with a compliance certificate on completion COC Electrical work including earth grounding and insulation should be carried out in compliance with local regulations and laws of your country Additional fuel tanks should comply with local regulations laws and by laws Generators installed within a structure should have the exhaust fumes vented out of the structure by an air tight exhaust The exhaust should vent the fumes away from the structure and be capable of very high temperatures WARNING Failing to vent the exhaust fumes out of a structure can lead to death by asphyxiation It is imperative that all fumes produced by the generator are not inhaled at any time Never lift or move the generator using the engine or alternator lifting points Always perform lifts or moves of the generators by using the holes provided at the bottom of the sound attenuated enclosure Ensure the lifting rigging and supporting structure is in good condition and has a capacity suitable for the load Keep all personnel away from the generator whilst it is suspended The generator should always be plac
10. GENT IS 15 GENERATOR CONTROLLER GENSET Controller vid KAS E f 4 n d L LE i CA AA EY eg A COMUNE Head the entire manual before operating this controller Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or damage to equipment or property Controllers contain static sensitive parts Observe the following precautions to prevent damage to these parts a ia A Do not disassemble the controller CAUTION 16 11 DESCRIPTION The GU611A is an Automatic Mains Failure Controller The controller will monitor the incoming MAINS electricity feed when in AUTO mode If the MAINS electricity fails the generator will automatically start and transfer the load to the generator When the MAINS electricity is restored the generator will be shut down and the load will be transferred back to the MAINS electricity feed In order for this to occur the controller needs to be coupled with an Automatic Transfer Switch ATS The generator will continue to run for a number of minutes when the MAINS electricity feed is restored to cool down In MANUAL mode the generator can be started and stopped using the buttons on the controller when needed The controller displays faults operational and metering data The controller has a backlit LCD display for easy viewing The controller can be used in AUTO or MANUAL mode The generator Output Voltag
11. NDEX GENERATOR 1 Installation and Handling sees 2 Safety ConsiderallOliS sss susce acne dade be A uto bee etes 2 1 Fire and EX PIOSION a oi to eet seis olen otros Jot a psp ei Te le EE 2 3 NM ari os EE LA First Aid for electric Shock sees IHR mmm I otarter Battell8s uo eov dia 5 Electrical Connections EE S Wi Eo 6 A o eT ET ECT RN 5 2 POWE e Le M AER 5 3 Grounding Heourements esses lA E e GE 7 GONG EEN WSA en EE 7 2 Preventative Maintenance cen 8 Period Maintenance reouirements cce ee e e e e e K ee e K o Ba EE HHT 8 2 E e EE 9 9 ENJINS Oll EE S A ONF IE EE 8 5 FUel Fleitas 8 5 Ai Filter Cien o i gu te 9 Maintenant octo E dede Rb dle ts DEA den phen Er ieee 10 Maintenance Checklist sese IHR RII INDEX CONTROLLER 11 Controller descrption cece eee 17 12 Control Panel Operation 17 13 Control Buttons and LED Display 18 14 Control Panel Operation Insiruchons ccc ee e cece ee eeeeees 19 14 1 Operation Mode and Gettngs 19 14 2 Automatic Control Geouence eee eee e e 19 14 3 Manual Control Geouence e e e e eee 21 15 Warnings Pre Alarms csse mmn 22 Lee et un TEE 24 14 Controller ele TEE 26 18 Warranty and Generator Details 31 19 Servico RECO asii its 32 1 INSTALLATION AND HANDLING This manual covers the basic procedures to install and maintain your generator as
12. T GEN UNDER VOLT P SENSOR j OPEN EMERGENCY STOP LOW OIL PRESS s Lj d START FAILURE Stee OVER CURRENT SPFL i ESEP PRES 26 GENERAL PARAMETERS Mo ITEMS PRESET VALUERANGE Under Voltage 20 200 0 not 2 1 Alarm set Warning set 23 Over Voltage 115 20 200 9999 not Warning set 24 Over Voltage Ka Hh 9999 20 200 9999 not Alarm a ne set 2 5 Hz low alarm 45 0Hz TRER TORO ur o not set l 10 0 100 0Hz Hz high alarm 57 0Hz 999 9 not set Over current arning alarm 0 electrical action shutdown alarm Alarm delay ef Na ws fo 600 S CICER o 2 12 GCBopening y q E 1 9999 S delay i ENGINE PARAMETERS ITEMS PRESET VALUE RANGE K PHS em Ge 27 3 5 Crank o Zeg 3 times 1 10 times attempt Crank cut out f Crank cut out 0 1 Oil P 1 0BAR 150 0BAR 999 9 not E 3 11 BEE d gt 0 1 608 ro not set delay Co Co Co Co de O 0 9999 RPM 0 not Under Speed F LJ yaaorpy 09999 RPM 0 not Warning mM set Over Speed 1600RPM 1 9999 RPM 0 not Warning set 1710RPM 1 9999 RPM 0 not set 3 1 1BAR 0 45 0 BAR 28 aa cL eM 1 4BAR 0 45 0 BAR Warning PE 2 Coolant l 70 320 C 9999 not E Warning ag if set 70 320 C 9999 not 1 0 25 0V 0 not set 1 0 35 0V 99 9 not set Charge Volt 1 0 25 0V 0 not i Warning set NO ITEMS PRESET VALUE RANGE e 0
13. above the warning threshold the generator will automatically shut down The Shutdown LED will be lit The over speed icon will be displayed on the LCD display OVER CURRENT If the controller detects over current above the warning threshold the generator will automatically shut down The Shutdown LED will be lit The over current will be displayed on the LCD screen with upward arrows alongside the phases with over current GEN OVER VOLT If the controller detects over voltage above the warning threshold the generator will automatically shut down The Shutdown LED will be lit The over voltage will be displayed on the LCD screen with upward arrows alongside the phases with over voltage ch g38 L3 25 EE B BC ET GEN UNDER VOLT GEN LIH If the controller detects under voltage below the warning threshold the generator will automatically shut down The Shutdown LED will be lit The under voltage will be displayed on the LCD screen with downward arrows alongside the phases with under voltage AUXILIARY FAILURE If the controller detects an auxiliary failure outside of the warning threshold the generator will shut down automatically The Shutdown LED will be lit The LCD screen will display the Auxiliary failure icon 17 CONTROLLER CODES NAME CODE NAME CODE CHARGE ENGINE HIGH r FAILURE TEMP v Ban UNDER SPEED 4 VOLT BATT OVER VOLT GEN OVER j STOP FAILURE VOL
14. du Power the mileage will be for the clients account The labour and warranty parts will be covered by the Warranty Agreement This is due to the nature of the equipment and the unknown location and distance of the generator once onsite GENERATOR INFORMATION MODEL PURCHASE DATE As per Invoice 31 18 SERVICE RECORDS 50 HOURS OF OPERATION 2 MAINTENANCE _ _ _ PERFORMED 1 Replace Engine Oil Le 2 Replace Oil Filter Le 3 Check Hose Connections S DEALER STAMP NOTES 250 HOURS OF OPERATION MAINTENANCE PERFORMED 1 Replace Engine Oil 2 Replace Oil Filter 3 Replace Fuel Filter 4 Replace Clean Air Filter 5 Check Belts and tension DEALER STAMP NO OF HOURS DATE JOB DONE BY 500 HOURS OF OPERATION MAINTENANCE PERFORMED 1 Replace Engine Oil Jo ooo 2 Replace Oil Filter o S RepaceFuelFiler Jo ooo 4 Replace CleanAirFilter 1 5 CheckBeltsandtension gt 9 o 6 Replace Cam Belt BP19 Only DATE NOTES DEALER STAMP 750 HOURS OF OPERATION MAINTENANCE PERFORMED 1 Replace Engine Oil Jo ooo 2 Replace Oil Pier 3 Replace Fuel Filter Le 4 Replace CleanAirFilter 1 5 Check Belts and tension S DEALER STAMP DATE 1000 HOURS OF OPERATION MAINTENANCE PERFORMED 2 Replace Oil Filter J 3 ReplaceFuelFiler Le 4 Replace Clean Air Filter 1
15. e Current Oil Pressure Coolant Temperature Frequency DC Source and many more parameters can be displayed by the controller 12 PANEL OPERATION The operation panel consists of 3 sections 1 LCD display indicating measurement and parameters 2 LED indicator lights 3 Push buttons for mode selection and setting parameters The LCD displays different measuring parameters When a failure occurs the LCD displays the corresponding fault indicator The backlight will automatically illuminate when a button is pressed and will automatically turn off 17 13 CONTROL BUTTONS AND LED INDICATORS NAME FUNCTION DESCRIPTION SCROLL Enter into submenu Modify confirm modification BUTTON scroll menu to display MUTE When a failure occurs an alarm will sound BUTTON Pressing mute button for 2 seconds will mute the alarm The LCD will display a mute icon The auto button is used for selecting AUTO mode When the controller is running in AUTO mode the LED above the auto button will be lit In AUTO mode a start signal will automatically be sent to the generator on the failure of the MAINS electricity feed when an ATS is attached The manual button is used for selecting MANUAL MANUAL mode When the controller is running in MANUAL MODE mode the LED above the manual button will be lit BUTTON The Start and Stop buttons can now be used to operate the generator The start button is used to manually start the START generato
16. earthed in accordance with all relevant regulations prior to operation The generator should be shutdown with the battery negative terminal disconnected prior to attempting to connect or disconnect load connections Do not attempt to connect or disconnect load connections while standing in water Do not touch the inter connecting cables conductors or electrical components of the generator which are not insulated Replace the terminal box and all covers once connected before attempting to start and run the generator Ensure that the bolts securing the load cables are securely fastened and are checked to ensure they have not loosened during operation Connect the generator only to load and that is compatible with its electrical characteristics and that is within its rated capacity Correct Hz Frequency Voltage and capable of supplying sufficient power for the load Be sure all electrical power is disconnected from electrical equipment being serviced Keep all electrical equipment clean and dry Replace any wiring where the insulation is cracked cut damaged or degraded Replace terminals that are worn discoloured or corroded Keep terminals clean and tight Insulate all connections and disconnected wires Use only class BC or class ABC extinguishers on electrical fires 3 FIRST AID FOR ELECTRIC SHOCK Do not touch the victim s skin with bare hands until the source of electricity has been turned off Switch off power
17. ed on a level and stable surface for transport and operation If the generator is to be installed in a permanent location a concrete plinth should be used Never operate the generator whilst itis moving The generator should only be operated when stationary 2 SAFTY CONSIDERATIONS 2 1 FIRE AND EXPLOSION Fuels and fumes which are used and produced by generators can be flammable and potentially explosive The proper precautions should be taken whenever dealing with these items to ensure that the risks of explosions are limited Safety compliance requires a fully charged class BC Regular dry chemical extinguisher and class ABC Multipurpose dry chemical extinguisher to be installed in the vicinity of the generator Personnel must know how to operate this equipment If the generator is installed in a room ensure the room is properly ventilated and that the generator has at least 1m open area around it for servicing requirements and ventilation Keep the room the floor and generator clear and clean of debris Spills of fuel oil coolant or battery acid must be cleaned immediately Never store flammable liquids near the generator Do not smoke or allow sparks flames or other sources of ignition around the fuel or battery s Fuel vapours are explosive Hydrogen gas generated by charging batteries is also explosive Turn off or disconnect the power to the battery charger before making or breaking connections with the battery Keep tool
18. eorganise the electrical distribution system if the generator is to be connected to an existing installation 5 2 POWER FACTOR The power factor cos of the connected load should be determined Factors below 0 8 will overload the generator The generator will provide its kilowatt rating and will operate satisfactorily from 0 8 to unity 1 0 power factor Particular attention must be given to installation with automatic or manual power factor correction equipment to ensure that a leading power factor is not present under any conditions This will lead to voltage instability on the generator output and may result in damaging over voltages The load power factor compensator for use with a commercial electrical power source should be automatically isolated while the generator is in operation 5 3 GROUNDING REQUIREMENTS Enquire with your local electrical company or supplier as to what the grounding earthing requirements are in your country Bundu Power connects the frame of the alternator to the frame of the generator The earthing of the star point neutral of the alternator is the responsibility of the electrician installing the generator 6 START UP Before starting the generator please see the relative chapter of the engine manual to ensure the engine is in good working condition If this is the first start up of the generator ensure that you have read the relevant chapters in this manual about the fuel oil coolant and batter
19. erator set PRE ALARM DESCRIPTION LCD DISPLAY CHARGE FAILURE ect If the voltage from the charging alternator is too low the common failure LED indicator flashes the LCD displays the Charge failure icon This affects the charging of the starting battery BATTERY UNDER VOLTAGE If the controller detects that the starting battery voltage is too low the common failure LED will flash and the voltage will be displayed in the bottom right corner of the LCD screen The downward arrow indicates low voltage BATTERY OVER VOLTAGE If the controller detects that the starting battery voltage is too high the common failure LED will flash and display the voltage in the bottom right corner of the LCD screen The upward arrow indicates high voltage LOW OIL PRESS If the generators oil pressure is too low the common failure LED will flash The current pressure will be displayed in the top right corner of the LCD screen The default pre set low pressure is 2 2 bar The downward arrow indicates low pressure HIGH TEMP If the generator temperature is too high The common failure LED will flash and the temperature will be displayed in the middle right section of the LCD screen The upward arrow indicates that the temperature is too high OVER SPEED If the engine exceeds its RPM threshold the common failure LED will flash The RPM will be displayed in the middle section of the LCD screen The upward arrow indicates the engi
20. irement should be carried out when the first interval is met hourly or calendar periods If your generator is used for emergency backup or used about once a week you should do a minimum of weekly check ups 8 MAINTENANCE EVERY 6 MONTHS OR X HOURS 250 HOURS 1500RPM 100 HOURS 3000RPM Repeat the daily requirements Check all safety devices by electrically simulating a fault to ensure that all systems will function properly in the event of a fault Clean the battery terminals Start the generator and observe the control panel does not have any warnings or faults displayed Tighten all exhaust connections Tighten all electrical connections Refer to the engine maintenance manual for further instructions 11 8 7 WATER Check the water level by opening the filler cap on the top of the radiator or by reading the gauge level on the top of the radiator and add water if necessary Replace the radiator filler cap if it is damaged or loose When pouring antifreeze solution first drain out the old antifreeze from cylinder block and radiator then flush them with a cleaning solution Check the percentage of antifreeze on the chart below Antifreeze solution Freezing Point C 10 20 20 O Table 1 If more than 50 of the solution is antifreeze this will cause the engine to overheat Avoid placing this amount of antifreeze into the engine Add at least 5 antifreeze to the engine t
21. ithin the pre set parameters and could harm your electrical equipment 19 Generator Auto Start Sequence When the Mains electricity feed fails or falls outside of the pre set voltage and frequency parameters the following sequence is implemented in AUTO mode when an Automatic Transfer Switch ATS is attached The Start delay timer begins to countdown On completion the engine preheater is initialised The preheater is used to prevent damage to the generator Once the preheat sequence has completed the generator will start When the engine has started and has reached operating speed the controller will monitor voltage frequency oil pressure coolant temperature to ensure they are within operating parameters If no failures are detected the LCD display will show various parameters this indicates the generator is running normally The ATS will now automatically transfer the load to the generator If the Mains electricity is restored during the above start up sequence the generator will automatically shut down and return to standby mode To avoid damage to the start motor please ensure the generator s battery voltage is higher than 15V CAUTION If the generator fails to start during the above starting sequence the controller will display the Failed to Start icon on the screen The controller will then attempt to start the generator again after a period of time The controller will attempt to start the generator continuall
22. k the fuel filters Replace if necessary a Every 250 Hours or 1 year 1500 RPM Engines b Every 100 Hours or 1 year 3000 RPM Engines ALWAYS use original Bundu Power parts 3 Check fuel solenoid is functioning correctly 14 Cooling System 1 Check the coolant level Replenish if necessary Check for water leaks clean up and repair any water leaks Check flexible water lines are not perished Replace perished or leaking lines Fan Belts and Battery 1 Check fan belts are in condition and are not perished Replace any necessary fan belts ALWAYS use original Bundu Power parts Check the battery is charged and there are no visible leaks NOTE BP19SK and BP19SK3 These models require the Cam Belt to be changed every 500 hours Additional technical support is available from Bundu Power on their Johannesburg office number 27 11397 7373 or via email on support bundupower co za Bundu Power reserves the right to change the content of this book at any stage and will not be held responsible for clerical errors It is the responsibility of the Generator Owner to schedule regular maintenance and keep the generator in good working order If the generator is not maintained the warranty will be void at the discretion of Bundu Power The Bundu Power warranty is offered on a carry in basis Mileage will be charged for in the event that a Bundu Power technician is dispatched to site for a warranty claim YOUR LOCAL A
23. ne warning of an over speed state UNDER SPEED If the engine falls below its RPM threshold the common failure LED will flash The RPM will be displayed in the middle section of the LCD screen The downward arrow indicates the engine warning of an under speed state OVER CURRENT If the phase output current of the generator is too high On any phase the common failure LED will flash The current for each phase L1 L2 and L3 If applicable will be displayed on the screen The upward arrows next to the current indicates the over current on that phase GEN OVER VOLT If the voltage output is too high the common failure LED will flash The voltage will be displayed on the LCD screen with an upward arrow to indicate the voltage is too high on that particular phase GEN UNDER VOLT If the voltage output is too low the common failure LED will flash The voltage will be displayed on the LCD screen with a downward arrow to indicate the voltage is too low on that particular phase GENAU GEN U E ETE z E L ES SE TN gt Maman I 23 LOW FUEL LEVEL If the fuel level is low the common failure LED will flash This is indicated on the LCD screen in the bottom right corner The downward arrow indicates that the fuel level is low AUXILIARY PRE ALARM If an auxiliary input is defined as a warning when the input signal is active the common failure LED will
24. ns in effect 8 6 AIR CLEANER Air filters Cleaners should be replaced on the following schedule o 1500 RPM Engines 250 Hours o 3000 RPM Engines 100 Hours Only fit approved Bundu Power Air Filters to the generator to ensure warranty remains in effect If air filters are still in good condition they can be cleaned and reused Clean ONLY using compressed air 13 9 MAINTENANCE Check the battery for damage or leaks Replace the battery if damaged Ensure there is no obstruction of the exhaust pipe Keep the battery away from fire and sources of heat Keep the generator in a well ventilated area 10 MAINTENANCE CHECK LIST If there is an Automatic Transfer Switch ATS Automatic Transfer Switch 1 Start Stop the generator by simulating a power cut 2 Transfer the load to the generator after warm up period 3 Record Loads General Operation 1 Record AC Voltage with and without load 2 Record Frequency with and without load 3 Record the Hours on the unit Oil System 1 Check the oil level 2 Check the oil filters Replace if necessary a Every 250 Hours or 1 year 1500 RPM Engines b Every 100 Hours or 1 year 3000 RPM Engines ALWAYS use original Bundu Power parts 3 Service the oil system drain and replace oil if necessary 4 Look for oil leaks clean up and repair them Fuel System 1 Check the fuel connections are secure and not leaking Clean up and repair any leaks found 2 Chec
25. o prevent possible engine corrosion in hot weather 8 2 FAN BELT Only use an approved Bundu Power fan belt of the correct dimensions for the generator in question to replace worn or broken fan belts Check the fan belt tension is correct If the belt tension is lower than specified limit adjust tension by relocating the charging alternator and idle pulley 8 3 ENGINE OIL Check oil level using oil dip stick and replenish with approved oil if needed Regular clean diesel motor vehicle can be used L ECD grade or 15W40 Check oil level on even ground when the engine has cooled Oil level must be between MAX and MIN lines on the dipstick 12 Engine oil to be changed at specified intervals The oil filter should be changed simultaneously 8 4 OIL FILTER Check for oil pressure and oil leaks and repair or replace filter if necessary Replace oil filter element every time engine oil is changed Oil filter should be replaced on the following schedule o 1500 RPM Engines 250 Hours o 3000 RPM Engines 100 Hours Only fit approved Bundu Power Oil Filters to the generator to ensure warranty remains in effect 8 5 FUEL FILTER Fuelfilters should be replaced on the following schedule o 1500 RPM Engines 250 Hours o 3000 RPM Engines 100 Hours fthe fuel quality is bad ensure you replace the fuel filter more regularly Only fit approved Bundu Power Fuel Filters to the generator to ensure warranty remai
26. oller is in AUTO mode it will automatically start under the following 3 conditions e Mains Electricity Feed Voltage below above threshold e Remote start signal is active e Mains Electricity Feed Failure 14 3 MANUAL CONTROL SEQUENCE The controller is in MANUAL mode If the mains electricity feed is present the ATS will feed the building or application when an ATS is attached to the controller When Mains is present the Mains LED will be lit 21 Manual Generator starting sequence Pressing the START button will start the start sequence After a 300ms delay the engine preheat will start on completion the engine will attempt to start Once the generator is up to speed the controller will monitor the various parameters to ensure the generator is ready to take load If successful the controller will display the various measurements onscreen Transfer to the load to the generator manually by switching the ATS to generator The Normal operation LED will now be lit 15 WARNINGS PRE ALARMS NOTE Warnings are non critical failure conditions and do not affect the operation of the generator They are intended to notify the operator of any impending problems or failures prior to them occurring When warnings occur the LED indicator flashes but the unit will not shutdown Once the warning has been cleared with LED will stop flashing Warnings are important and should be attended to ensure the longevity of your gen
27. r when in manual mode INCREASE BUTTON It is also used to increase values when setting parameters The stop button is used for manually stop the generator when in manual mode Press and hold STOP the button for 2 seconds RESET DECREASE BUTTON AUTO MODE BUTTON If a failure occurs press this button to clear the failure It is also used to decrease values when setting parameters COMMON The LED will flash when a warning occurs FAILURE The LED will remain lit when a shutdown alarm LED OCCUIS 18 14 CONTROL AND OPERATION INSTRUCTION The controller has 2 modes AUTOMATIC and MANUAL 14 1 OPERATION MODE SETTINGS OPERATION BUTTON Press and hold the AUTO button for 2 seconds to select AUTO mode the LED above the button will be lit when AUTO mode has been selected Press and hold the MANUAL button for 2 seconds to select manual mode the LED above the button will be lit when Manual mode has been selected NOTE Only 1 mode can be selected at a time from the above 2 modes 14 2 AUTOMATIC CONTROL SEQUENCE Controller is running in AUTO mode When Mains Electricity feed is available Live When the Mains electricity feed is present and the voltage and frequency of Mains are within the normal operating parameters the Mains LED will be lit If the Mains LED is not lit this indicates that the Mains feed is either not available or that the voltage or frequency of the Mains feed is not w
28. s and other metal objects away from exposed electrical parts such as terminals to avoid arcing Sparks and arcing might ignite fuel or vapours or cause electrocution if touched Avoid refuelling the generator while it is running Do not attempt to operate the generator with any known leaks in the fuel system Repair all leaks before operation Only use recommended fuel oil and coolant Ensure that the fuel is not contaminated and that the fuel cap is secured tightly to prevent contamination 2 2 MECHANICAL The generator has protective covers for moving parts but precautions should be taken when working around the generator to prevent bodily harm or damage to the mechanical components of the generator Do not attempt to operate the generator with the protective covers removed Do not attempt to do any maintenance or modifications while the generator is running as it could result in damage to the generator or cause bodily harm Keep all body parts away from the generator its belts and mechanisms at all times Also ensure that jewellery and hair is kept clear of the moving parts while in operation Some moving parts cannot be seen clearly when the generator is running Keep access doors closed and latched at all times unless specific access is required Avoid contact with hot oil hot coolant hot exhaust gases and hot surfaces Wear protective clothing when working on or around the generator Do not remove the radiator cap until
29. y Connect the battery wires to the output terminals of the battery Ensure the circuit breaker is in the OFF position START DR Turn the key on press and hold the green start button for 5 seconds You will then see Preheat on the screen wait for the generator to start STOP O First turn off the circuit breaker then push and hold the red button until engine stops 7 GENERAL To ensure the longevity of your generator it is imperative to have a strict and rigorous maintenance regime At the back of this book there is a program that should keep your generator in optimal running condition Ensure that all servicing is conducted by a trained and competent technician preferably with experience on generator sets In addition records of the servicing regime should be kept A record can be kept in the back of this manual These records will allow quick reference and may help diagnosing a problem in the future 10 7 1 DAILY OPERATION Prior to starting the generator check the oil and fuel level in the engine Should the levels be low add the necessary liquids In addition check the radiator coolant level and battery electrolytes before starting up the generator 7 2 PREVAENTATIVE MAINTENANCE Depending on the application of each generator the requirement for preventative maintenance operations will vary The following schedule is outlined with intervals based on the calendar and hours of service The maintenance requ
30. y for the pre set number of starting attempts If a failure occurs during any of the attempts the controller will stop attempting to start the generator immediately and an error will be displayed on the screen unless it is manually cleared Start Failure If after attempting the pre set number of start attempts the engine does not start Fail to Start will be displayed on the LCD screen If this occurs check the whole generator to determine the reason for the start failure 20 If Fail to Start is displayed The operator must check the whole Generator to determine what has caused the failure Only after determining the cause of the failed start E y attempts press the STOP RESET button to reset the CAUTION generator and attempt to start the generator again Generator Auto Shutdown Sequence When the Mains electricity feed is restored the Mains LED will be lit A delayed sequence is activated to shut down the generator The ATS will automatically receive the signal from the controller to transfer the load back to the Mains electricity feed The generator will start its cool down procedure running under no load for a period of time Once the generator has shut down it will return to its standby state ready for any future Mains failures Stop Failure If the generator fails to shutdown correctly the Failure to Stop icon will be displayed on the screen Conditions Required for Automatic Start When the contr
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