EG20 / EG25 - Telecogroup

EG20 / EG25 - Telecogroup
Installation handbook
(which must be done by specialized
workshops)
Use / Maintenance handbook
EG20 / EG25
By
Via Guido Rossa, 2/2 40055 Villanova di Castenaso Bologna
International Customers : Tel: +39 051 5947602 e-mail: export-ksye@egasperini.it
ITALIA
www.egasperini.com
Lpg Gas Generators & Innovative Devices
•
•
•
The “key” points for the assembling technician are indicated by using the
symbol
Fill in the warranty form
Handbook to deliver to the user client
•
The installation procedure for model EG20 and model EG25 is the same.
•
The “key” points for the User Client are indicated by using the symbol
For an optimal performance of the SELF-ENERGY EG20 / EG25, we suggest to
use service batteries with > = 160 ÷ 250 Ah overall capacity. (for ex. 2 parallel
batteries of 100 Ah )
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page 1 of 44
Installation handbook
(which must be done by specialized
workshops)
Use / Maintenance handbook
The present handbook describes the conditions of security installation use and maintenance of the
“12V Electric Energy Supplying group SELF-ENERGY EG20 / EG25” Evolution
“then calling generator”
Read this handbook before starting the installation use and maintenance.
INDEX
0.
1.
Page 1,2
Security
For the assembling technician
2.
3.
4.
5.
6.
7.
8.
Packaging content
Handling the EG20 / EG25 Evolution
List of security and identification labels
Preliminary controls
Identification components
Installation – connection - scheme
Test
For the user client
9.
10.
11.
12.
13.
14.
15.
Generator use
Suggestions for a right use
Maintenance
Damage’s research
Transport
Elimination
Technical Features and “CE Accordance Declaration”
Warranty
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Use / Maintenance handbook
1
Security
The EG20 / EG25 generator is secure and trustful in all its phases of work (transport, installation, use and
maintenance) on condition that the instructions given by this hand-book are respected.
It is obligatory to know and understand the hand-book’s content before proceeding to one (just the first)
phase of work.
On the contrary, personal lesions, damages to the generator EG20 / EG25, to the connected uses or to the
vehicle on which it has been installed, may occur.
The electric generator EG20 / EG25 has been planned and made for the installation and use on motor
homes.
( just for entertainment use).
•
Anomalous working or anomalous noise
In presence of anomalous working or anomalous noise deactivate the generator and please contact
Elettromeccanica Gasperini s.r.l. or the authorized assistance’s workshops.
•
The engine exhaust gas are toxic
The exhaust gas have always to pipe outwards .
Do not run the generator in closed environments.
When the motor home lies in closed environments, as garages, ferry-boat holds etc., make sure that the
generator doesn’t work ( electrical switch on module command remote in position “0” or “OFF”, knifeswitch EG20 / EG25 open and gas tap EG20 / EG25 closed)
•
Cooling air and exhaust gas
EG20 / EG25’s hot air exit holes ( EG20 / EG25’s cooling ) and exhaust gas MUST NOT be obstructed or
piped inside the motor home. Exhaust gas and cooling air must not penetrate into inhabited areas of the
motor home.
•
Cooling fan
Attention!! Open the electric knife-switch before removing the service cover.
By removing the service cover we will find the cooling fan which can start running.
•
Installation
The generator has to be installed outside and, in any case, in open and ventilated environment.
Never install the generator in domestic environments (such as cellars, garages, or closed spaces of every
kind).
The ground’s distance of the installed generator must guarantee security also during the reverse and during
the way through rambling roads, bumps and ramps!
Do not make electrical connections between EG20 / EG25 and the 12V service wiring which are different
from those shown in this hand-book .
On the contrary, damages to the electric generator EG20 / EG25, to the connected uses or to the wiring of
the vehicle on which it has been installed, may occur.
The EG20 / EG25 generator is supplied with LPG gas pressure 30 mbar (±2).A pressure reducer (30mBar)
must always be inserted ( the motor home is normally equipped with it) between the LPG tank and EG20 /
EG25. Never connect the EG20 / EG25 directly to the LPG tank.
•
LPG Gas is toxic, inflammable and explosive
Do not use fire next to the LPG tank or EG20 / EG25 generator. Do not smoke, do not generate sparks or
use fire during the installation or the LPG supplying. Always supply LPG in open spaces.
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2
Packaging content
2.1
Photo n° 1
code 932.000.E
Photo n° 2
code 931.075
Photo n° 3
code 931.059/5
“12V Supplying Group of Electric Energy”
SELF-ENERGY EG20 / EG25” Evolution
2.2
Module Command remote with acoustic and
visible signalling
code 931.075
2.3
Signals cable (with connectors) for the
connection of the EG20 / EG25 gear case.
2.4
Photo n° 4
code 932.186
Photo n° 4/a
code 932.202
Gear case ( adapted
for the Module
Command remote)
with the control
software.
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2.5
Photo n° 5
code 932.067
Support frame cod. 932.067 for assembling to
the motor home, equipped of two steel cables.
3
HANDLING THE EG20 / EG25
3.1
Photo n° 6
Handle the EG20 / EG25
always
in
horizontal
position.
(see photo)
4
List of security and identification labels
4.1
-
Label product identification
Label that shows the guaranteed acoustic power level LWA, according to the directives 2000/14/CE
Exit Label “exhaust gas”.
Label “fan warning”.
5
Preliminary controls
- Verify that each element listed above and its integrity is present in the packaging.
- Start the installation just if everything is regular, on the contrary, please contact Elettromeccanica
Gasperini
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6
Components identification
6.1
Photo n° 7
A1 and A2 = Hot air (produced by the EG20 /
EG25 while running) to pipe outwards the
motor home.
A1 – A2
B = Exhaust gas ground piped or roof piped
B
6.2
Photo n° 8
932.004
Photo n° 9
SER2300/07
Service cover (932.004)
6.3
Oil tank stopper
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6.4
Photo n° 13
code 931.042
Cooling fan.
Attention:
It can set on suddenly !
6.5
Photo n°
11
code 932.053
Service schedule
Terminal board (A) to connect
battery
CN1 connector (B) for signal cable
M3 Terminal board ( C ) to
activate “security blockage”
B
6.6
C
A
Photo n° 12
Cooling holes
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6.7
Photo n°
“Module Command remote” to drive electric
gear case
13
code 931.075
Button for manual starting (Automatic turning off)
code 931.075
Note:
The EG20 / EG25’s working time depends on
Level of the battery; its working time
oscillates from few seconds to more
minutes
Switch turn ON / turn OFF EG20 / EG25
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7
Installation and connection schemes
(installation made by specialized workshops)
It is compulsory to read all the sections of this hand-book before proceeding to the installation of the
generator.
The installation of “12V Supplying Group electrical energy SELF-ENERGY EG20 / EG25”( for motor
homes) has to be made by qualified technicians who have specific knowledge in the motor homes field, in
particular: auto body, system electrical worker and system Gas.
7.01
Photo n°
14
Legend :
(1) Self Energy EG20 / EG25 - (2) Service Battery - (3) LPG Gas’s tank with pressure reducer
(30mBar) - (4) Electric gear case - (5) Knife-switch ( on positive cable) - (6) Connection to activate
“security Switch-off” by using the connection +D or SC - (7) Flexible homologated tube (to use with gas
LPG gas) - (8) Tap for LPG gas’s supplying - (9) Rigid gas tube Ø 8mm(10) Multiple cable for the connection between EG20 / EG25 and electronic gear case (in equipment)
(11) Fuse 80A
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7.1
Before starting with the EG20 / EG25’s installation
(Checks and preliminary valuations )
The EG20 / EG25’s installation requests the assembly of the generator under the vehicle’s ground (however
in an isolated area from the inside of the motor home).
Before starting with the installation, make sure that the vehicle’s constructer admits the assembling of the
EG20 / EG25.
The fixing point must guarantee a traction force not inferior to 110 Kg.
Note: EG20 / EG25 has to be installed in horizontal position !
7.1.1
Positioning choice and 1) Decide EG20 / EG25 positioning according to the following criteria:
checking free needed area
for
EG20
/
EG25 • Minimum requested space:
700x400x280 mm.
installation.
• Minimum ground distance:
It has to guarantee security also during the reverse and during the way
through rambling roads, bumps and ramps!
• Warmth source distance (silencer)
At least 20 cm from the catalyst
At least 10 cm from silencer’s terminal part.
• Air grating
It must not be directed towards:
motor home’s exhaust gas / water and mud splashes from motor home’s
wheels
• Please avoid that the EG20 / EG25 is directly hit by the water or sand jet
from a wheel or by the engine exhaust gases; It could be useful to fit a
mudguard or another kind of protection, e.g. a rubber bar.
7.1.2
To estimate with the user client as follows:
To agree with the user • Hot air piping modality:
client
to use just for external use !( See also the specific section on this
handbook )
• EG20 / EG25’s exhaust gas piping modality :
Ground piped (back side of the motor home !?) ) or roof piped (suggested
because the smell of exhaust gas is less felt)
• Oil topping up:
To estimate the user client’s necessities
The oil topping up is requested each 100 working hours.
• Installation inside a motor home van’s storage locker:
Execute a hole of about 14 cm of diameter to allow air entrance both for EG20
/ EG25’s cooling and for security. The storage locker must be hermetic
towards the living areas!!
Hot air (taken from EG20 / EG25’s cooling) and exhaust gas tubes must be
piped outside of the motor home van !!
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7.2
Installation needed components
7.2.1
M8 screws with their self locking nuts, both To use for the fixing support code 932.067 to the motor
of them made of Stainless steel
home’s frame.
Or:
Steel tubular Rivet (M8).
Note:
To value the most suitable fixing system.
7.2.2
Unipolar 80 A Knife-switch
In case of failure or because of specific necessities, it
gives us the possibility to separate the EG20 / EG25
from the electric plant of the motor home.
7.2.3
80 A fast (or Automotive) Fuse and its Necessary for plant’s protection between the battery of
housing fuse .
service and the EG20 / EG25 .
7.2.4
Red and Blue of 10 or 16mm² unipolar
electric cable able to resist until
temperature of 90° C. Anti-Flame
For the connection between the battery of service and the
a EG20 / EG25.
To choose the most suitable section, see the specific
paragraph.
7.2.5
1 mm² unipolar electric cable able to resist For the connection of the “Security switch-off”
until a temperature of 90° C .
Anti - Flame
7.2.6
Photo n° 15
Exhaust gas’s 50mm Ø int.
flexible steel (or Aluminium) tube
7.2.7
Photo n° 16
Self-extinguished 57mm Ø int. PVC flexible
corrugated
tube able to resist until a
temperature of 90 °C .
This tube is used to pipe hot air (*) produced
by the EG20 / EG25 during its working.
code 931P2GEN
(*)= Taken from the EG20 / EG25’s cooling
air engine.
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7.2.8
Photo n° 17
Flexible tube, LPG gas homologated
(check norms for your country, for example CIG
or IMQ in Italy)
7.2.9
Ø 8 mm Copper or iron tube for gas plant.
7.2.10
LPG Gas tap
7.2.11
Steel adjustable wrapper used for :
- exhaust gas tube (Ø 50 mm)
- LPG flexible tube
7.2.12
Sheath for electrical plant.
7.3
Generator’s mechanical installation
7.3.1
Photo n° 18
Mark on the side frame the fixing holes (*)
you want to use. Where possible, use the holes
already existing
Note:
(*) Possible added holes must be made just by
following
the
vehicle’s
manufacturer
directives.
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7.3.2
Photo n°
19/1
Photo n°
19/2
A
D
B
C
The squares installation (B) is superfluous if the C
Execute the final fixing of the two vertical rod (B) point is in contact with the side frame (D)
and of the two squares (A).
In this case (C) has to be fixed to the side frame
(D) by using self locking screw and nuts
Lock the self-locking screws. The used fixing system must forbid slackening or unscrewing!
Note: Use self locking nuts .
7.3.3
Photo n°
20
Place EG20 / EG25 on the support frame
code 932.067
7.3.4
Photo n°
Fix the two steel cords
A
(A) with the ends
towards the outside
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21/1
Photo n° 21/2
A
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7.3.5
Photo n° 21 /3
Do not throw the steel cords strenghtly, the
anti-vibrating rubber has just to be slightly
pressed.
code
7.3.6
Photo n° 22
Lift the support with the EG20 / EG25 and
bring them to the right position.
7.3.7
Photo n°
Fix definitively the support
frame (code 932.067) to the
uprights by using their
screws and grower.
23
Photo n° 23/1
Fix deeply the screws
blocking the support’s frame
to the vertical rods by using
the grower in equipment in
the right way.
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7.4
Electrical connections
7.4.1
Cable’s section for the connection to the battery of service
Use two cables ! ( The first for the positive pole, the second for the negative pole)
Do not use the vehicle’s frame as mass connection!
EG20 / EG25 and battery of
service’s distance
Inferior to 4 metres
Section to use
Note
10 mm²
From 4 to 8 metres
16 mm²
Red (+) Blue (-)
Anti-flame type 90°C
The same
7.4.2
Electric installation
Photo n°
24
Do not connect the battery’s cables before the installation of an electric knife-switch !
(see installation scheme)
Remove the service cover code 932.004
7.4.3
Photo n° 25
Locate the 80 Ampere knife-switch (B) and
80 Ampere fusible ’s fixing parts (A) .
Expand the connection’s cables from service
battery to EG20 / EG25.
Notes:
-Use a restraint/cables protection’s sheath.
-the cable’s fixing must not cause traction,
abrasion or slope .
-Avoid the cable’s conduit next to warmth
sources and/or cutting areas.
-The knife-switch “B” has to be installed in a
position easy to achieve by the user .
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Recommended fuses
14x51GL(32A); 10x38GL(32A); Automotive Megaval (40÷50A);
Automotive Midival (50÷60A); Automotive Maxival (50÷60A);
Buss Class T (40÷50A); Buss Class F (60÷70A);
Buss Class UF (70÷80A);
A
B
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EG20 / EG25
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7.4.4
Photo n° 26
Connect the cables to the EG20 / EG25’s
terminal board by going themselves through
the two Ø8 chock’s holes .
Battery
7.4.5
Photo n° 27
Install 80 A’s fuse ( as close
as possible to the battery of
service’s positive pole).
Install 80 A’s knife-switch;
leave it in
position open.
Execute the connection as
clear on the installation
scheme .
Note
Mark the knife-switch and the
fuse (Example: “EG20 /
EG25”)
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7.4.6
PRELIMINARY CHECK of electric
connections:
Photo n°
28
a) Close the 80 A’s knife-switch: EG20 /
EG25 must not set out! (If it starts, verify that
the battery’s and EG20 / EG25’s connection’s
polarity is correct.).
b) Verify the battery’s tension’s presence on
the terminal board of the service’s schedule
(see photo).
The photo shows an indicative value
c) Reopen the knife-switch.
7.4.7
Photo n°
-Install the gear case (normally within a
wardrobe)
29 code 932.186
7.4.8.
Photo n° 35
-Positioning on OFF of the remote module’s
switch
-Remote
module’s
installation
connection to the gear case.
code 931.075
and
Note:
The installation’s area of the remote module
has always to guarantee acoustic and visual
signalling to the user.
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7.4.9
Photo n° 31
Connect the signaling cable (code 931.059)
to the service schedule which lies on the EG20
/ EG25.
931.059
7.4.10
Photo n°
32
Identify on the motor
home’s electric plant a +12
Vdc clamp when the motor
home’s engine is running ;
0 Vdc clamp when the
motor home engine is not
running.
This clamp (+D or SC) is
normally used to drive the
trivalent refrigerator.
Make the connection as
shown in the picture to
activate “security blockage”
which has the following
functions:
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Motor home engine condition
EG20 / EG25’ s condition
Running
NOT running
Switch-off (motor home in pause)
After having received the approval (OFF, then ON on
EG20 / EG25 command remote control ) EG20 / EG25 is
ready to start the automatic running
Note:
As soon as the motor home stops (engine off), the
gearcase of the EG20 / EG25 activates an acoustic
signaling (“Bip”). The “Bip” advices the user to make
sure that all the conditions to make possible EG20 /
EG25’ s running have been respected. Do not use EG20 /
EG25 inside ferryboats, garages, close and not suitable
places..
7.4.11
Photo n°
33
Photo n° 33/1
Execute the wires ’s connection which activate the “security blockage” by using the M1 terminal board
(on gear case cod. 932.186) or M3 ( on service schedule cod.932.053). NOT BOTH OF THEM!
On M1 and M3 terminal board there aren’t polarities to respect.
To insert M1 or M3 cables :
use a screwdriver of little dimension; push the M1 or M3 spring contact and insert the cables as shown in
the photo.
-Connect a wire between
M1 (or M3) and the
negative pole of the
vehicle.
-Connect a wire between
the free terminal (of M1
or M3) and an “under key”
contact which on the motor
home is indicated with the
abbreviations +D or SC.
Verify that this signalling is
to 12V ( 10v minimum –
16V maximum) when the
motor home engine is on
and 0V when the motor
home engine is off.
M3
M1
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7.5
LPG gas plant’s installation
7.5.1
Photo n° 34
Install a gas tap (B) and a new feeding line
(A) to feed the EG20 / EG25 starting from the
pressure reducer (30 mBar).
code
30 mBar
To use:
- Ø 8 mm suitable copper ( or iron ) tube next
to EG20 / EG25.
-Mark the tap with the sign “EG20 / EG25”
B
A
7.5.2
Photo n° 35
- homologated flexible
Gpl (30 mBar)
tube (about 50 cm) to
connect EG20 / EG25 to
the copper (or iron ) tube.
- Close the flexible tube
by using steel bands .
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7.6
Tube’s installation to pipe exhaust gas and hot air
7.6.1
Relevant notes about the “exhaust gas’s tube” and “hot air’s tube”(produced by the EG20 / EG25 during
its running)
•
•
The tube’s minimum internal diameter to use, in order to pipe exhaust gas and hot air, is 50mm.
The tube’s minimum internal diameter to use, in order to pipe EG20 / EG25’s cooling air , is
55mm.
Tubes with inferior internal diameter alters the right generator’s cooling, causing repercussion
on the EG20 / EG25’s working and endurance.
• If exhaust gas are not piped to roof and /or hot air is not used to warm possible motor home’s areas,
it’s necessary to install anyway three tubes with a minimum length of 0,5 metres .
To avoid the liquid’s flowing back inwards the generator, the tube’s ends must be directed
downward.
A1
A2
A1 ………………………...< 5 metri / meters /mètres
A2 ………………………...< 5 metri / meters /mètres
B …………………………< 5 metri / meters /mètres
(A1 + A2 + B ) ……….
< 12
metri / meters /mètres
B
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7.7
Exhaust gas’s piping
7.7.1
Modality
7.7.1.1
SELF- ENERGY EG20 / EG25
Photo n° 36
Summary of the different installation
modalities of the EXHAUST GAS TUBE
The noise is greatly directed under the floor
panel; more silent in the passenger department
and in the area where the chimney lies
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The noise is greatly directed under the floor
panel; more silent in the area where the ending
of the tube is
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7.7.1.2
Photo n° 37
Modality A
-
MODALITY A
SELF-ENERGY EG-20
Modality B
( Exhaust gas roof piped )
INSTALLATION EXHAUST GAS TUBE PIPED TO THE ROOF (suggested)
1 SELF-ENERGY
2 STEEL TUBE
(SIPHON SHAPED)
3 / 4 STEEL TUBE
5 “TRUMA” TYPE CHIMNEY
MODALITY B
1 SELF-ENERGY
2 STEEL TUBE
(SIPHON SHAPED)
3 PVC TUBE
cod. 931.P2GEN
(∅ INT 55, ∅ EXT 62)
4 STEEL TUBE
5 “TRUMA” TYPE CHIMNEY
HOW TO CHOOSE THE INSTALLATION METHOD
Exhaust gas tube
piped to the ROOF
Exhaust gas tube
piped to the
GROUND
•
When energy consumption and the user’s needs require prolonged functioning times of the EG20
/ EG25
Note :
o
please check that roof lights are provided with a ventilator taking air out of the vehicle
When energy consumption and the user’s needs require short functioning times of the EG20 /
EG25.
Note :
the fumes should be piped beyond the rear side of the motor caravan
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7.7.1.3
Photo n° 38
SELF ENERGY EG-20
INSTALLATION EXHAUST GAS TUBE TO THE GROUND LATERAL
MODALITY D
MODALITY C
1 SELF-ENERGY
7.7.2
2 STEEL TUBE (SIPHON SHAPED)
3 STEEL TUBE
1 SELF-ENERGY
2 STEEL TUBE (SIPHON SHAPED)
3 PVC TUBE cod. 931.P2GEN
(∅ INT 55, ∅ EXT 62)
Tube’s installation necessary to pipe the exhaust gas
7.7.2.1
Photo n°
Insert the flexible steel tube inside the EG20 /
EG25
Fix it with silicone or polyurethane.
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7.7.2.2
Photo 40/1: Fold the siphon tube as shown in the photo. Pierce the lowest part by using a Ø 3,5÷4 pin
Photo 40/2: If exhaust gas is ground piped, the last piece of tube ( the final part) must be made of flexible
steel or PVC cod. 931.P2GEN (suggested – see photo - )
Photo n°
7.7.3
40/1
Photo n°
40/2
Exhaust gas ground piping
7.7.3.1
Photo n°40/3
cod. 931P2GEN
Foto 40/3: The last part of the exhaust gas tube must be directed
slightly downward to avoid the entrance of water
( rain, vehicle’s washing etc)
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7.7.4
Exhaust gas roof piped
7.7.4.1
Foto n° 41/1
In the picture, chimney is backward compared
to the motor home wall. The noise which goes
out from the chimney should be further more
roof
“deadened” because the roof comes between
as a shield towards the other motor homes
parked nearby.
This type of installation is a proposal; it has to
be analysed chance by chance.
Use a steel tube inside the vehicle (normally
the tube lies inside a wardrobe). The tube has
to be used exclusively for the EG20 / EG25’ s
exhaust gas.
7.7.4.2
Photo n° 41/2
Chimney must not
obstruct exhaust gas’s
emission upward!
wardrobe
Photo 41/3
Use
(for
instance)
chimneys as in the
photo.
Chimney
must
be
placed far from the
windows or aspiration’s
fans.
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7.8
Tube’s installation necessary to hot air piping
7.8.1
Photo n° 42
EG20 / EG25 ’s recovered hot air can be piped towards exhaust valves, engine cabin and / or tank.
Note:
Hot air’s exits MUST NEVER be obstructed !
EG20 / EG25 hot air’s exits MUST NOT be piped inside the motor home !
SELF-ENERGY EG20 / EG25
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HOT AIR FOR THE EXTERIOR CRITIC PARTS
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7.8.1.1
Generator side:
Photo n° 43
Code 931P2GEN
-Mark the two tubes
COD.931.P2GEN (Ø int 57 mm) to a distance
of 40 mm from the end.
7.8.2
Photo n° 44
Apply silicone on the tubes.
931.P2GEN
Insert the two tubes inside the hot
air’s holes as long as the marked point
is reached
Attention:
Do not insert the tubes beyond the
marked point ! (nearby the hot air’s
tubes there are parts moving ).
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7.8.3
Photo n° 45
Code 931P2GEN
Fix the hot air’s tubes to the vehicle by using
bands.
Note:
The tube’s free end must be directed
downward ( to avoid rain water’s entrance)
8
Test
8.1
Battery of service’s efficiency
1) Connect a load of about 50 Watt to the service battery (for instance: lighting inside the lamps on the
motor home )
2) Use a tester to gauge ( to control ) the service battery’s level.
The measured level has to be superior to 12 Volt
8.2
Test procedure
What to make
Result
Close the EG20 / EG25’s battery knifeswitch.
Open the EG20 / EG25’s gas tap .
direct on ON ( I ) the remote module’s On the remote module we have to see in sequence:
switch
1) two green and red led lighting which lasts one second
2) Acoustic signal’s emission which lasts one second
3) The green led starts lightening slowly.
If the battery’ tension is inferior to the EG20 / EG25 activates immediately.
programmed threshold (about 11,9 Volt)
If the battery’s tension is superior to the EG20 / EG25 does not start running; it remains in “stand
programmed threshold (about 11,9 Volt) by”
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8.2.1
How to create EG20 / EG25’S starting conditions
First possibility
Second possibility
Apply a load (lightings, hair dryer etc ) When the battery’s tension is superior to 12 Volts ( and
to unload the battery of service; The
inferior to 13 Volts) the EG20 / EG25 can be activated by
EG2O activates as soon as the tension goes pushing the button (A) which lies on the remote module:
down the programmed threshold ( about
the switching off is always automatic .
11,9 Volt)
Note: Also in this case, EG20 / EG25’s running goes on as
long as the service battery will reach the programmed highest
threshold (about 14,5 Volt)
Photo n°
46
A
Once started, EG20 / EG25 runs as long as the battery’s tension reaches the programmed highest
threshold (about 14,5 Volt)
The running length depends on the battery condition : from few seconds to some hours
Note:
If there is air in the plant which feeds the EG20 / EG25 (installation phase or tank changing ) the EG20 /
EG25, probably, will begin running by using the starting with “modulated gas dosage” that starts
automatically after the second starting attempt.
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9
Generator use
9.1
Introduction
EG20 / EG25 generator is managed in an automatic manner by a gear case which constantly controls the
battery’s tension .
The user has just to activate or deactivate the EG20 / EG25 through ( by using ) the remote module
(I) switching on - (0) switching off
9.2
Motor home running (see 12.2)
(motor home engine runs).
9.3
Motor home in pause
(motor home engine , switched off)
The security blockage’s circuit forbids EG20 / EG25’s
running
The switching off followed by a subsequent switching on
of the button on the remote module, permits the EG20 /
EG25’s running.
The user has to verify the presence of security conditions
which are suitable to the EG20 / EG25’s running.
The EG20 / EG25 must not be activated in closed or not
suitable environments (as garages, ferryboats).
9.3.1
-
Open the gas all’EG20 / EG25
-
Close EG20 / EG25’s knife-switch
-
Direct on 1(on) the remote module’s knife-switch
EG20 / EG25’s starting
- The gear case makes a system’s check.
9.3.1.1
“ loaded battery ” situation
(12÷14 Volt)
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EG20 / EG25 in “stand by”. In this case, the green led
starts lighting (cadence of 1 par seconds) .
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9.3.1.2
“partially unloaded battery”
situation
(tension inferior to 12 Volt)
In this case, the gear case makes EG20 / EG25’s starting
procedure. When EG20 / EG25 starts running, the green
led is constantly alight.
9.3.1.3
“completely unloaded battery”
The generator can’t work .
In this case the gear case emits a “damage” acoustic
(exhausted battery which cannot be charged signaling.
again )
Change the battery
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9.3.1.4
•
•
Start/Stop threshold
Variables functioning times
As long as the battery’s tension level
goes down below the minimum threshold (about 12Volt)1,
EG20 / EG25 automatically activates taking the battery back
to the border superior threshold ( about 14,5 Volt )1.
(1)
: Mess on the terminal box of the EG20 / EG25 as indicated in the photo
EG20 / EG25 ‘s running time changes, it depends on the following elements:
1) battery’s loading level
2) battery’s ageing condition
3) capacity (Ah).
4) battery’s doorway temperature.
5) current’s use assimilation .
6) battery’s inactivity time.
7) battery’s unloading modality:
• slow discharge (slow discharge’s currents but long lasting) it needs relatively long loading time
• rapid discharge (high discharge’s currents but short lasting) it needs relatively short loading time.
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9.3.1.5
FREQUENT EG20 / EG25 START UPS
Causes:
A) “Sleeping” leisure battery
DO NOT replace the battery. Please carry out de-charging and re-charging cycles (points 1,2,3,4)
This situation can occur when the leisure battery is not used very often (or is new) and/or in winter.
See advice 1.
B) Empty/faulty leisure battery
Replace the battery
C) How to check whether the leisure battery is “sleeping” or empty/faulty
(the following tests are just a suggestion/indication!)
1) EG20 / EG25 in OFF mode
2) Empty the leisure battery up to about 11,3 V with a charge of about 5 A (e.g.: you can switch on
4/5 lights)
3) When the battery is 11,3 V (about)
EG20 / EG25 in ON mode and increase current up to 12-15
Amps (e.g.: you can switch on 7-8 lights + TV)
4) Switch on the EG20 / EG25 until it switches off automatically. If the Self-Energy EG20 / EG25 has
been running for less than 2 hours, it is recommendable to repeat points from 1 to 4 .
5) If the Self-Energy EG20 / EG25 has been running for more than 2 hours (remark 1) the battery us
likely to be “sleeping”.
One or two cycles (points 1,2,3,4) will “wake up” the ”sleeping” battery.
________________________________________________________________
Advice 1
Use leisure batteries with a total capacity of at least 150 – 200 Ah if using the vehicle also in winter or
if the battery is often “sleeping”.
(a device that monitors and controls the
Alternatively, it is possible to use the “BRIDGE”
parallel connection between the engine battery and the leisure battery. See also www.egasperini.com)
Remark 1
If the EG20 / EG25 has been running for more than 12 hours, the tests could have been carried out
incorrectly and it is advisable to call a technician.
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9.4
Deactivation
9.4.1
Momentary deactivation
Turn on “0” (OFF)the button of the remote module.
9.4.2
Prolonged deactivation
Switch off the module remote’s switch ( 0-OFF)
Close the gas tap (dedicated to EG20 / EG25)
Open the electric knife-switch ( dedicated to EG20 / EG25)
Note:
The procedure suggested aboard may be used to deactivate and isolate completely both the generator and the other
motor home’s plants
Suggestions for a proper use
10
10.1
With temperature inferior to - 5°C
When EG20 / EG25 runs with a temperature inferior to –5°C ,
please wait at least 2 minutes of running before switching off
it.
10.2
During the night
Consider the possibility of switching off EG20 / EG25
during the night in order to make no noise; leave it
automatically running during the day.
RELEVANT:
- If the mobile home is used also throughout the winter, we
recommend the installation of service batteries with a global capacity
indicated on point 15 of manual (Technical features)
- Before a possible nocturne switching off, make a manual
switching on by using the remote module’s button
10.3
Oil filling up
10.4
“BRIDGE”
(#) Patented and homologated product :
see www.egasperini.com
10.5
Once a year it is recommended to make an oil level’s check to
avoid making an oil filling up during the trip
OPTIONAL
Elettromeccanica GASPERINI launched a new product: the
Bridge(#), an automatic/manual device that monitors and
controls the parallel connection between the engine battery and
the leisure battery/ies.
OPTIONAL
“TimeSwitch”
see www.egasperini.com
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Elettromeccanica GASPERINI has created the TimeSwitch (a
timer) which enables to programme the functioning of the
EG20 / EG25.
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11
Maintenance with replacement of worn parts
11.1
The maintenances linked below, are made by “Elettromeccanica Gasperini” laboratories
(or Authorized Assistance Centers):
Maintenance period
Each 300-400*
running Equivalent to
hours
consumption
3÷4
litre
Each 600÷800*
running hours
Equivalent to
consumption
6÷8
litre
Each 1500÷1800 *
running hours
*Indicative value
Equivalent to
consumption
15÷18
litre
Main working
oil Substitute the silencer with possible
calibration of GMC.
Possible updating
oil Possible starting spunk and cooling
fan’s replacement .
oil Dynamo rotor’s replacement.
11.2
Oil filling - up
(1 litre ≈ 115 running hours)
The oil level is checked by a probe which lies within the
EG20 / EG25 tank. The minimum oil level is signalled on
the remote module and causes the automatic deactivation
of the EG20 / EG25. To make the oil filling-up use
exclusively 100% synthetic oil as showed on the list
which follows: ELF Moto 2xT Tech - MOBIL 1 Racing
2T – AGIP 2T Racing – ERG K Kart 2T Corse –
CASTROL TTS EP 2T – PUTOLINE TT Scooter+ –
CASTROL Biolube
11.3
Checks to make at least one time / a year
“Aeration holes” and “ drainage condense oil”
* Make sure that the holes are open, above all after having driven through distances with muddy bottom,
high grass etc.
Gas plant and tube’s check
* Check the gas plant and particularly the expiry date of the flexible tube ( its security’s period).
Generator EG20 / EG25 group’s check ( use this check to make the oil filling – up )
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* Check that the cover has not breakings, deformations.
* Check the whole fixing system ( chassis, electric cable’s condition )
12
Failure’s research
12.0
Tests to execute when the EG20 / EG25 does not start (see 12.1 and
12.2)
Carry out following operations:
1. Disconnect (A1) the gas pipe
from the Self-Energy
A3
2. Temporarily connect (B1)
another gas bottle
3. Disconnect (A2) the battery
cables
4. Temporarily connect (B2) to
another battery (12V 100Ah).
C
5. Disconnect (A3) the hot air and
fumes pipes from the generator.
6. Start the generator (C) (if it does
not start automatically, press the
manual-start switch).
7. If the Self-Energy EG20 / EG25
does not start :
A1
30 mBar
A2
B1
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B2
A) Write down the status of the
LEDS (see 12.2)
B) Contact the technical
assistance
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12.1
Failure’s research ( see 12.0 & 12.2 )
The head gear case makes a diagnosis which identifies, in many cases, the EG20 / EG25’s improper
functioning.
A possible improper functioning is coded through proper acoustic (buzzer) and lighting (green and red led)
signaling on the remote module .
12.2
Failure’s signalling ( see 12.0 & 12.1 )
Acoustic and visible signalling on the EG20 / EG25 running conditions
GREEN led
RED led
Acoustic signaling
Indicated Condition
1 flash
Switched off
every 0,8 sec
Constant alight
Switched off
Switched off
Constant alight
Switched off 1 flash
every 0,1 sec
Switched off 1 flash
every 0,8 sec
1 flash
Constant Alight
every 0,2 sec
1 flash
1 flash
every 0,8 sec
every 0,2 sec
1 flash
Switched off
every 0,2 sec
1 flash every
Switched off
0,8 or 0,2 sec
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Switched off
Stand by - Waiting
Switched off
1 every 10 sec
1 every 10 sec
It supplies energy
Gas shortage / damaged
Oil shortage
1 every 10 sec
High internal temperature
1 every 10 sec
Extremely unloaded/damaged battery
1 every 10 sec
F1 and F2 fuse’s replacement (service schedule)
Switched off
Starting phase
1 every 5 sec
Security blockage activated (see 9.2 )
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12.3
Anomalies - Checks / Solutions
Anomaly
Check / Solution
Generator doesn’t start
signaling or consumed gas)
(damage Check that the gas is enough and that the tap is open.
Verify that the gas pressure is of 30 mBar. In order to make
a test, feed the EG20 / EG25 by using another tank and
another pressure reducer!
Fuse F1 and /or F2 break’s signaling on replace F1 and F2 fuses with others of the same kind (do
power’s circuit
not increase the capacity!)
High temperature’s signaling
check that the cooling holes are open
check the fan’s integrity (*)
EG20 / EG25 starts, runs for a few check that the cooling holes are open
minutes and then it stops by signalling check the fan’s integrity (*)
consumed or damaged gas
A loud mechanical noise comes from the Check the fan’s integrity. (*)
EG20 / EG25
Lubricant lack’s signaling with full tank Contact the assistance centre
The generator oscillates from running and Hypothesis (A):The battery of service is “asleep” (#)
stopping which last few seconds.
Hypothesis (B): The battery of service is exhausted (#)
The generator runs making efforts and it Hypothesis (A):
works badly
The gas pressure in the motor home’s plant is not right.
Verify that the gas pressure is of 30Mbar; eventually change
the pressure reducer.
Hypothesis (B):
The engine’s exhaust “light” is obstructed and / or the group
silencer has to be changed. (#)
Other anomalies
Please contact Elettromeccanica Gasperini S.r.l.
(*) Attention: Read the “Security” section.
(#) Read the previous paragraphs
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13
Transport
13.1
To send the generator to Elettromeccanica Gasperini or to a specialized assistance centre, please execute
the following instructions::
Empty out the oil tank.
Arrange EG20 / EG25 in the packing by directing the oil stopper upwards.
Make a good and suitable packing.
Use the original box or a suitable box.
Apply labels that indicate the necessity to transport the box without overturn it.
If possible, use a pallet
ATTENTION !!
**An unsuitable packing causes serious damages to the internal and external frame of the EG20 /
EG25 ***
14
Elimination
14.1
In case of scrapping, consider that the generator contains metals ( steel, copper, aluminium, lead) and
plastics (abs, polyethylene, silicone). Deliver them to car scraps collecting centres. Do not disperse them in
the landscape.
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15
Technical features and Conformity Declaration
15.1
Technical features
Working
EG20
managed
Automatic,
by microcontroller
Working Temperature
+50 °C ÷ -25 °C
(in case of
< 0 °C
use
propane gas)
Working relative humidity
0 ÷ 95% without condensation
Rated voltage
12 V
Rated current
20 A
Two – stoke engine feeding LPG (pressure 30 mBar ±2)
LPG Consumption
0,27 Kg / hour actual working
Lubricating to use
100%synthetic lubricating for twostroke engine
Lubricating consumption
1 liter / ≈ 115 hours of real working
Oil tank capacity
1,1 litres
EG20 / EG25 block and With minimum oil level
trigger box signal
Sound pressure at 7 m Lpa 51 dB (A)
In compliance with directive
Measured sound power LwA:
2000/14/CE:
74 dB (A)
Assured sound power LwA:
76 dB (A)
Weight
19 Kg with full lubricating tank ( +
2 Kg for console support)
Length,
Width,
Height 565x380x250 H
(mm)
700x400x280 H
Dimensions space useful for
installation
(mm)
Advised capacity of the > = 160 ÷ 200 Ah
battery
Storage temperature
From -25 °C ÷ to +70 °C
Maximum altitude working 2000 meters above sea level
Maximum inclination with 17%
operative EG20 / EG25
Note: Performance and consumption values change with the altitude
Modification and updating can be done without any notice
EG25
managed
Automatic,
by microcontroller
+50 °C ÷ -25 °C
(in case of
< 0 °C
use
propane gas)
0 ÷ 95% without condensation
12 V
25 A
LPG (pressure 30 mBar ±2)
0,295 Kg / hour actual working
100%synthetic lubricating for twostroke engine
1 liter / ≈ 115 hours of real working
1,1 litres
With minimum oil level
52 dB (A)
Measured sound power LwA:
76 dB (A)
Assured sound power LwA:
78 dB (A)
19 Kg with full lubricating tank ( +
2 Kg for console support)
565x380x250 H
700x400x280 H
> = 160 ÷ 250 Ah
From -25 °C ÷ to +70 °C
2000 meters above sea level
17%
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WARRANTY
The 12V Self-Energy System EG20 / EG25 is always rigorously tested in the production unit before leaving the factory. The
generator is covered by a warranty for any defect in the materials used or in manufacturing discovered within 24 months after the
date of installation. The installation must be carried out within 6 months (*) after the date of end of production and no later (the
date is indicated on this form). The warranty does not cover fuels or consumption materials (e.g. oil) nor replacement for wearing
of: spark plug, muffler and dynamo brush (see also “maintenance” section in the user’s handbook). The warranty provides free
repair of the generator, which has to be sent to Elettromeccanica Gasperini s.r.l premises or to an approved repair station. The
two-way transport, assembling and disassembling costs will be charged to the Customer. The present warranty does not provide
the replacement of the generator. The present warranty does not cover damages caused by external factors or by mistakes due to
inexperience or carelessness of the installer/user. The present warranty does not cover possible refunds requested by the customer
(direct or indirect damages caused by system breakdown or malfunctioning, etc.) Place of lawful jurisdiction for any controversy
is the court of justice of Bologna (Italy).
(*): In some exceptional cases (for some EG20 / EG25 identification numbers and within 6 months after the end of production),
the retailer/workshop can ask for an postponement of the installation deadline. The request must be sent to Elettromeccanica
Gasperini, who will evaluate it and state whether the conditions for a postponement are valid. Request and authorization must be
written and faxed through to Elettromeccanica Gasperini s.r.l.
In order for the product to be covered by the warranty, the following requirements must be fulfilled
A) The “Self-Energy EG20 / EG25” generator may exclusively be installed on motor-caravans and caravans with
leisure vehicles function.
B) Please, fill in this warranty form and send it to Elettromeccanica Gasperini within 10 days after the
installation (fax: +39 051782428), please attach also the purchase receipt reporting the EG20 / EG25 serial
number.
C) Unless there is a written authorization from Elettromeccanica GASPERINI, do not remove the cover and the
warranty seals (marks painted on the screw bolts and on other parts of the EG20 / EG25).
The Warranty will not be valid if requirements (A) and/or (B) and/or (C) are not fulfilled.
In order to check any possible malfunctioning, carry out the operations indicated in par. 12.0 of the present handbook
Production date
Self-Energy EG20 / EG25 serial number
**************************************
****************************************
Customer/ User:
Name:__________*********____________Surname:__________****************_______________________
Address:_______********_______________ZIP code:____*****___City:______********_________
Tel/mob:______********________________e-mail:__________************_____________
Stamp
With Company’s details
(company performing the installation )
**********************************************************
Your personal data will be used with IT or manual means for after-sales technical assistance purposes.
Customer/User’s signature
Installation performing Company’s signature
Purchase and Installation date
*************************
************************
Modification and updating can be done without any notice
******************************
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