DIESEL GENERATOR

USERwww.BunduPower.co.za
MANUAL
INDEX QUICK START GUIDE 1500RPM
1 Quick start guide – 1500RPM 3 1 Check the battery is connected (Positive and negative terminals are tightened)
2 Quick start guide – 3000RPM 4 2 12 - 50kVA ONLY: Check the battery lock-out switch is in the correct position
3 Installation guidelines 5-7 3 60kVA+ ONLY circuit breakers are all in the up position behind the control screen
4 Installation and handling 8 4 Fill the tank with diesel. The generator will not run without being filled first. If the generator is started
5 Fire and explosion 9 without diesel, it will need to be primed again once filled with diesel.
6 Safety considerations 10 - 11 5 Switch the screen on with the ON/OFF key.
6.1 Mechanical 6 Check for any alarms and rectify them before starting.
6.2 Chemical 7 Select the AUTO button to place the generator in automatic mode. Be careful as the generator will start
6.3 Electrical without warning if it does not have mains connected. Select RUN to start the generator manually.
7 Electrical 12 8 Once started, use the arrow buttons to check the output voltage are correct before connecting load
7.1 First aid for electric shock to the generator.
7.2 Electrical connection
7.3 Electrical loading
7.4 Grounding requirements SINGLE PHASE: +/- 230V THREE PHASE: +/- 230/400V
7.5 General
10 Preventative maintenance 13 - 15
9 To use the generator in automatic mode, you must have an automatic transfer switch (ATS) installed
11 Controllers 16 - 18
by a qualified electrician. The ATS should be installed as close to the distribution board (DB) as possible
13 Maintenance log 19
in order to reduce the cost of cabling. The electrician must issue a Certificate of Compliance (COC)
on completion of the work.
10 A communications cable and electricity supply cable need to be run from the ATS to the generator.

WARNINGS
11
Refer to the wiring diagram supplied with the generator. Cable not included.
All BPD Series generators have a battery charger built into the generator. This allows the generator
to be used with a manual transfer switch whilst still keeping the battery charged from the mains power.
Read and understand all safety precautions and warnings before operating or performing maintenance This must be connected by a qualified electrician.
on the generator.

Failure to follow instructions, procedures and safety precautions in this manual may increase the
possibility of accidents or injuries.
NOT STARTING?
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. If the generator is not starting having been through the above sequence, try the following 3 steps.
It is very important to regularly carry out checks suggested in this manual to maximise the generators
lifespan and prevent accidents from occurring. If the generator is cranking but not starting:
STEP 1 Prime the diesel through the system using the priming pump on the engine.
Never start the generator unless all foreign items are removed from inside the sound attenuated canopy
and the doors are securely closed.
If the generator is not cranking but the screen is on,
Do not attempt to operate the generator in unsafe conditions.
STEP 2 it is likely that the battery is flat.
If the generator set is unsafe to operate, disconnect the battery negative (-) lead to prevent starting
the generator until the problem has been rectified.
If the screen does not come on at all, the battery lock out is in the wrong position or the
Disconnect the generators negative battery lead prior to attempting any repairs or cleaning the inside battery is completely flat. For models BPD12 – BPD50, the battery lock-out can be found
of the sound attenuated canopy. STEP 3 below the control panel. For models BPD60S3 and larger, the circuit breaker can be found
behind the control screen.
Install and operate this generator within the local and national legislation applicable to your territory.

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 QUICK START GUIDE 3000RPM INSTALLATION GUIDELINES
STARTING ELECTRICAL INSTALLATION
1 Make sure the generator is on level ground. 1 Install surge protection.
2 Check the battery is connected (Positive and negative terminals are tightened). 2 Bond generator and automatic transfer switch (ats) to main incoming earth from mains supply.
3 Fill the tank with diesel BEFORE attempting to start the generator. The generator will not run without being
3 Check voltage between neutral and earth (should be no residual voltage).
filled first. If run without diesel you will have to prime the engine again to run the generator once filled.
4 Switch the screen ON with the ON/OFF key. 4 Cable should be sized to carry the full load of the generator.
5 Ensure the breaker is in the OFF position. 5 Ats or manual switch should be sized to carry full load of mains or generator, whichever is highest.
6 Press the Green button on the screen “RUN” and wait for the generator to crank.
6 Check all nuts are tight on mains and generator connectors in ats or manual change over.
7 Once started and running, turn the breaker to the ON position to supply power.
7 Certificate of compliance (coc) to be issued by the installing electrician.

STOPPING CIVIL WORKS

1 Switch the breaker to the OFF position 8 Generator placed on level concrete surface.
2 Allow the generator 1 minute to cool down.
9 150Mm thick plinth with wire mesh reinforcing.
3 Press the red STOP button.
4 Turn off the screen with the key. 10 Exhaust and hot air to be directed outside if installed in a room.
11 If installed outside it is recommended that the generator is placed under a roof.
Ensure you keep the battery sufficiently charged if not installed with an ATS and battery charger.
Start the generator a minimum of once per month to ensure it is in working order when required.
GENERAL
NOTE: If the screen is left in the ON position, the display will go into sleep mode. It will still drain the
12 1M space around the generator for service access.
battery. Ensure you turn off the screen when not in use. If used with an ATS, the screen will remain
in sleep mode until needed and the battery will remain charged with a battery charger.

WARNING The above checklist is provided in order to standardize the installation of your generator set. If the above
checklist and following explanations are adhered to, this will reduce the possibility of any issues arising
in the future.
DO NOT: Run this generator indoors. The exhaust fumes are dangerous and can cause death.
This generator is air-cooled and any restriction to the air-flow of the generator can cause
Always use qualified personnel for the installation of your generator. Qualified electricians are required
the generator to overheat.
by law to do the installation of your generator. Please insist on an ECBSA certified electrician.
DO NOT: Run this generator in a closed room. The hot air will recirculate and cause the generator to overheat.
This is a fire hazard.

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 INSTALLATION GUIDELINES
CHECKLIST EXPLAINED FAQ
1 Surge protection should be installed on the mains incoming feed to avoid over voltage which could harm your Q Do I need to anchor the generator?
electrical equipment and generator. In addition to protecting your equipment the generator is setup to sense A No, the generator once placed on the plinth will not move. The only possible reason to need to anchor the
voltage fluctuations within a specific range and turn on and off accordingly (If in automatic mode with an ATS). unit is for theft.
2 As per the electrical regulation of South Africa. (Bonded neutral earth).
Q Do I need anti-vibration mountings or a rubber mat?
3 Any residual voltage found between the neutral and earth will increase the voltage supplied which will A No, the engine is mounted on anti-vibration mountings already so the generator will not move once placed
eventually have adverse effects on electrical items. on the plinth. You can place a rubber mat under the generator but it is not necessary.
4 Cable should be sized to carry the full load of the generator.
a BPD SERIES - The communications cable should be 1.5mm (Up to 40m). Q I don’t have space for 1m around the whole unit?
3-Phase generators need a 6-core communications cable. A Each model is different, chat with your sales consultant who can advise the optimal position of the
1-Phase generators need a 4-core communication cable. generator within a confined space. Alternatively have a steel framed trolley made to move the generator
around easily.
5 The ATS or Manual switch should be sufficiently sized to carry the maximum load from either generator
or mains. Our switches are normally sized to the maximum generator output.
Q Will my generator start automatically when the power fails?
6 The connections inside the ATS or manual change over switch should all be checked and tightened by the A If you have installed an automatic transfer switch (ATS) and it has been installed correctly, then yes
electrician prior to signing off. Transportation of the ATS and generator can often cause these nuts and bolts provided the generator and ATS are in automatic mode.
to become loose.

7 A Certificate of Compliance (COC) is required by law to be issued by the installing electrician. This certificate Q The screen stays on all the time?
will be needed for your insurance as well as by Bundu Power should there be an issue with the installation A When the generator is in automatic mode, the screen and indicator lights remain illuminated for 60 mins.
of the generator at a later date and for warranty claims. This can be adjusted in settings.

8 The generator operates optimally when on a level surface. The fuel tank and oil are designed to be used
on a level surface. Q Do I need to do anything once the generator is installed and operational?
A You should check that everything on the generator is working at least once a month. Start the generator
9 The concrete slab is required to ensure a solid and level surface for the generator. In some instances, placing and check that it is automatically switching over if you have no mains electricity. You should keep
the generator on solid paving will also suffice. The reason for the concrete plinth is to avoid any subsidence maintenance records. Ensure the fuel tank is kept topped up.
in the future.

10 Should the generator be installed in a room or garage it is imperative that the exhaust gases and hot air are Q Does the generator include cabling and installation?
vented out of the room. The generator produces toxic gases which must be expelled from the area. In addition, A Installation and cables are not included.
the room should be well ventilated so that the generator has cool air to cool it down when in operation.
Q Does the generator battery stay charged?
11 Installing the generator under a roof is optional but is recommended to avoid any adverse weather damaging
the generator. Due to the generator being outside and often in direct sunlight for parts of the day the paint is A The BPD series and Gas generators have battery chargers built-in. They need to be connected to the mains
prone to fade over time. electricity to keep the generator charged. Please ask your sales consultant if your generator includes a
battery charger.
In addition to this the possibility of water damage from cloud bursts or hail damage is greatly reduced by
installing the roof over the generator.

We recommended at least 1m clearance above the generator for the roof.

12 One meter of space around the generator is required for maintenance. The technician will require access
to both sides of the generator when servicing and inspecting the generator. A service should be performed
every 12 months or at the required intervals as per the user manual.

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 INSTALLATION & HANDLING FIRE & EXPLOSION
This manual covers the basic procedures to install and maintain your generator. In addition, it outlines Fuels and fumes which are used and produced by generators can be flammable and potentially explosive.
the general safety precautions whilst utilizing the generator. 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)
All relevant chapters should be read before attempting to install, lift, move or perform maintenance and class ABC (Multipurpose dry chemical extinguisher) to be installed in the vicinity of the generator.
on the generator. Installation should always be performed by a qualified electrician who will supply you Personnel must know how to operate these devices.
with a compliance certificate on completion (COC).
Ensure the generator room is properly ventilated and that the generator has at least 1m open area around
Electrical work, including earth grounding and insulation should be carried out in compliance with local it for servicing and ventilation.
regulations and laws.
Keep the room, the floor and generator clear and clean of debris.
Additional fuel tanks should comply with local regulations and laws.
Spills of fuel, oil, coolant or battery acid must be cleaned immediately.
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. Never store flammable liquids near the engine.

Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries. Fuel vapours are
explosive. Hydrogen gas generated by charging batteries is also explosive.

WARNING Turn off or disconnect the power to the battery charger before making or breaking connections with the battery.

Keep tools and other metal objects away from exposed electrical parts such as terminals, to avoid arcing.
FAILING TO VENT THE EXHAUST FUMES OUT OF A STRUCTURE CAN LEAD TO DEATH BY ASPHYXIATION. Sparks and arcing might ignite fuel or vapours.
IT IS IMPERATIVE THAT ALL FUMES PRODUCED BY THE GENERATOR ARE NOT INHALED AT ANY TIME.
Do Not refuel the generator while it is running.

Do not attempt to operate the generator with any known leaks in the fuel system.
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 or the lifting eye’s Only use recommended fuel, oil and coolant.
if available.

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.

Ensure that the generator is placed on a level surface. The generator should always be placed 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.

Generators mounted on trailers should be fixed to a flat surface. Ensure that the trailer is suitable and capable
of sustaining the weight of the generator. Never move the generator while it is running.

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 SAFETY CONSIDERATIONS
MECHANICAL ELECTRICAL
The generator has protective covers for moving parts, but precautions should be taken when working around Ensure all electrical equipment and components are correctly installed to prevent damage to the components
the generator to prevent bodily harm or damage to the mechanical components of the generator. and the operator. Ensure that these items are regularly maintained.

Do not attempt to operate the generator without the protective covers. Do not attempt to do any maintenance The generator must be connected to the load only by trained and qualified electricians who are authorised to
or modifications while the generator is running. 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
Keep all body parts away from the generator, its belts and mechanisms at all times. Also ensure that jewellery operating the generator or a certificate of compliance (COC) should be issued.
and hair is kept clear of the moving parts while in operation.
Ensure the generator is effectively grounded/earthed in accordance with all relevant regulations prior to
Some moving parts cannot be seen clearly when the set is running. operation.

Keep access doors closed and latched at all times unless specific access is required. The generator should be shutdown with the battery negative (-) terminal disconnected prior to attempting to
connect or disconnect load connections.
Avoid contact with hot oil, hot coolant, hot exhaust gases and hot surfaces.
Do not touch the inter-connecting cables, conductors or electrical components of the generator which are not
Wear protective clothing when working on or around the generator. insulated.

Do not remove the radiator cap until the coolant has cooled. Then loosen the cap slowly to relieve any excess Replace the terminal box and all covers once connected before attempting to start and run the generator.
pressure before removing the cap completely.
Ensure that the bolts and connectors securing all cables are securely fastened and are checked to ensure they
have not loosened during operation. This applies to the generator and switch-gear.

CHEMICAL 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)
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. Be sure all electrical power is disconnected from electrical equipment being serviced.

Do not swallow or allow skin contact with fuel, oil, battery acid or lubricants. If swallowed seek medical Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut, damaged
treatment immediately. For skin contact, wash with soap and water thoroughly. or degraded. Replace terminals that are worn, discoloured or corroded. Keep terminals clean and tight.

Wear an acid resistant apron and face shield or goggles when servicing the battery. If acid gets onto the skin Insulate all connections and disconnected wires.
or clothing, flush immediately with large quantities of water.
Use only class BC or class ABC extinguishers on electrical fires.

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 ELECTRICAL PREVENTATIVE MAINTENANCE
Depending on the application of each generator the requirement for preventative maintenance operations
FIRST AID FOR ELECTRIC SHOCK will vary. The following schedule is outlined with intervals based on the calendar and hours of service.
The maintenance requirement should be carried out when the first interval is met (hourly or calendar periods.)
Do not touch the victim’s skin with bare hands until the source of electricity has been turned off.
If your generator is used for emergency backup or used about once a week, you should do a minimum
Switch off power, if possible, or pull the plug or cable away from the victim as quickly and safely as possible. of weekly check-ups.
Use the emergency stop button where 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. DIESEL ENGINES 1500RPM 3000RPM
PERIOD Every 12 Months Every 12 Months
ELECTRICAL CONNECTION HOURS Every 250 Hours Every 100 Hours
The cables connecting the generator with the distribution system should be protected by means of a circuit breaker, OIL (15W40)
fuses or other means to disconnect the generator in case of overload or short circuit. Please refer to installation
guidelines. OIL FILTER
FUEL FILTER
ELECTRICAL LOADING AIR CLEANER

When planning your distribution system, it is important to ensure that a balanced load is placed on the generator ONLY USE GENUINE BUNDU POWER PARTS
(3-Phase). 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. • Check all safety devices by electrically simulating a fault to ensure that all systems will function properly,
in the event of a fault.
It may be necessary to reorganise the electrical distribution system if the generator is to be connected to an • Clean all battery vent caps.
existing installation. The generator will shutdown if phases are not balanced.
• Start the generator and observe the control panel and make sure all parameters are operating correctly.
• Tighten all exhaust connections.
• Tighten all electrical connections.
GROUNDING REQUIREMENTS • Refer to the engine maintenance manual for further instructions.

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.
FAN BELT
• Only use an approved Bundu Power fan belt of the correct dimensions for the generator in question

GENERAL
•
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
To ensure the longevity of your generator it is imperative to have a strict and rigorous maintenance regime. and idle pulley.
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.
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 PREVENTATIVE MAINTENANCE
WATER FUEL FILTER
• Check the water level by opening the filler cap on the top of the radiator or by reading the gauge level • If the fuel quality is bad ensure you replace the fuel filter more regularly.
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.
AIR CLEANER
• Check the percentage of antifreeze on the chart below.
• If air filters are still in good condition, they can be cleaned and reused.
• Clean ONLY using compressed air.
ANTIFREEZE SOLUTION (%) FREEZING POINT (°C)
20 -10
MAINTENANCE CHECKS
27 -15
• Check the battery for damage or leaks. Replace the battery if damaged.
33 -20 • Ensure there is no obstruction of the exhaust pipe.
• Keep the battery away from fire and sources of heat.
40 -25
• Keep the generator in a well-ventilated area.
44 -30
50 -40

• 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 to prevent possible engine corrosion in hot weather.

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.
• Engine oil to be changed at specified intervals. The oil filter should be changed simultaneously.

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.

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 CONTROLLERS
DATAKOM D300 CONTROLLER (1500RPM) BUTTON FUNCTION

FAULT CONDITION GRAPHIC LCD MIMIC DIAGRAM Selects TEST mode. The genset runs and takes the load.
INDICATORS SCREEN (SYSTEM STATUS)

PREVIOUS NEXT DISPLAY

DISPLAY GROUP GROUP Selects RUN mode. The genset runs off-load.

Selects AUTO mode. The genset runs when necessary

and takes the load.

Selects OFF mode. The genset stops.

Selects next display screen in the same display group.

LAMP TEST when held.

Selects previous display group.

TEST MODE RUN MODE AUTO MODE STOP MODE Selects next display group.
BUTTON BUTTON BUTTON BUTTON

NEXT SCREEN PREVIOUS SCREEN Selects previous display screen in the same display group.
IN THE SAME GROUP. IN THE SAME GROUP. Resets the ALARM RELAY.
LAMP TEST IF HELD. ALARM MUTE.

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 CONTROLLERS MAINTENANCE LOG
PERSON / COMPANY DESCRIPTION
HOUR METER
DATE CONDUCTING OF MAINTENANCE /
DATAKOM D300 CONTROLLER LED LAMPS READING
MAINTENANCE REPAIR / SERVICE

SHUTDOWN MAINS
ALARM INDICATOR AVAILABLE LED

WARNING MAINS
INDICATOR CONTACTOR ON LED

SERVICE REQUEST GENSET

INDICATOR CONTACTOR ON LED

GENSET
AVAILABLE LED

TEST MODE STOP MODE

INDICATOR INDICATOR

RUN MODE AUTO MODE

INDICATOR INDICATOR

DATAKOM DKG-116 CONTROLLER

LOW OIL PRESSURE

HIGH ENGINE TEMPERATURE

SPEED (OVERSPEED OR UNDERSPEED)

FAIL TO START

VOLTAGE (OVER/UNDER VOLTAGE)

EMERGENCY STOP

18 19
JOHANNESBURG
2 Bravo Road, Jetpark, Johannesburg

011 397 7373

[email protected]

PIETERMARITZBURG
Unit 9, Willowood Park, 21 Du Toit Viljoen Road,
Willowton, Pietermaritzburg

033 007 0812

[email protected]

NELSPRUIT
Unit 1, 14 Meander Crescent, Riverside, Nelspruit

013 007 1753

[email protected]

www.BunduPower.co.za