usage and maintanence manual

usage and maintanence manual
IS3501 &
IS5501
USAGE AND MAINTANENCE
MANUAL
#16501
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TAB "A"
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WIRING DIAGRAM
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CONTENTS
FIGURES ............................................................... page 2
TAB."A" TABLE SUGGESTED OILS ...................... page 2
WIRING DIAGRAM ................................................ page 4
1
SAFETY REGULATIONS ....................................... page 6
2
PRELIMINARY CHECKS ....................................... page 6
3
GENERATOR USE ................................................ page 6
Starting
Generator Stop
4
SAFETY DEVICES ................................................ page 6
Low oil pressure device
Warning
High temperature device
Alternator overload/over temperature device
5
MAINTENANCE ..................................................... page 7
Engine maintenance
6
INACTIVE PERIOD ................................................ page 7
7
CONTROL PANEL ................................................. page 7
8
PROTECTION FUSE .............................................. page 8
9
DIMENSION AND WEIGHT .................................... page 8
10 WIRING DIAGRAM DESCRIPTIONS ...................... page 8
11 MAINTENANCE CHART ......................................... page 8
12 TROUBLE SHOOTING ........................................... page 8
13 TECHNICAL FEATURES ....................................... page 9
DANGER
Indicates that significant attention must be paid in order to prevent serious danger which
could lead to injury or death.
WARNING
A condition which may occur during the lifetime of a product, system or plant that has
the potential for human injury, damage to property, damage to the environment, or economic loss.
CAUTION
Indicates that particular attention must be paid in order to prevent serious damage to the
product or other property.
General helpful information
INFORMATION
The drawings in this manual are provided as examples of generic installations. Even if your installation differs
considerably from the illustrations contained in this manual, the drawings should still provide you with general
guideline and principles of a proper installation.
Note: the information contained in this publication is correct at the time of printing. The manufacturer may make
regular improvements and upgrades to the product which are not reflected in the illustrations.
5
3. GENERATOR USE
MASE GENERATORS
This manual contains necessary information for proper
maintenence and use of the generator. It is essential for
your safety and the reliability of the generator, to carry out
proper installation and careful pre-delivery tests.
An error in installation or an oversight in testing may
compromise the efficiency of the generator and even
jeopardize your safety.
All information and illustrations in this handbook refer to
the latest produced model at the time of printing.
For any further information, please get in touch with your
nearest Mase dealer.
Mase reserves the right to introduce changes without
prior notice. No part or illustration contained in this
handbook can be reproduced without previous approval
by Mase
Before starting the generator, make sure all preliminary
checks, as per section 1 , have been properly performed.
Starting
To start the engine, push the button << ON >> (fig. 3 ref.
4), all the pilot and warning lamps will glow for 5 sec. as
a self -check function. Afterwards the << panel on >> will
stay lighted (fig. 3 ref. 5). Start the engine by pushing the
<<Start >> button (fig. 3 ref.3), for 5 sec. max. Release
it only when the engine runs. During proper genset
operation, the led will (fig .3 ref. 6) glow. Once started, the
safety shut-downs on the generator are automaticily
activated (see item. 4).
Generator Stop
The generator can be stopped by pushing the <<OFF>>
button on the control panel (fig. 3 ref 2).
4. SAFETY DEVICES
1. SAFETY REGULATIONS
- Carefully read all the instructions in this manual and in
the installation manual; they are very important for correct
installation and use of the unit.
- Do not allow unskilled or untrained people to use the
unit.
- Do not allow children or animals to get close to the
generator while it is operating.
- Do not handle the generator or the remote control panel
with wet hands; any misuse may cause electric shocks.
- Any testing of the unit is to be carried out only when the
engine is stopped. Possible checks on the generator
when it’s running must be performed only by skilled
personnel.
2. PRELIMINARY CHECKS
When starting the generator for the first time and after any
servicing, it is advisable to make sure that:
- The oil is at the right level through the dipstick ref. 1 Fig.
1 , as per table for suggested oils.
- The generator is well secured to the soundproofing box
with the proper bolts.
- The electric loads are disconnected so as to avoid
starting the generator under load.
- Every connection (fuel, exhaust, remote control, A.C.,
battery) has been properly carried out and there are no
bad connections.
- The sea cock is open, as per (ref. 2 fig. 2)
- If a non-return valve is used, the cooling circuit from the
valve up to the pump must be manually filled (ref. 1 fig. 2)
The generator is equipped with a set of safety shut-downs
in case of any misuse or running problems:
- Low oil-pressure device:
shuts down the generator in case of insufficient oil
pressure. Its intervention is shown by the warning light
going on (fig. 3 Ref. 7). It is usually enough to top off the
oil before starting the generator again.
WARNING
The low oil-pressure device does not necessarily show
the oil level; a check of the oil level is consequently
necessary at regular intervals.
- High temperature shut-down:
shuts down the generator in case of high engine
temperature. Its intervention is shown by the warning light
going on (fig.3 ref.8).Should this device illuminate, refer
to the troubleshooting charts in Section 11 & 12 of this
manual, eliminate the cause(s) of the shut-down, then
restart the generator.
- Alternator overload/over temperature shut-down:
shuts down the generator in case of thermo or electric
overload of the alternator.
Should this warning light illuminate, (fig. 3 ref. 9), wait
until the temperature of the alternator windings returns to
normal. However, it is recommended to refer to the
troubleshooting charts in Section 11 & 12 of this manual
and eliminate the cause(s) of the shut-down, then restart
the generator.
WARNING
If one of the above safety devices intervenes refer to the
troubleshooting charts in Section 11 & 12 of this manual,
look for and eliminate the cause(s), then push the <<
STOP >> button to reset the panel.
6
7. CONTROL PANEL (fig. 3)
WARNING
In case the two fuses (ref.1/2 Fig.4) have blown,
the generator will not start.
5. MAINTENANCE
CAUTION
Any servicing must be performed with the engine stopped,
and only by skilled and licensed staff.
Engine maintenance
The engine must be serviced at regular intervals as shown
in the table in Section 11 of this manual. For further and
more detailed information, please consult the Yanmar
handbook supplied by the engine manufacturer,
accompanying this generator.
INFORMATION
Check oil level with the proper dipstick (fig. 5 ref. 1) and
make sure it is always in the minimum and maximum
range of the dipstick.
Engine oil capacity:
IS 3501 1.2 qt.
IS 5501 1.7 qt.
Oil changing and filling can be carried out through the
valve on the side of the sump pump. (fig. 1 ref. 1).
1) HOURMETER
2) OFF BUTTON
3) START BUTTON
4) ON BUTTON
5) PANEL ON LED (GREEN)
6) GENERATOR OUTPUT LED (GREEN)
7) OIL PRESSURE LED (RED)
8) ENGINE TEMPERATURE LED (RED)
9) GENERATOR TEMPERATURE LED (RED)
If the unit stops because the circuit breaker trips, the
operating time indication disappears from the control panel
display and a code appears to indicate the cause of the
generator shut-down.
The table below lists the codes and their meanings.
ALARM CODES
CODE
CAUSE OF CIRCUIT-BREAKER TRIP
E - 80
No power on generator
E - 81
Low oil pressure
E - 82
High motor temperature
E - 83
High alternator temperature
E - 85
Generator overload
E - 87
At 30sec. from start unit does not
reach 80% of nominal voltage
batt
Low battery
We suggest to carry out the draining when the oil is still
warm enough to allow easy flow.
INFORMATION
Before performing maintenance on the water-air exchanger
(ref. 3 fig. 6), it is necessary to empty the water intake
circuit through the special valve.(ref. 3 fig. 2)
Code E - 80
This code indicates the unit has stopped
because of no voltage. When this code appears, it
means:
- the control panel is unable to measure the alternator
voltage for cut-off of an electrical connection;
- the alternator is damaged.
6. INACTIVE PERIOD
Should the unit go unused for a long time, it is necessary
perform the following maintenance.
- Replace sump oil.
- Replace oil filter.
- Replace fuel filter.
- Replace the zinc anodes (ref. 1 fig. 6)
- If the generator room temperature is near or below 32°C
drain the engine cooling circuit using the drain valve (ref.
3 fig. 2)
- Lubricate the water pump impeller.
Code E - 81
This code indicates the unit has
stopped because the motor lubrication system pressure
is insufficient.
Code E - 82
This code indicates the unit has
stopped because the engine has reached too high a
temperature.
Code E - 83
This code indicates the unit has
stopped because the alternator has reached too high a
temperature.
7
Code E - 85
This code indicates the unit has
stopped because the voltage has dropped to below 70%
of the nominal value for longer than 15 seconds.
11. MAINTENANCE CHART
Code E - 87
This code indicates the unit has
stopped because the generator voltage has not reached
80% of the nominal value 30 seconds after starting. This
could be caused by insufficient motor RPM or a broken
alternator.
batt
This code indicates the battery is low.
When this code appears, the generator is not stopped.
C
WARNING
When a circuit breaker has tripped and the generator
has stopped, the panel must be reset by pressing the
“OFF” button in order to restart the unit.
INFORMATION
If the unit is started and the alternator does not produce
voltage, or the control panel does not read voltage, the
control panel switches off completely after one minute,
stopping the unit.
8. PROTECTION FUSE ( fig. 4 )
1) RELAY CIRCUIT FUSE
2) BATTERY CHARGER FUSE
10. DESCRIPTION WIRING DIAGRAM (fig. 8 )
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
ROTOR
STATOR
DIODE 3A
VARISTOR
PRINTED CIRCUIT RELAY
POWER TERMINAL BOARD
RELAY CIRCUIT TERMINAL BOARD
CONTROL PANEL TERMINAL BOARD
FUSE 1A
CAPACITOR
BATTERY CHARGER REGULATOR
FUSE 20A
STARTER
BATTERY
FUEL PUMP
FUEL SOLENOID
OIL PRESSURE SWITCH
OVERHEAD ENGINE THERMOSTAT
WATER TERMOSTAT
ALTERNATOR THERMOSTAT
z
z
COMPLAINT
PROBABLE REASON
Defective starting buttons
z
Defective fuel solenoid
Defective battery
cable section
z
Battery
z
z
Defective starting motor
z
Piping fuel filter choked
z
12V circuit fuse
z
Avv./Ev.relay
z
z
Too much oil in crankcase
Safety device intervention
z
z
z
Overload
z
Defective governor linkage
z
Worm valve guides
Blocked valves
BLACK SMOCKE
WHITE SMOCKE
IS 5501
28-7/8"
20-1/2"
24-5/8"
286 lb
START AND
STOP
IS 3501
26-1/4"
18"
23-1/2"
211lb
DOES NOT
START
L) Length
W) Width
H) Height
Weight
UNSTABLE
RUNNING
12. TROUBLE SHOOTING
9. DIMENSIONS AND WEIGHT( fig. 7 )
z
z
Worm cylinder and position rings
Defective injector
z
Defective injector pump
z
z
z
Defective feeding pump
z
z
z
z
13. TECHNICAL FEATURES
IS
IS5501
Engine
IS3501
Engine
Model:
Type:
Cylinders:
Cylinder block material:
Bore:
Stroke:
Displacement :
Power @ 3600rpm:
RPM:
Compression ratio:
Combustion system:
Engine head material:
Speed governor:
Lubrication system:
Oil sump capacity with filter:
Engine stop system:
Fuel pump:
Fuel pump discharge:
Fuel consump. @ full load:
Air combustion requirement:
Starting battery:
Starter:
Max. inclination:
Water pump flow:
Yanmar L70AE
Diesel / 4-stroke
1
Aluminium
3.07"
2.44"
296cc
6.7hp
3600
20:1
Direct injection
Aluminium
Centrifugal mech
Forced
1.2qt.
Fuel solenoid
Electric
2.3'
.396gal/hr
16.9cfm
45Ah - 12V
0.8kW - 12V
30°
4.4gal/min
Generator Ratings (@77o F)
Type:
Synch., 2-poles, self-excited
Cooling:
Air/water (Intercooler w/a)
Voltage:
120 - 240V
Nominal current:
26.6 - 13.3A
Frequency:
60Hz
BLA
Max. power:
3.2kW
Continuous power:
2.9kW
Battery charging output:
10A - 12V
Power factor (cos ø):
1
Insulating class:
H
Voltage stability:
±10%
Frequency stability:
±5%
Model:
Type:
Cylinders:
Cylinder block material:
Bore:
Stroke:
Displacement :
Power @ 3600rpm:
RPM:
Compression ratio:
Combustion system:
Engine head material:
Speed governor:
Lubrication system:
Oil sump capacity with filter:
Engine stop system:
Fuel pump:
Fuel pump discharge:
Fuel consump. @ full load:
Air combustion requirement:
Starting battery:
Starter:
Max. inclination:
Water pump flow:
Yanmar L100AE
Diesel / 4-stroke
1
Aluminium
3.38"
2.75"
406cc
10.0hp
3600
20:1
Direct injection
Aluminium
Centrifugal mech.
Forced
1.7qt.
Fuel solenoid
Electric
2.3'
.660gal/hr
23cfm
45Ah - 12V
0.8kW - 12V
30°
4.4gal/min
Generator Ratings (@77o F)
Type:
Synch., 2-poles, self-excited
Cooling:
Air/water (Intercooler w/a)
Voltage:
120 - 240V
Nominal current:
47.5 - 23.7A
Frequency:
60Hz
Max. power:
5.7kW
Continuous power:
4.8kW
Battery charging output:
10A - 12V
Power factor (cos ø):
1
Insulating class:
H
Voltage stability:
±10%
Frequency stability:
±5%
9
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