MG 20 SS-D Generator Owners Manual

GENERATING SET

MG 20 SS-D

OWNERS MANUAL

MI455-02-00-00

March 2008

Generating Set MG 20 SS-D

1. TECHNICAL SPECIFICATIONS

1.1 GENERATOR

Type

Three phase power (Cos

M = 0,8)

Single phase power (Cos

M = 1)

Frequency

Insulation class

Mechanical protection

1.2 ENGINE

Make/Type

Number of cylinders

Displacement

Power

Engine speed

Cooling

Fuel

Oil sump capacity

Starting system

Hour fuel consumption @ 75%

1.3 GENERAL FEATURES

Noise level

Battery

Fuel tank capacity

Average operating hours @ 75%

Dimensions (L. x W. x H.)

Dry weight

Weight

Asincrono / Asynchronous

20 kVA 415 V

15 kVA 240 V

50 Hz

H

IP 23

Deutz F3M 1011F

3

2184 cm

3

20,9 kW

1500 r.p.m.

Olio – Oil

Diesel

5.5 l

Elettrico - Electric

4,167 l/h

93 Lwa

12 V - 62 Ah

100 l

24 h 30 min.

1900x800x1100 mm

950 kg

1030 kg

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2. CONTROLS DESCRIPTION

2.1 FRONT PANEL

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18

19

20

14

15

16

17

21

22

11

12

13

9

10

7

8

3

4

1

2

5

6

Fuel level gauge

Earth leakage relay bypass

Remote control switch

Earth leakage relay bypass alarm lamp

MP24 control unit

Starting key

“Breaker on” push button

“Breaker on” alarm lamp

Open door alarm lamp

Low oil level alarm lamp

DC 24 V supply selector

“Breaker off” push button

32 A 1 pole circuit breaker

Emergency stop button

Remote control connector

240 V 32 A single phase socket

415 V 32 A three phase socket

63 A 4 poles circuit breaker

240 V tripping coil

RD2 earth leakage relay

12 V fuse

240 V fuse

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2.2 REMOTE CONTROL PANEL

3

4

1

2

5

6

7

Timer / Manual switch

Manual mode Stop / Start selector

Timer

“Breaker on” alarm lamp

Emergency stop button

12 V fuse

Fuel level gauge

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2.3 PANNELLO LATERALE / SIDE PANEL

3

4

1

2

Earth clamp connection

R,S,T,N output

Safety switch

R,S,T,N output cables

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3. RICAMBI / PARTS LIST

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42

43

37

38

39

40

34

35

36

30

31

32

33

44

45

27

28

29

23

24

25

26

20

21

22

16

17

18

19

13

14

15

9

10

11

12

N° Ordering N° Denomination

1 6033 Fan

2

3

6032 Fan pin

4235 Seeger ring

4 4026 Bearing

5 115743/DX Alternator right support

6 114221 Alternator traverse

7 115743/SX Alternator left support

8 133757 Lower alternator protection

114366 Rotor

119849 Right engine holder spacer

6036 Blade for inox plate

105303 Inox plate

116222 Battery switch cap

140224 Battery switch support

139177 Battery switch aluminium plate

138686 Battery switch

119850 Left engine holder spacer

6048/A T3 shoch absorber

119736 Left engine holder

120159 Silencer extension

119927 M10 L.330 tierod

119851 1° part silencer

4532 Silencer gasket

117442 2° part silencer

2962 Silencer flap

119738/A Radiator frame

131560 Pipe fitting

137578 Cap

130678 Pressure sensor

131927 10x16x1 ring

133968 Puradyn pipe

PTF8 Puradyn filter

100741 M22x1,5x620 oil drain tube

133949 Puradyn support

140227 Puradyn support clamp

133967 Murphy cup connection pipe

131560 M10x1 pipe fitting

133356 Murphy oil level

135862 Murphy oil level support

136115 18x1,5 ring

9876 Pipe clamp nipple

4830 Oil drain pump

133188 Oil drain pump support

105096 Perforated screw

133933 Ring

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46 105089 Oil drain tube

47

48

119735 Right engine holder

133790 Top alternator protection

49

50

51

52

129090 3 poles terminal board

133747 Terminal boards support

134159 Terminal boards protection

133932 Stator

53

54

55

6013/A Alternator flange

110129 O-ring

5633 Feather

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14

15

9

10

11

12


1 137640 D.22 push button

2

3

133744 MP24 control unit

134823 Moeller key switch

6

7

4

5

8

134825 Moeller auxiliary contact

2062 Fuse holder

9451 5 A fuse

6518 Fuel level gauge

118183 O-ring

16

17

18

7346 1N diode

4456/A 3 poles switch

4395 Red auxiliary contact

115140 Green auxiliary contact

134195 Puradyn fuse

141767 Instrument front panel

141765 Aluminium front panel

133385 D.22 red lamp

140660 Moeller selector

137639 D.22 green lamp

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24

25

26

27

28

20

21

22

16

17

18

19

13

14

15

9

10

11

12


1 135455 Washer for stop button

2

3

32468 10 poles female connector

32471 Immovable cover

6

7

4

5

8

4082 240 V 32 A plug

4061 240 V 32 A single phase socket

6266 415 V 32 A plug

6258 415 V 32 A three phase socket

5828/160 L.160 omega profile

105283 Current reduction

5856 100/5A transformer

133207 12 V DC relay

116805 12 V DC relay support

129870 RD2 earth leakage relay



133059 240 V tripping coil

103206 63 A 4 poles circuit breaker

3311 32 A 1 pole circuit breaker

135318 Circuit breakers spacer

138183 12 V relay with diode

141766 Lower plate

108273 8 module transparent cover

135136 2 module transparent cover

33484 NO contact

33485 Contact

33483 Stop button base

33482 Stop button

129871 “Emergency Stop” rating plate

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14

15

9

10

11

12


1 129843/Z Output door assembly

2

3

112178 Knob

129843 Output door

6

7

4

5

8

116121 Output cover

110247 Output insulator

110711 8x50 tierod

131463 Aluminium front plate for output

117623 Screw

16

17

117345 Wire holder plate

132513 Reinforcement

117331 Rubber wire holder support

134200/R Right front panel

117330 Rubber wire holder

129850 Opened door support

9881 Safety switch

102740 Stud

141885 Single phase output aluminium plate

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21

22

16

17

18

19

13

14

15

9

10

11

12


1 129871 “Emergency Stop” rating plate

2

3

135455 Washer for stop button

33483 Stop button base

6

7

4

5

8

33484 NO contact

33485 Contact

140660 Moeller selector

134825 Moeller NA auxiliary contact

134824 Moeller NC auxiliary contact

141819 Aluminium plate

32469 10 poles male connector

33305 Mobile cover

3465 Wire

120501 PG21 wire holder


141761 Timer

137759 Box

137639 D.22 green lamp

118183 O-ring


9451 5 A fuse

2062 Fuse holder

33482 Stop button

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35

36

30

31

32

33

37

38

39

40

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23

24

25

26

20

21

22

16

17

18

19

13

14

15

9

10

11

12


1 118603 Fuel tank

2

3

118602 Fuel tank box

134199/R Left front panel

6

7

4

5

8

133064 Battery clamp

4351 Positive battery clamp

133108 Battery door

4352 Negative battery clamp

116232 62 Ah 12 V battery

109606/R Red clamp cover

109606/B Blue clamp cover

135650/R Side door assembly

135650 Side door

112178 Handle

135666 Plate

2873 Hinge

133216 Silencer extension protection

119959/R Rear panel

129868/A Radiator cover

117435 Exit air grate

115119 Knob

140246/R Canopy cover

140230 Lifting bracket

140229 Lifting tie rod

140228 Lifting tie rod support

119747 Conductor

137830 3x70 mf capacitor

141759 240 V 4 poles contactor

117426 Capacitors support

120806 PG29 wire holder

113637 D.38 cap

9098 D.30 cap

117428/R Insulating panel

133948 Seeger ring

133947 Pin

133945 Lock plate

135625 Lock plate support

129554/R Front door assembly

129554 Front door

117831 Lexan panel

140226/R Frame

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9

10

11

12

6

7

4

5

8


1 141613 Fuel tank plate

2

3

100546 Fuel filler cap

141660 Cover plate gasket

141664 Cover plate

134029 3/8 pipe fitting

135615 17x23x3 gasket

117343 3/8 male rapid attachment

117344 3/8 female rapid attachment

141863 Tube

118023 Pipe fitting

9669 3/8 nipple


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4. WIRING DIAGRAM

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SUPPLY DC -

Fuel level

REMOTE START

GE breaker ON

EMER. STOP

SUPPLY DC +

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5. CONTROL DEVICES MOUNTED ABOARD

5.1 MP24 CONTROL UNIT FOR GENERATING SET (picture 1)

This controls and commands the genset unit.

5.1.1 CONTROL UNIT PUSH-BUTTON AND LED FUNCTIONS

4 DIGIT DISPLAY (UP-DOWN) PUSHBUTTON

MYMIC

PANEL

ENGINE

RUNNING

GREEN LED

(F1)

PUSHBUTTON

(ENTER)

PUSHBUTTON

(AUTO)

PUSHBUTTON

AUTO

OPERATING

MODE

(YELLOW LED)

KEY SWITCH

(OFF-ON-START)

(+) PUSHBUTTON (-) PUSHBUTTON

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MP24 features Engine and Generating Set (hereinafter GEN-SET) control and monitoring. The

MP24 provides visual indication by means of LEDs and Display. It features OFF-AUTO-MAN operating modes. The display gives Messages for the following failures: Low Fuel Level,

Emergency Alarm, Low Oil Pressure, High Temperature, High/Low Battery Voltage, Belt

Break/Charger Failure, Over/Under Frequency, Fail to start, Alternator Failure, Over/Under

Voltage, Over/Under Speed, Overload.

The following measurements are obtained on the front panel by using the (DISPLAY) pushbutton:

Generator Voltage/Current/Frequency, Battery Voltage, Hours Meter, Charger Alternator Voltage and R.P.M.

The MP24 provides static outputs for START, STOP, ALARM (or GENERATOR CONTACTOR),

FUEL SOLENOID and PRE-GLOW.

The MP24 features 31 programmable parameters, measurements calibration; the front panel includes 6 pushbuttons, 2 LEDs and a 4-digits DISPLAY

.

5.1.2 DAS, AUTOMATIC ENGINE SHUT OFF

Safety device mounted aboard. It shuts off the engine automatically to avoid possible damage, in case of one of the following irregularities:

(OIL) Low oil pressure:

Indication of Low Oi1 Pressure alarm. The input is connected to an external normally closed contact (input #3). The Oil Pressure Switch is by-passed by means of the [P.25] timing.

(°C) High engine temperature:

Indication of High Temperature alarm. This input (terminal #4) Is connected to a normally open or closed temperature switch. The polarity of the contact is selected by means of a code in the [P.18]

(option [n.o.] or [n.c.]). The alarm is bypassed 1 second.

(O.SPd.) OverSPEED:

The source of the alarm is derived from the Pick-UP (or “W” of the Charger Alternator). The parameters [P.22]-[P.23] allow full monitoring of the speed. The message flashes to indicate Over

(1 second by-pass). To know the Speed that caused the failure push the [F1] pushbutton.

(U.SPd.) UnderSPEED:

The source of the alarm is derived from the Pick-UP (or “W” of the Charger Alternator). The parameters [P.21]-[P.22] allow full monitoring of the speed. The message flashes to indicate Under

Speed shut down (6-second timing by-pass). To know the Speed that caused the failure push the

[F1] pushbutton.

(bELt) Belt break:

The alarm is enabled by means of the (on) code into [P.15] There is a ‘Belt Break’ alarm when the

Generator voltage is within the settings but the output voltage of the Charger Alternator is lower than the threshold of the [P.3]. A 20-second delay prevents false trigger of the alarrn. The [OFF] code, inserted in the [P.15], inhibits the alarm.

(ALAr) Emergency alarm:

This is an indication of External Emergency Stop (input #5). The MP24 stops the engine without delay. The polarity of the EMERGENCY ALARM contact is programmed into the [P.19] (option

[n.o.] or [n.c.]).

(FUEL) Fuel alarm:

This is an indication of Low Level Fuel in the tank (input#6).

(FAIL) Starting failure:

This alarm is aciivated if the engine does not start after a complete starting cycle (see settings of the parameters [P.2]-3]-4]-5]) or after a MANUAL starting cycle.

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(E 04) Generator failure:

This message will be displayed if the Voltage or the Frequency of the alternator lacks for 150 seconds after the engine has been started. The alarm monitoring is disabled if the [ P.12] contains the [OFF] code or the MP24 is in MANUAL operating mode.

(Hi H) Over frequency:

The Over Frequency setting is programmed into the [P.9]. The protection is delayed 2 seconds. The

MP24 shuts down the engine. To know the Frequency that caused the failure push the [F1] pushbutton.

(Lo H) Under frequency:

The Under Frcquency setting is programmed into the [P.8]. The protection is delayed by 6 seconds.

The MP24 shuts down the engine. To know the Frequency that caused the failure push the [F1] pushbutton.

(Hi U) Over Voltage:

If the voltage rises above the [P.7] setting for more than 2 seconds, the Over-Voltage alarm energises and the engine shuts down. To know the Voltage that caused the failure push the [F1] pushbutton.

(Lo U) Under voltage or Short circuit, the alarm energises if:

- the voltage drops under the [P.6] setting for more than 6

seconds

- the voltage drops under the [P.6] setting (minus 20%) for

more than 1 second

To know the Voltage that caused the failure push the [F1] pushbutton.

(XX.X) Battery voltage alarm:

The alarm settings are automatically fixed to 118/15.0V for a 12V battery or 23,6/30.0V for a 24V battery. The alarm is delayed by 120 seconds and is ignored during Pre-Glow and starting cycles.

The engine does not shut down and the user can select other display menus by using the [UP-

DOWN] pushbutton.

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5.1.3 PARAMETERS DESCRIPTION

DISPLAY

[P.0]

[P.1]

[P.2]

[P.3]

[P.4]

[P.5]

[P.6]

PARAMETERS

Remote Start Delay Timing

(Input #7)

Factory default: [10”] sec

Range: 1-59 secs or 1-15 mins

Seconds or minutes of continuous

REMOTE START command to initiate the automatic engine start.

(see section 9.0 and [P.20] in this section).

Remote Stop Delay Timing

(Input #7)

Factory default: [10”] sec

Range: 1-59 secs or 1-15 mins

Seconds or minutes of continuous absence of the REMOTE START command to initiate the stop cycle.

(sec section 9.0 and [P.20] in this Section).

Crank Timing (Output #l0)

Factory default: [7”] secs

Range:1-20 seconds

Maximum insertion time of the Starter motor. The timer is cleared if the engine starts to run.

Engine Running Trigger (Input #1)

Factory default: [5] V

Range: 3.0V-24.0V, [inh.]

If the voltage of the Charger Alternator rises above the [setting] the Starter Motor is disconnected (see section 12.0). The programming is allowed in step of 1V. The

[inh.] code allows the use of engine without Charger Alternator.

Rest Timing

Factory default [7”] secs

Range: 3-20 secs

Time interval between starting attempts.

Starting Attempts

Factory default: [5] attempts

Range: 1-10

The parameter contains the number of automatic starting attempts of the automatic start cycle.

Generator UnderVoltage, short-circuit


Range: 80-400V (5V Step)

If the voltage rises above the [setting], the MP24 enable the protection. If the voltage drops under the [setting] for at least 6 secs or under [setting]-20% for 1 sec, the Under-Voltage protection [Lo U] energises

The [inh.] inhibits the overvoltage.

Generator Over-Voltage

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[P.7]


Range: 110-550V or [inh.](5V Step)

If the Generator voltage rises above the [setting] for at least 2 seconds, the MP24 will energise the over voltage protection [Hi U] (see section 4.0) and stops the engine.

The [inh.] inhibits the overvoltage.

[P.8]

[P.9]

[P.10]

[P.11]

[P.12]

[P.13]

[P.14]

[P.15]

Generator Under-Frequency

Factory default: [47] Hz

[inh.] to 99Hz ([inh.]=disables the under frequency)

The protection is delayed by 6 seconds. The MP24 shuts down the engine and the display will show [Lo H] (see section 4.0).

Generator Over-Frequency

Factory default: [56] Hz

45 to [inh.] ([inh.]=disables the over frequency)

The protection is delayed by 2 seconds. The MP24 shuts down the engine and the displays [Hi H] (see section 4.0).

Current Transformer Size

Factory default: [100]/5

The range is 10/5 up to 1000/5

The settings are allowed only in steps of 10.

Generator Overload Setting

Factory default: [inh.] (inhibited)

Range: [inh.] to 1000 A

The MP24 shuts down the engine after a delay of 6 secs and shows the message

[E04]. The settings are allowed in steps of 1A (CT 10/5 up to 100/5) and 10A (CT

100/5 up to 1000/5).

Generator Failure Alarm

Factory default: [ON]

Selection: [on] or [OFF]

The code [on] enables the generator failure alarm. The alarm energises if the voltage (or the frequency) is lower than the UnderV/Hz settings for more than 150 seconds. The MP24 shows the [E04] message and the engine will shut down.

Glow Plugs/Choke Control

(Output #11)

Factory default: [10”] (seconds)

Range: 1 to 99 secs

The MP24 energises the output #11 for the programmed time. The [P.14] controls the operating mode of the output #11

(Pre-Glow or Choke section 7.0 and 8.0)

Output Control

Factory default: [2] (none)

The following possibilities are available:

[0] None, [1] Choke Control (section 8.0), [2] Glow Plugs Control

[3] Choke Control (section 8.0)

Belt Break Control

Factory default: [ON] (inhibited)

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Selection: [on] or [OFF]

The Belt Break (or Charger Alternator failure) alarm is indicated by means of the message [bELt] (see section 4.0)

[P.16]

[P.17]

[P.18]

[P.19]

[P.20]

[P.21]

[P.22]

[P.23]

Stop Solenoid Timing

(Output #12)

Factory default: [10”] secs

Range: 2-99 secs

Duration of the Stop cycle (output #12). The stop solenoid will remain energised for the programmed time.

Alarm Output Timing

(Output #2)

Factory default: [inh.]

[inh.]-59 secs 1-15 mins and [cont]

Time-out of the alarm output #2. The code [cont] disables the time-out and the alarm remains energised until the OFF operating mode will be selected. The [inh.] mode enables the use of the external contactor

(see parameter [P.28]).

Temperature Switch (INPUT #4)

Factory default: [n.o.] (normally open)

Selection: [n.o.] or [n.c.]

[n.o.] normally open contact: the engine shuts down if the contact closes.

[n.c.] normally closed contact: the engine shuts down if the contact opens.

ALARM Control (INPUT #5)



[n.o.] normally open contact: the engine shuts down if the contact closes.

[n.c.] normally closed contact: the engine shuts down if the contact opens.

Remote Start (INPUT #7)



[n.o.] normally open contact: the engine starts if the contact closes.

[n.c.] normally closed contact: the engine starts if the contact opens.

Under Speed setting


[Inh.] or 100-4000 r.p.m.

The MP24 by-passes the protection by 6 seconds to avoid false trigger action.

The [Inh.] code (setting <100 r.p.m.) disables the Under Speed shut down.

Over Speed setting


100-4000 rpm or [Inh.].

The MP24 provides one second bypass delay. The [Inh.] code (>4000 r.p.m.) disables the Over Speed shut down.

Number of Teeth of the Flywheel

Factory default: [Inh.]

[Inh.] or 1-500 teeth.

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The [Inh.] code (setting <1 ) disables the reading of the Speed (section 3.0), the

Over/Under Speed shut downs and the

Crank OFF action.

[P.24]

Crank OFF

Factory default: [Inh.]

Crank Termination setting: 100-800 rpm

This speed threshold terminates crank. One second delay is added to avoid false termination. The allowed range is 100 up to 800 R.P.M. The code [Inh.] inhibits the crank termination.

[P.25]

[P.26]

[P.27]

[P.28]

[P.29]

Low Oil Pressure Alarm By-Pass

Factory default: [ 6"] secs

Range: 0-99 secs

By-Pass Delay to ignore the Oil Pressure

(input #3) during the engine starting cycle.

The input requires normally closed contact.

Automatic Periodic Test Cycle

Factory default: [inh.] (inhibited)

Range: [inh.]-99 days

This is the interval time between the automatic periodic tests of the engine. The code [inh.] disables the Automatic Periodic

Test (see section 22.0).

Automatic Engine Test Duration

Factory default: [ 5'] mins

Range: 1-99 minutes

This is the duration of the automatic engine test (see section 22.0).

Generator warm-up timing

Factory default: [ 10”] secs

Range [inh.]-15 minutes ([inh.]=No warmup)

Active only when [P17]= [inh.] the

ALARM output is used to drive the GEN-SET contactor

.

Generator cooling timing

Factory default: [ 30”] secs

Range [inh.]-15 minutes ([inh.]=No warmup)

Active only when [P17]= [inh.] the

ALARM output is used to drive the GEN-SET contactor.

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[P.30]

[P.31]

Enabling frequency Revolution Counter

Factory default: [ inh.]

Range: 2 = alternator 2 poles 3000 turns

4 = alternator 4 poles 1500 turns

Enables the reading of the revolution counter motor drawing the value from the frequency of the alternator.

Planning Fuel End Alarm

Factory default: [1’]

Range: [99’ - 1’ - inh.]

[inh.] = only optic signaling, no motor stop

[from 1’ to 99’] = delaty for motor stop

5.2 RD2 EARTH LEAKAGE CIRCUIT BREAKER

The unit is equipped with an RD2 earth leakage circuit breaker capable of ensuring user protection in case of accidental contact with live parts or failure of the insulation system of connected users.

If an earth leak current occurs (differential current), the toroidal transformer supplies a signal to the

RD2 differential relay, which processes it and compares it with the set sensitivity value. When this threshold level is exceeded, the set delay is enabled and then the alarm contact is tripped.

On-panel controls

1- Green LED “ON” : power ON

2- Red LED “TRIP” : alarm status the connection between the toroidal transformer and the differential relay is continuously controlled by the latter - if the connection is interrupted, the differential relay goes into “alarm” status.

3- The “TEST” push-button simulates a fault inside the differential relay: when the button is pressed, the differential relay must changeover to alarm status.

4- The “RESET” push-button returns the differential relay to its initial “non alarm” status.

5- To select tripping steps I.

6- To select tripping steps in seconds.

WARNING! Apply only to authorised Gen Set centres for technical service on electrical components.

• Before connecting a load to sockets on the front panel of the unit, make sure that the generator supplies enough power for the tools that are connected.

Beware: electric motors’ starting current requirements are considerably higher than rated full load values.

• Before connecting a load to single phase and/or three phase sockets, make sure that the circuit breakers are open.

• At the end of work, before removing plugs from panel sockets, open the circuit breakers.

• Connect loads to generator’s sockets only by using cables of suitable size and in good conditions, with plugs fitted for the sockets on the panel. Do not use adapters.

WARNING! This device does not exempt the user from checking the engine oil level by using the dipstick located on the left side of the unit. This check must be done daily.

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Setting selection

5.3 EMERGENCY STOP BUTTON

The power generator is equipped with an EMERGENCY STOP device to stop immediately the generator in case of danger. The device is actuated by pressing the red pushbutton located on the front of the generator. The engine stops. To disengage the emergency stop device, rotate the red pushbutton clockwise until it pops out.

WARNING! The generator cannot be restarted if the emergency stop device is activated.

5.4 OPEN DOOR

The machine has been equipped with a “Open door” protection device. Take note that the generator will not operate or start if the indicated doors are open.

5.5 BATTERY ISOLATOR SWITCH

This device placed on the left side of the machine isolates starting system to prevent illegal use of machine or flattening the battery. Please remember to switch off the battery and remove the key from the switch when the machine is not in use. Turn the key clockwise to connect the battery.

Turn the key anticlockwise to disconnect the battery, now is possible to remove the key.

WARNING! The battery must be not switched off when the engine is running.

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Battery off

Battery on

6. EARTHING THE POWER GENERATOR

(picture 1)

Before starting the generator, connect it to earth by using the earth connection provided (1) and a cable of suitable size without interposing switches or other devices capable of breaking the electrical connection to earth. The earth system must conform to CEI 64-8 regulations.

WARNING! Do always connect the power generator to earth. Check that the cables are in perfect condition.

Picture 1

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7. STARTING THE MACHINE

7.1 PROCEDURE FOR MANUAL STARTING (WITHOUT REMOTE CONTROL)

(picture 2 page 37)

To start the generator proceed as follows:

(a). Make sure that the generator is correctly positioned.

(b). Use the oil dipstick located on the right side of the machine to check that the engine has been filled with the right oil quantity. If it doesn’t, then fill as described in this manual.

(c). Check if the radiator contains the right quantity of coolant. If doesn’t fill the radiator as described in this manual. Check the right coolant level.

(d). Make sure that the battery insulator switch is in “ON” position.

(e). Make sure that no load is connected to the machine. It is recommended that the main breaker switch (15) is disengaged.

(f). Make sure that the differential relay (E.L.R.) (14) has been adjusted for the required sensitivity.

Make sure that the By-pass key (2) is in the position required by the application. The coming on of the By pass warning light (4) indicates that the E.L.R. protection is excluded from the generating plant.

(g). Switch the DC Supply selector (12) to the “ON” position.

(h). Switch the “REMOTE CONTROL ON/OFF” selector (3) to the “OFF” position.

(i). Turn the starting key (6) to the “ON” position; the MP24 illuminates all LED and Display.

(l). The Display (5) shows the flashing message [uuuu]; the MP24 is counting the PRE-GLOW time.

(m). When the Display shows the flashing message [StA-] turn the starting key (6) in “START” position (momentary position with spring-loaded return) until engine starts.

NOTE: MP24 shows the flashing prompt message [StA-] for 20 seconds. After this time, if the engine does not start, the MP24 shuts down the FUEL SOLENOID and displays the message

[FAIL]. To clear the alarm it is necessary to turn the starting key in “OFF” position.

(n). To press the push button “ ON” (8); the green light (9) will energise.

(o). Connect the load.

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Picture 2

AUT

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8. USING THE REMOTE CONTROL IN MANUAL MODE (picture 2 page 37)

The user can start and stop the machine manually

The following operation must be done on the machine when you have to start the job.









(h). Switch the “REMOTE CONTROL ON/OFF” selector (3) to the “ON” position.



(m). Press the “AUTO” button (17).

NOTE: Before the starting the Display (15) shows the flashing message [uuuu]; the MP24 is counting the

PRE-GLOW time.

ON THE REMOTE CONTROL

(a). Switch the MODE selector (16) to the “MANUAL” position.

(b). Using the start and stop switch (17) you can decide to start and stop the machine. The contactor switch will be closed or opened by the MP24.

WARNING! In case of short circuit, over load or fault to the groud the main breaker will trip off and the user have to remove the fault and than he has to close the main breaker manually.

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9. USING THE REMOTE CONTROL IN TIMER MODE (picture 2 page 37)

The timer will start and stop the machine automatically

The following operation must be done on the machine when you have to start the job.









(h). Switch the “REMOTE CONTROL ON/OFF” selector (3) to the “ON” position.



(m). Press the “AUTO” button (17).

NOTE: Before the starting the Display (15) shows the flashing message [uuuu]; the MP24 is counting the

PRE-GLOW time.

ON THE REMOTE CONTROL

(a). Switch the MODE selector (16) to the “TIMER” position.

(b). The timer will start and stop the machine using the adjustment. The contactor switch will be closed or opened by the MP24.

WARNING! In case of short circuit, over load or fault to the groud the main breaker will trip off and the user have to remove the fault and than he has to close the main breaker manually.

9.1 TIMER SETTING

Default setting:

At 07:00 the machine would automatically start.

At 08.00 the machine would automatically stop.

At 17:30 the machine would automatically start.

At 18:30 the machine would automatically stop.

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10. STOP PROCEDURES

10.1 PROCEDURE FOR MANUAL SWITCHING OFF (picture 2 page 37)

(a). To press the push button “ OFF” (13); the green light (9) will switch off.

(b). Disconnect the load.

(c). Turn the starting key (6) to the “OFF” position.

(d). Switch the DC Supply key (13) on the OFF position.

Switching off the machine, it disengages the main circuit breaker (15) automatically.

WARNING! If none emergency situation occurs, don’t use the emergency stop button to stop the machine.

10.2 PROCEDURE FOR REMOTE CONTROL SWITCHING OFF (picture 2 page 37)

In TIMER MODE the machine would automatically stop

In MANUAL MODE switch the selector (17) to the “STOP” position.

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11. GENERAL USE INSTRUCTIONS

Read the instructions carefully; proceed according to the regulations in use in the country where the machine will operate.

11.1 TRANSPORTATION

The machine must be fixed carefully to the motor vehicle if it has to be moved to the place of use. Raise the machine using the lifting eye if the model foresees it; otherwise, lift it using a forklift, taking care that the weight is well balanced on the two forks. It is advised not to stay in the range of action during these operations; furthermore we suggest not to keep the machine hung up for long.

If the machine is delivered without the wheels on, mount them before switching the machine on.

During the normal use of the machine mounted on wheels (in a building yard or anywhere), the operator must ascertain that the machine is weel placed in order to avoid unforeseen displacement.

11.2 CAUTION

Be careful: the generating set or the welder is furnished WITHOUT lube oil. Provide the machine with “10 W 40” multigrade oil indicated for temperatures from - 20° C to 40° C in the quantity indicated in the engine SPECIFICATION section.

Be careful: if the machine is fitted with a water cooled engine fill the radiator circuit with a solution made up by 50% water and 50% antifreeze liquid inthe quantity indicated i the engine SPECIFICATION section.

Be careful: the generating set is furnished with flat battery and without acid. Fill it using sulphuric acid in a 30% - 40% concentrated solution up to the complete covering of the elements. During this operation, we suggest the operator to use the gloves; the accidental contact with the sulphuric acid solution must be washed up immediately with cold water and, if necessari, a doctor must be consulted.

Be carefull: don’t disconnect battery cables when the engine runs. This coud result in serious damages to the machine.

Be carefull: BEFORE OPERATING THE MACHINE the neutral, or the equivalen winding point, MUST be connected effectively to the earth (without any switch or other device that may interrupt the electric connection) from the earth clamp available on the machine, and identified by the symbol:

Be carefull: for normal transportation, follow the instructions as specified in the TRASPORTATION section. Make sure that the machine doesn’t overturn in order to avoid spill of acids from the battery.

11.3 RUNNING IN

For the first 50 hours of operation of the machine do not employ more than 70% of the maximum power indicated in the technical specifications. In this way, a proper engine running in is guaranteed.

11.4 STARTING AND WORKING

Make the earth connection (see the USE INSTRUCTIONS).

If the machine model IS NOT equipped with a earth leakege circuit breaker the available socket is intended ONLY for connecting the machine to a switch board equipped with all protection devices imposed by current law regulations.

Check the perfect state and efficiecy of the cables.

Make sure that all the switches, electric connections and regulations are inthe right position for the starting (see USE INSTRUCTIONS and CONTROL PANELS

DESCRIPTIONS).

While welding, eyes and body must be protected by gloves, maskes Use the machine in well ventilated places, taking care that the exhaust gas and the welding smokes eventually produced (where welders are used) do not stagnate. Keep the machine away from walls or other kind of obstacles i order to avoid air or gas recycling. If the machine is employed in closed places, use aspirators in order to guarantee a proper air recycling.

While welding, eyes and body must be potected by gloves, maskes and proper clothes.

The fuel refill must not be made while smoking or close to flames. This operation must be done when the engine is switched off.

Do not fill the tank at its maximum level and clean up the fuel eventually overflowed.

Check daily if there is loss of fuel or lubrificating oil on the ducts or on the engine.

For machines provided zith liftable canopy insert the foreseen security sistems in order to avoid injures caused by an unexpected closure.

11.5 FORBIDDEN USE

Do not connect the machine to the commercial electric network.

Do not work close to inflammable materials or where there are explosive gas and vapours.

Do not work in narrow and badly ventilated places.

Do not work without using the protections placed in their proper positions and in perfect conditions.

Do not touch the exhaust muffler and the parts of the engine next to it.

Do not make service operations while the engine is running.

Any service made on the electric parts must be done when the engine is stopped and by specialized technicians.

Keep away from the moving parts of the engine while working and do not approach the machine with free and too long clothes.

11.6 SERVICE AND CLEANING

We suggest a frequent cleaning of the machine since the presence of dirt can compromise the efficiency of the machine. The frequency of this operation tightly depends on the place where the machine is used. We advise, anyway. to pay special care to the service of:

OIL LEVEL, OIL FILTER, AIR FILTER, COOLING LIQUID LEVEL, COOLING LIQUID LEVEL, HEAT EXCHANGER, VENTILATION DUCTS AND INTAKES,

BATTERY

Consult the ENGINE USE AND SERVICE manual and the SPECIFICATION section to know how and when it is useful to do it. The extraordinary service operations not mentioned hereabove require the aid of specialized technicians (see the assistance centre list).

11.7 ADJUSTMENT AND REGULATIONS

All the necessary controls are located on the main control panel and they are properly explained in the section FRONT PANEL DESCRIPTIONS.

We advise the operator against tempering with the engine or the electric part if not specialized.

Be careful: eventual modifications of the normal parameters originally foressen, can compromise the reliability of the machine.

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11.8 TEMPORARY STANDSTILL

If the machine has to be stopped for a long period (more than one year), we suggest to leave the motor oil and the fuel in and the water in the radiator in order to avoid oxydizing effects.

When the machine turns to work again, the liquids must be replaced, the battery must be charged; the belts and their statem the pipes, the rubber hoses and their resistance must be checked and a visual inspections of the electric connections must be done.

11.9 SCRAPPING

In order to preserve the environnement, it is advised to dispose of the oil, the fuel and the bettery that will be destroyed in proper places and ccording to the current laws.

For the complete range of the materialsm see the list below:

FERROUS MATERIALS: steel, cast iron, aluminium, copper, brass are udes in the bearing structure of engine, alternator, transformers, etc.

PLASTIC MATERIALS: rubber, bakelite, epovit, lexan are used for the instruments, engine pipes, junction boxes and connectors, fuel tank, fuel cap, wheels, antivibration damper, condenser housing, fans, belts, filters and hoses.

ELECTRONIC MATERIALS: various components, diodes, resistances, electronic panels.

VARIOUS MATERIALS: rock woll, sound proofing materials.

LIQUIDS: fuel, gasoline, cooling liquids, battery acid.

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12. SYMBOLS

Battery Charging Condition

Engine Oil

Engine Coolant Temperature

Engine Oil Temperature

Fuel Level

Chocke, Cold Starting Aid

Diesel Pre-Heat

Welding

Manual Metal Arc Welding

Mig/Mag Welding

Tig Welding

Positive Polarity

Negative Polarity

On (Power)

Off (Power)

Protective Earth (Ground)

Min-Max Regulator

Alternating Current

Direct Current

Single Phase Generator a.c.

230 (240)V - 110V 50Hz

Three Phase Generator a.c.

400 (415)V 50Hz

Do Not Touch: High Temperature Zone

Voltage On

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13. EUROPEAN SERVICES CENTERS

ASSISTANCE

Moreweld N.V.

Ilo Motor APS

Papadopoulus A. & C.

Greymo S.A.

Blaker S.A.

Baier Sarl

Gen Set PLC

Interlas B.V.

Genetech AB

Luna AB

Lundab

Gen Set Hungaria KFT.

Ferto-Tavi Nadgazdi RT.

Agessa

Paroli SP. ZO.O.

CP Mores

President Neva

Costa Y Garcia

Serpantinas LTD

ADDRESS

Europark - Noord 15 - 9100

Neverland 14 via Afroditis 22

Poligono Igarsa

Recta Los Tarahales 11

48 Rue Docteur Basset

Stallcourt Works

Oranjelaan 56

Brosslarvagen 13

P.O. Box 44100

Nytorpsvagen 18

1116 Bazsalikom U. 27

9444 Fertodi U.1

Chemin Des Fleurettes 33

UL. Grojecka 45 M 10 A

Otakarova 48

PR. Engelsa 16-2

Rua da Cavadao 801 - Apartado 23 –

4408

Gelezinkelio 2

CITY

Sint-Nicklaas

Glostrup

Salonicco

Madrid

Las Palmas de G.C.

ST.Ouen Cedex

Port Talbot

Rozenburg

Ostersund

Alingsas

Sollentuna

Budapest

Fertoszentmiklos

Losanna

Warszawa

Budejovive

ST. Ptersburg

Valdares Cedex

Panevezys

COUNTRY

Belgium (B)

Danmark (DK)

Greece (BR)

Spain (E)

Spain (E)

France (F)

England (GB)

Holland (NL)

Sweden (S)

Sweden (S)

Sweden S)

Hungary (H)

Hungary (H)

Svizzera (CH)

Polonia (PL)

Rep. Ceca

C.S.I. (SU)

Portugal (P)

Lithuania (LT)

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14. WARRANTY

GEN SET warrants its products, provided they have not been modified, for a period of 12 months from the date of handing over to the End User. Within these terms, in all the countries where a service organization is in place GEN SET commits itself to replace or repair the defective parts resulting from faulty material, workmanship and/or assembly through its authorized service stations.

The choice whether to replace or repair the defective parts is exclusively reserved to GEN SET and/or its authorized service stations.

The warranty in the rest of the world is limited to the supply ex-works free or charge of those parts which will result unsuitable for reuse due to original defects.

The warranty will apply after a check of the defective parts from the factory.

The warranty will apply after a check of the defective parts from che factory.

The travel, board and lodging expenses of the personnel who will perform the repairs are at the charge of the End User as are the packing and transportation costs both for the defective and the replaced parts.

In no case the client can claim the cancellation of the contact or a damage compensation due to the use or the impossibility to use the equipment both totally or partially.

The present warranty does not apply to starting batteries, diesel and gasoline engines mounted on gen set machines for which the respective manufactures will intervene directly.

The warranty will automatically expire:

y if the customer has not fulfilled the contractual payment obligations.

y when the factory seals have been broken.

y when dismantling, repair or modifications have been executed by unauthorized personnel not being part of the GEN SET service organization.

y when the equipment has been subject to negligent or improper use.

The present warranty does not apply to wear and tear parts.

COMING IN FORCE OF THE WARRANTY RIGHTS

Each GEN SET machine is delivered with a warranty certificate which must be filled out in each part and be validated by the stamp and signature of the dealer.

Cut out and send to: GEN SET S.p.A. - Servizio Assistenza Via stazione, 5 - 27030 Villanova D’Ardenghi (Pavia)

The guarantee certificate must be kept and shows before any request of intervention.

15. ENGINE WARRANTY AND SPARE PARTS

15.1 INTRODUCTION

Please follow carefully the engine operation manual, in order to obtain a safe use of the machine.

15.2 ENGINE WARRANTY

On purchase, please fill in the engine warranty certificate and mail it to the engine manufacturer.

15.3 SPARE PARTS

Spare parts have to be ordered as follows:

For the engine: Please contact assistance service giving the reference codes that you find on the engine SPARE PARTS USE AND MAINTENANCE manual.

For the generator and relevant equipment: Please contact directly GEN SET, giving the serial n°. of the machine and the reference codes that you find on the SPARE PARTS.

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TABLE OF CONTENTS

1.

TECHNICAL SPECIFICATIONS............................................................................................ 2

1.1 GENERATOR ......................................................................................................................... 2

1.2 ENGINE................................................................................................................................... 2

1.3 GENERAL FEATURES.......................................................................................................... 2

2.

CONTROLS DESCRIPTION.................................................................................................... 3

2.1 FRONT PANEL....................................................................................................................... 3

2.2 REMOTE CONTROL PANEL ............................................................................................... 5

2.3 PANNELLO LATERALE / SIDE PANEL ............................................................................. 6

3.

RICAMBI / PARTS LIST .......................................................................................................... 7

4.

WIRING DIAGRAM ................................................................................................................ 22

5.

CONTROL DEVICES MOUNTED ABOARD ...................................................................... 26

5.1 MP24 CONTROL UNIT FOR GENERATING SET............................................................ 26

5.1.1

CONTROL UNIT PUSH-BUTTON AND LED FUNCTIONS................................... 26

5.1.2

DAS, AUTOMATIC ENGINE SHUT OFF .................................................................. 27

5.1.3

PARAMETERS DESCRIPTION .................................................................................. 29

5.2 RD2 EARTH LEAKAGE CIRCUIT BREAKER ................................................................. 33

5.3 EMERGENCY STOP BUTTON........................................................................................... 34

5.4 OPEN DOOR ......................................................................................................................... 34

5.5 BATTERY ISOLATOR SWITCH ........................................................................................ 34

6.

EARTHING THE POWER GENERATOR ........................................................................... 35

7.

STARTING THE MACHINE .................................................................................................. 36

7.1 PROCEDURE FOR MANUAL STARTING (WITHOUT REMOTE CONTROL.............. 36

8.

USING THE REMOTE CONTROL IN MANUAL MODE ................................................. 38

9.

USING THE REMOTE CONTROL IN TIMER MODE...................................................... 39

9.1 TIMER SETTING.................................................................................................................. 39

10. STOP PROCEDURES .............................................................................................................. 40

10.1

PROCEDURE FOR MANUAL SWITCHING OFF ......................................................... 40

10.2

PROCEDURE FOR REMOTE CONTROL SWITCHING OFF ...................................... 40

11. GENERAL USE INSTRUCTIONS ......................................................................................... 41

11.1

TRANSPORTATION ........................................................................................................ 41

11.2

CAUTION.......................................................................................................................... 41

11.3

RUNNING IN .................................................................................................................... 41

11.4

STARTING AND WORKING .......................................................................................... 41

11.5

FORBIDDEN USE ............................................................................................................ 41

11.6

SERVICE AND CLEANING ............................................................................................ 41

11.7

ADJUSTMENT AND REGULATIONS........................................................................... 41

11.8

TEMPORARY STANDSTILL.......................................................................................... 42

11.9

SCRAPPING...................................................................................................................... 42

12. SYMBOLS ................................................................................................................................. 43

13. EUROPEAN SERVICES CENTERS...................................................................................... 44

14. WARRANTY ............................................................................................................................. 45

15. ENGINE WARRANTY AND SPARE PARTS ...................................................................... 45

15.1

INTRODUCTION ............................................................................................................. 45

15.2

ENGINE WARRANTY..................................................................................................... 45

15.3

SPARE PARTS.................................................................................................................. 45

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MG 20 SS-D Generator Owners Manual

Assistant Bot

GENERATING SET

MG 20 SS-D

OWNERS MANUAL

1. TECHNICAL SPECIFICATIONS

2. CONTROLS DESCRIPTION

3. RICAMBI / PARTS LIST

4. WIRING DIAGRAM

5. CONTROL DEVICES MOUNTED ABOARD

Battery off

Battery on

6. EARTHING THE POWER GENERATOR

7. STARTING THE MACHINE

10. STOP PROCEDURES

12. SYMBOLS

Key Features

Frequently Answers and Questions

How do I start the MG 20 SS-D generator manually?

What are the different modes of operation for the remote control?

How do I set the Timer on the remote control?

Is there an emergency stop button?

Related manuals

MG 20 SS-D Generator Owners Manual

Assistant Bot

GENERATING SET

MG 20 SS-D

OWNERS MANUAL

1. TECHNICAL SPECIFICATIONS

2. CONTROLS DESCRIPTION

3. RICAMBI / PARTS LIST

4. WIRING DIAGRAM

5. CONTROL DEVICES MOUNTED ABOARD

Battery off

Battery on

6. EARTHING THE POWER GENERATOR

7. STARTING THE MACHINE

10. STOP PROCEDURES

12. SYMBOLS

Key Features

Frequently Answers and Questions

How do I start the MG 20 SS-D generator manually?

What are the different modes of operation for the remote control?

How do I set the Timer on the remote control?

Is there an emergency stop button?

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