1.- welcome
Contents
1. GESAN ALARMS The following chart describes each alarm NUMBER SYMBOL DESCRIPTION Fuel below minimum level Low battery voltage Emergency stop Engine overspeed Low oil pressure High engine temperature If engine does not start after three attempts the unit will stop and this icon will be displayed Low engine speed Alternator frequency outside established limits Alternator voltage outside established limits lt gt lt If itis detected during a long period of time that generator s output current exceeds the established value the following warning will be displayed If the cutoff point for overcurrent is exceeded by 10 for one hour the unit will be stopped Note If the established limits defined as warning or stop are exceeded the module will display the corresponding alarm None of these will be shown if not detected by the system Note The Deep Sea 52XX module will show a Warning displaying this icon 1 as well as the identifying alarm icon If the warning leads to the unit stopping this icon will turn on 53 as well as the corresponding icon both of which will flash 8312s S GESAN Event log To view the event log press the following button repeatedly 10 This icon will flash I A screen similar to this will be shown On November 1 2002 at 08 17 the unit detected that the oil pressure was2. 259091 ossis 03 9513 9845 13 57 GESAN WELCOME BASIC SAFETY RULES ESCRIPTION OF GENERATOR SET 4 GECO GPM 2 analog control module Lai Rand 22 DEEP SEAdgHalcntolmegle CEN T II XN ELECTRICALCONFIGURATION QNEM NEN NM 4 INSTALLATION OF THE GENERATOR SET MEAN Hc pens DENM CU MN 4273 2 2 000000000005 2 STARTUP 23 OPERATION MANUAL 6 DEEPSEASHOSDDOTALCONILMODUE TEUGEN OTL CONTRO MN NN MAINTENANCE OF GENERATOR SET 7 TROUBLESHOOTING PROTECTION FROM THE ENVIRONMENT 62 WARRANTY 63 NOISE LEVEL 64 DECLARATION OF CONFORMITY 64 APPENDIX 1 FIGURES 64 APPENDIX 2 IMAGE INDEX 67 JEWS GaN ay On aT GESAN 1 WELCOME Thank you for choosing a GESAN generator set The purpose of this manual 15 to familiarize the user on how to use and work with the electrical generator its components and maintenance We recommend a carefully reading this document prior to working with the equipment to ensure its correct use Save this manual for future reference and if the generator set is resold be sure to include the manual along with the unit The following is a general description of the unit and the information necessary for installation operation and preventive maintenance Additionally you should have received a specific user manual for the
3. Indicates remote startup continuous green light turns on when unit is operating remotely Indicates unit is warming up continuous yellow light turns on when unit is being heated Indicates stop signal Flashing Indicates engine cooling period Continuous The control module issues a stop command to the engine stays lit for 20 seconds following the complete stopping of the engine Indicates maintenance flashing light the first time the light turns on after 50 operating hours and afterwards every 150 hours To reset the maintenance hour meter the generator set must be running turn the key to the STOP position while pressing down the button 12 until the control module becomes completely deactivated Contact button If service is needed engine contact must be maintained With the key turned to the STOP position press button 12 and without releasing it turn the key to the MAN position 9811 8 9 1 51 ALARMS The following is a chart describing the possible alarms of the GPM 2 module NUMBER SYMBOL DESCRIPTION IDENTIFICATION Unit startup failure If liaht i ti T 13 ight is continuous indicates low frequency If it runs below nominal frequency for more than 30 seconds unit is shut down If light is continuous and the engine is topped indicates CONTACT Alternator battery charge If light is flashing indicates failure and
4. O The LCD screen 8 will normally look similar to this Example of the screen indicating the voltage readings for each phase of the generator set 71 11 195118 li L3 L1N L1 L2NjL2 L3N GESAN OR SST DESCRIPTION Indicates that the screen display information refers to the mains power Indicates that the screen display information refers to the generator set Indicates that the event log reading is being accessed Flashing Indicates that the programming mode is being accessed Indicates that the generator set is idle Indicates that the generator s set system date and time is being shown This icon indicates a stoppage or alarm Warning Stoppage 54 Indicates fuel level percentage Indication related to the battery Indicate battery level outside established limits Indicates keypad is locked KW and kVAr indicate units of current power Cos Indicates power factor 9 Measurement given in degrees celsius Measurement given in degrees Fahrenheit Measurement related to alternating current Measurement of voltage Measurement of intensity Amperes Indicates direct current If Lx Lx is displayed Indicates measurement of phase phase voltage If Lx N is displayed Indicates measurement of phase neutral voltage Bar rpm PSI Hz kPa Indicate measurement units for the corresponding parameter The lock icon indicates keypad is locked JUS f
5. 3 3 ELECTRICAL CONFIGURATION The supplied unit may be one of three types The generator unit is supplied with ATS generator unit is supplied without ATS Note that its installation is required GENERATOR SET MAIN POWER SUPPLY UTILIZATION CONSUMERS Image 11 LOAD TRANSFER DIAGRAM Note PCS Power control switch ATS may be with contactors or motorized transfer switch Standby by signal The generator set without ATS sits idle until it receives a signal from an autonomous external system which monitors the mains and controls the transfer switch for startup S3 GESAN 3 4 RETENTION BATH The generator set may include a built in galvanized drip pan to prevent spills from the unit such as fuel oil or coolant with a capacity of 11096 with respect to the total volume of liquids in the generator set Image 12 DRIP PAN 1 4 drain plugs 2 on each side of the pan 2 Slots for inserting forklift arms 3 Retention bath level senders optional 98 5 0 GESAN 4 INSTALLATION OF THE GENERATOR SET 4 1 UNLOADING AND TRANSPORT When unloading an generator set certain minimum conditions should be observed in terms of safety and efficiency The loading and transport of the unit should be done by qualified personnel The ground must be capable of supporting the full weight of the generator and the forklift Make sure that the battery is discon
6. 008 1 mage outeur naos 37 USE OF HEARING PROTECTION REQUIRED e images COQANTFUUSH 1 96 images OLDRANNG BATIERYISOUNOR 176 67 A N NO 1 5 oa GESAN Pol gono Malpica Alfind n c Encina n 8 Tel fono 434 976 107 332 Fax 34 976 107 366 50171 LA PUEBLA DE ALFIND N Zaragoza SPAIN WWW gesan com export gesan com info gesan com V 2 05
7. GESAN To view the values of the various parameters press v and the LCD indicator 8 will display the items listed below in the following order RPM of generator frequency Hz Line Neutral AC voltage of generator Line Line AC v oltage of generator Oil pressure Coolant temperature Fuel level Engine operating hours DC voltage of battery AC line current Total kW Voltage V Intensity A Phase angle cos Supply frequency Hz Phase Neutral AC supply voltage normal Phase Phase AC supply voltage normal The following is an example of what the LCD screen 8 will look like when the various parameters are checked SCREEN SEQUENCE DESCRIPTION Rem 1501 Initial screen in which engine speed and generator frequency are measured To measure the next parameter press v Then the second measurement screen appears indicating the voltage readings between each phase and neutral mio 2351 WI To measure the next parameter press The third measurement screen will appear indicating the voltage readings 12 39 0 V r between phases i213 4010 V 4093 To measure the next parameter press Indicates status of the configurable input Illuminates to indicate an alarm configured in combination with these icons Warning 5 otoppage 55 LCD screen will appear as follows when a configurable alarm is activated JUDA
8. 953 4 2 7 2 Installation of ELECTRICAL POWER section A A diagram of a connection can be seen in image 15 The ELECTRICAL POWER installation may be done in two ways 1 ATS supplied by GESAN Connect the generator s current output terminals U V W N to the ATS terminals V WN Connect the electric company s power control switch PCS to terminals R S T N Then connect terminals X Y Z N to the installation for which you want to guarantee electrical power 2 ATS not supplied by GESAN or the generator set is the Standby via signal type Connect the generator s current output terminals U V W N to the input of the ATS on the generator set Checkthe manual of your ATS This installation should be performed by qualified personnel who should determine the conductor section to be used Rememb er that you must ground the unit according to the current regulations in effect where the installation is performed 4 3 STORAGE If you think your generator will be inactive for a long period of time follow these instructions 1 2 3 4 5 6 7 8 Switch the control module to the OFF position Press the emergency stop button to avoid future involuntary startups when connecting Empty the fuel tank Leave the battery disconnected Avoid storing the unit in spaces with high dust accumulation or excessive humidity Do not use pressurized water when cleaning the unit Check your engine manual for care inst
9. GRUPOS ELECTROGENOS GESAN S A Image 1 GENERATOR SET WITH SOUND PROOF CANOPY Image 2 GENERATOR SET WITHOUT CANOPY 31519517 gaa E Bu 1 Coolant tank hatch 2 Side access door 3 Fuel tank cap 4 Exhaust silencer 5 Engine 6 Shock absorbers 7 Base frame 8 Base support 9 Canopy AIOR m Image 3 DETAILED VIEW OF IMAGE 1 10 Electrical panel door 11 12 13 14 15 16 17 ua 0 a Ventilation grill Lifting frame and eyebolt Electrical control panel Alternator Electrical power control panel Battery Fuel tank av 21409 f 981511 98 GESAN Image 4 DETAILED VIEW OF IMAGE 2 1 Lifting frame 6 Base 2 Engine 7 Electrical control panel 3 Shock absorbers 8 Electrical power control panel optional 4 frame 9 Alternator 5 Fuel tank 10 Battery f 62128101 28 GESAN 3 1 SOUND INSULATION The supplied unit may be Soundproofed Includes sound insulating canopy Open skid Please keep in mind that compliance with current regulations requires that proper sound insulation be provided for this model See 4 2 INSTALLATION Each generator set is provided with a sticker indicating the level of noise output produced and the need to use hearing protection Use of hearing protection Noise output 90 dBA Noise output 114 dBA required The noise level has been measur
10. Green LED Button for switching to NO LOAD TEST mode SE Button for switching to LOAD TEST Green LED available on model 5220 mode only Button for switching to AUTOMATIC Green LED mode Button for starting up generator set If turned on indicates that generator Green LED set is ready Configurable LCD indicators kW kVAr 0 205 eoe Tt B BOOS vd Screen indicating the status of the ii aid E BENE Down button on the screen menu Event Log button LED turned on mains power Green LED available on available model 5220 only Status of ATS for mains and generator Left LED indicator mains closed set Right LED indicator Generator closed LED turned on Generator set supplying consumers Status of the generator set 1 195 283 GESAN The Deep Sea 5220 control module is an automatic module that controls the main power supply if a mains failure occurs generator set will start up Loads are transferred when the mains supply fails This control module also gives the option of manual startup The user can also control all of the generator units parameters as well as the status of mains power supply This module is supplied with automatic generator set with or without ATS The Deep Sea 5210 control module is supplied in standby by signal type units AUTOMATIC mode AUTO This is the normal operating mode Automatic mode will be activated b
11. If the ATS was not supplied by GRUPOS ELECTROGENOS GESAN S A check the user manual of the corresponding ATS and follow these steps Connect the terminals R S T N of the control panel referential Mains Voltage to the input of the electric company mains Connect the terminals numbered 37 to 47 to the ATS control panel check the electrical setup on the electrical generator control panel Make sure that the electrical and mechanical interlocking is completed correctly Also make sure that the ATS that you want to install is compatible with the generator unit provided Assembly is typicall y done with contactors for motorized switches please check with GRUPOS ELECTROGENOS GESAN S A The conductor section must be adequate for installation 3 If your generator unit is the Standby by signal type it will not monitor the mains or control the ATS these must be controlled by the user s management system The terminals through which the generator set receives the startup signal are 184 and 185 which should be volt free The generator set uses terminals 120 and 121 to return a volt free signal when the voltage and frequency of the generator set are correct Terminals R S T N should be connected to a mains input prior to the ATS as these terminals provide the power supply for the engine block heater and battery maintainer The conductor section should be appropriate for your installation 4 2 7 2 1 4195 f
12. below the minimum level and has shut down the generator To move from one event to the next press v 9 To exit the main screen press 10 Note Warning alarms are not logged Adjusting date and time The date and time are adjustable When the battery is disconnected the date and time are frozen when the battery is reconnected the date and time shown will be from the time the battery was disconnected The date and time reflected in the event log will be taken from the configuration according to the following steps 1 IO simultaneously This icon flash indicating that configuration mode is active The calendar will be shown 93590 LIST OF POSSIBLE INDICATORS 2 ee 06 5 1 E LE E GESAN Energize to stop Low battery voltage High battery voltage Low frequency 20 High frequency 21 Generator under voltage L1 N 22 Generator over voltage 23 Generator under frequency gems 25 ___ doc 2 2 ce d f 9 18 191 51 GESAN Deep Sea Electronics Modal 5320 RUNNING IN AUTO Warming 10s L N 240V DA 50Hz L L 415V Image 22 GE Deep Sea Electronics RUNNING IN AUTO Warming 10s L N 240V DA 50Hz L L 415V OKW 96705 6 Image 23 P JEWS SANBORN 28 GESAN NUMBER SYMBOL DESCRIPTION IDENTIFICATION Stop butt
13. damaged 1 Make sure nothing is preventing the unit from functioning properly Strange noise inside the unit 1 Various causes 2 Contact technical sSvcs IN THE ELECTRICAL PANEL Engine does not start Engine starts ORIGINATING ENGINE S INTERIOR Unit in operation 9 PROTECTION FROM THE ENVIRONMENT Once the generator set has been installed it is necessary to clean the packaging accessories electrical tools etc that were used during the installation process When it is time to dispose of the batteries in keeping with environmental regulations it is advisable to take them to an authorized recycling center For a cleaner environment recycle all possible items and be sure to not throw electrical components in with the regular garbage so as to comply with european directive 2002 96 EC These items should be stored separately until being taken for ecological recycling 1 195 935 UH 22 GESAN 10 WARRANTY The generator set warranty covers an entire year starting from the date it is installed This should be communicated to GRUPOS ELECTR GENOS GESAN S A hereinafter manufacturer in writing via fax or email The following information must be included MODEL SERIAL NUMBER and INSTALLATION DATE If the manufacturer is not informed of the installation within a maximum of sixty days from the invoice date the latter shall be considered the effective start date of the warranty period If for a
14. heating of coolant water by means of a boiler connected to the mains voltage It will be correctly indicated on the panel by a lamp which will be turned on or off automatically as needed Note The generator set includes a regulated factory thermostat between 40 y 60 C The startup system used by the generator set is electrical and consists of a 12 or 14 V electric engine powered by one or more batteries usually lead If the unit has been shipped to somewhere outside Spain the placement into service of the dry charged batteries should be done by removing the vent caps filling each cell using sulfuric acid with a density of 1 28 or 1 23 in tropical countries Let it sit for at least 20 minutes and check the electrolyte level 25 mm above the plates never fill to the brim Put the caps back on IN It is recommended that protective eyewear and gloves be worn when adding battery acid Make sure that there is nearby access to running water in order to wash any areas that come into contact with the acid IN All operations must be performed with the utmost precaution and safety as indicated in this manual Be especially careful with potential short circuits that could occur when coming in contact with the unit s metallic objects 1 4195 9518501 98 GESAN 4 2 7 Electrical connection 2 These connections should be made while following number of safety measures 1 Use the proper individual protection equipment to ensure comp
15. load regardless of the status of the mains power supply Ve To terminate this mode press the button 4 Once button 4 is pressed and there is adequate mains power supply without the remote startup signal activated the shutdown sequence will begin as described in the automatic mode e Press 1 or the emergency stop button to intentionally stop the unit 1 195 SOLN EAU 2 GESAN LOAD TEST mode Manual 5320 Select by pressing 3 3 Test for proper functioning of the generator set To start up press the start button 6 In this operating mode a mains failure is simulated with the loads being transferred to the generator set Ve To terminate this mode press the button 4 Once button 4 is pressed and there is adequate mains power supply without the remote startup signal activated the shutdown sequence will begin as described in the automatic mode After this period of time the load will be carried by the mains power Press 1 or the emergency stop button to intentionally stop the unit ALARMS Press 5 to silence the audible alarm and the common alarm LED Generator on load L N 230v 240A 50uz 1 1 400v 133kw the screen will display the following Alarm Alarm type Shutdown or warning Shutdown Higt temperature gt Alarm description Example High engine temperature If shutdown occurs while a warning is active the s
16. mains failure occurs or a remote startup signal is received loads will be transferred to the generator set 5220 the unit will continue operating with a load regardless of the status of the mains power supply Ve To terminate this mode press the button 4 Once button 4 is pressed and there is adequate mains power supply without the remote startup signal activated the shutdown sequence will begin as described in the automatic mode Press 1 or the emergency stop button to intentionally stop the unit Us 8 LOAD TEST mode Manual Select by pressing 3 Test to check proper functioning of the generator set To start up press the start button 5 In this operating mode a mains failure is simulated with the loads being transferred to the generator set To terminate this mode press the button 4 Ve Once button 4 is pressed and there is adequate mains power supply without the remote startup signal activated the shutdown sequence will begin as described in the automatic mode After this period of time the load will be carried by the mains power Press 1 or the emergency stop button to intentionally stop the unit The status screen of the Deep Sea 52XX control module will indicate all of the possible events of the generator set This image shows all of the indications of the LCD screen 8 Bem kW 50 Off
17. the control module issues unit stop command If light is continuous and the engine is stopped indicates CONTACT Low oil pressure If light is flashing indicates failure and the control module issues unit stop command If light is continuous indicates low Coolant level and module issues unit Low level High coolant stop command temperaturee If light is flashing indicates high coolant temperature and the control module issues unit stop command Light will flash and indicate that the Overload protection switch is open module issues stop unit command If light is flashing indicated WARNING Low fuel level If light is continuous module issues unit stop command If light is continuous module issues unit stop command indicating an emergency 7 Emergency stop stop emergency button activated Overspeed If the light is flashing module issues unit stop command indicating engine High speed If the light is continuous indicates WARNING 1 7 Programmable alarm If light is flashing module issues unit stop command Note If at any point 3 or more LED indicators turn on it could indicate low battery level STANDBY GENERATORISE GESAN E Model 5220 Image 20 DEEP SEA 5220 CONTROL MODULE Deep Sea Electronics hodei 5210 ELIT Image 21 DEEP SEA 5210 CONTROL MODULE aw GENSAT 981 GESAN DESCRIPCI N IDENTIFICATION Stop button
18. the battery is reconnected the date and time shown will be from the time the battery was disconnected The date and time reflected in the event log will be taken from the configuration according to the following steps Press and Press simultaneously then enter the correct PIN number until the date and time screen appears When date and time screen appears press the button The minutes will start to flash Press Press the button to confirm the value entered The hour will begin to flash press to adjust to the desired value 283 GESAN Press the button to confirm the value entered and select the day The day will begin to flash press again to adjust to the desired value Press the button to confirm the selection made and select the month The value will start to flash press again to adjust the month To input the year press The year will start to flash press to adjust to the desired value Press to save the changes made to date and time Date and time 19 Sep 2003 10 00 The screen will display the date and time entered GESAN 6 6 INTELIGEN DIGITAL CONTROL MODULE 24 48 21 18 InteliGen reget Image 24 INTELIGEN DIGITAL CONTROL MODULE EE E 14 195 283 GESAN SYMBOL DESCRIPTION IDENT
19. the connection and the load sharing Review the connections of the startup battery clean and cover with vaseline Make sure the battery charger is functioning properly Make sure fuel pump is functioning properly Check fuel level on the main fuel tank MONTHLY Check coolant and oil levels Make sure smoke extractor is functioning properly Make sure all of the electrical panel lights are functioning properly Make sure the ATS functions properly in transfers Check the state of all of the gauges and indicators on the electrical panel Check the engine manufacturer s manual for specific tasks Start up the engine manually three times noting each time the voltage and density readings for each of the battery s elements If any of the voltage readings varies significantly from those of the battery s other elements do not perform the remaining manual engine startups Fully charge the battery and check the electrolyte level Make sure there are no leaks in the coolant tubes Make sure that all of the unit s alarms display correctly Check the engine manufacturer s manual for specific tasks Clean the outside of the fuel tank and check the diesel lines Clean radiator change antifreeze Clean and lube the water pump and fan Make sure the control apparatus measurements given are correct YEARLY Clean control panel and tighten the panel s connections Verify that the antivibration feet fittings and belts in proper c
20. to start up the generator set When the generator voltage is within the established limits the LED indicator will be lit Next press ON OFF button 10 The loads will be transferred directly to the generator set To stop the unit press STOP 6 LOAD TEST mode Manual This operating mode is used to allow the generator set to check the state of the mains power or to disconnect from the mains when an imminent mains failure is detected When this operating mode is selected the unit starts up at no load To transfer the loads to the unit press the MCB ON OFF button and after press the GCB 12 At this time synchronization occurs between the generator set and the mains for 60 seconds to assume the loads OFF mode The generator set will not start Even if we press the buttons START aM 5 STOP 6 GCB ON OFF 10 the generator will not respond 958 eue ALARMS The InteliGen control module includes the following warnings INCIDENT Startup sequence initiated Shutdown of the Gen Set Generator set circuit breaker closed Generator set circuit breaker opened Some GCB in group was opened in MINT Mains circuit breaker closed Mains circuit breaker opened Time mode has been changed STARTUP INFO AMF startup Remote startup by binary input SPM SPtM Remote stop by binary input SPM SPtM System startup by binary input MINT MEXT System stop by binary input MINT M
21. 230 volts Image 33 Possible battery leakage Image 36 Noise output 114 dB Image 39 Oil draining f 95185101 221 Image 28 General warning Image 31 Electrical hazard 400 volts Image 34 Electrical grounding Image 37 Use of hearing protection required ISOLATOR Image 40 Battery Isolator 1 4195 95 8501 98 GESAN 14 ANEXO 2 INDICE DE IM GENES image GENERMTORSETWTHCANOBY image 3 pEmtEDVEWOFWAGE _ S _ imag 4 DEmMEDVIEWOFWAGE2 _ Image 5 NTERIOROFASOUNDPROOFEDGENERATORSET 7 image 6 GENERICCONTROLPANEL 1 8 mage 7 ELECTRICALPANELOFGECOCONTROLMODUE o Image 17 DAGRAMOFCONTROLEANEL 120 image GECO DIGITAL CONTROL MODULE mage 19 _ 39 Image 20 DEEPSEASZIDCONTROLMODUE ______ 39 _ Image 21 DEEFSEASMOCONTROLMODUE 1 Image 22 DEEP 5 5320 CONTROL MODULE 1 4 __ 23 DEEFSEASMOCONTROLMODUE 1 4 magez4 INTELIGEN DIGITAL CONTROL MODULE 1 a _ DENTFICATONLABEL 1 __ 26 PLACNGINOPERATON Image 27 CAUTIONWITHGENERATORSTARTUR e GENERALWARNING 9 Image 20 UNDERNEDWARNNGNOTIGE Image 30 ELECTRICALHAZARDz3DVOLIS e Image 31 ILECTRICALHAZARDAVOLIS 1 image 32 umNGPONT Image POSSIBLEBATTERYLEAKAGE images ELECTRCALGROUNDNG _ image 35 NOISE
22. EXT Peak start SPtM Peak stop SPtM EVENT SPECIFICATION Generator set startup failure Generator set overspeed Generator set underspeed SD stop fail Emergency stop RPM pickup fail Battery voltage warning Battery is discharged GenSetSysStop GenSet PKstart GenSet PKstop ENGINE Sd start Fail Sd overspeed Sd underspeed Sd stop fail Emergency stop Sd pickup fail Wrn batt volt Sd batt flat av 325105 9818 91 51 GESAN GENERATOR f 92321501392 eue GESAN PHASE SEQUENCE f 9 9 8 GESAN 7 MAINTENANCE OF ELECTRICAL GENERATOR You must make sure that the person who will perform this duty is qualified to do so and utilizes the appropriate individual protection equipment 7 1 PRIOR TO MAINTENANCE You must first e Switch control module to the OFF position Press the emergency stop button Disconnect the battery use the battery shutoff switch To cut mains voltage disconnect the 10 A electromagnetic circuit breaker in the ATS panel supplied by GRUPOS ELECTROGENOS GESAN S A If made by another manufacturer make sure that this cut is done properly before handling the unit 7 2 DURING MAINTENANCE Preventive maintenance tasks are necessary to preserve the unit doing so will result in optimum performance Be sure to verify the following items 1 While the engine is cold the oil level should be between the minimum and maximum
23. IFICATION OFF MAN AUT TEST Scrolls through different operating modes OFF MAN AUTTEST Fault reset Acknowledges faults and alarms Start button In manual mode Stop button In manual mode Green if unit voltage is present Generator voltage present and within limits Flashes during synchronization with mains Generator set failure Flashing Red LED indicates alarm State of GCB Green GCB is closed Flashes during synchronization with mains GCB ON OFF Opens and closes GCB in manual mode State of MCB Green is MCB Is closed flashes during synchronization with mains MCB ON OFF Opens and closes MCB in manual mode State of mains power Green if mains power correct Red light flashes if mains failure occurs State of voltage supplied to and generator stops continuous if consumers generator is operating turns off when mains power restored Enter button Confirms on screen value Increases value N Selects on screen value Decreases value Cycles through display screens Button to cycle through the MEASUREMENT menus ADJUSTMENT HISTORY NOTE GCB Generator circuit breaker MCB Mains circuit breaker 1 1195 9 9 8 The InteliGen module contains the following three menu screens Measurement Adjustment Can be selected using the following button 18 History To display the different instruments on
24. NOS GESAN S A 7 The supply line between the generator set and the consumers should be protected by means of a differential relay for protection against earth leakage 8 The electrical installation between the generator unit and ATS should be protected using electromagnetic circuit breaker for protection against short circuits The circuit breaker is supplied optionally by GRUPOS ELECTROGENOS GESAN S A 9 Do not operate the unit with the doors open risk of electrocution burns or entrapment 10 The exhaust system produces enough heat to ignite certain materials 11 Do not inhale exhaust gases produced by the unit 12 Do not touch the engine or the exhaust while the generator set is operating as this could produce serious burns 13 Ensure proper ventilation in the area where the generator is installed in order to guarantee sufficient flow of cooling air 14 Do not refuel while the engine is running or in poorly ventilated areas 15 Know how to stop the unit in case of emergency 16 The fuel used is flammable and volatile 17 Do not overfill the tank and make sure it is closed properly after filling Use extreme precaution if fuel is spilled the vapors and the fuel itself are flammable Clean the area completely before starting up the unit 18 Do not smoke or bring any flames or sparks in the vicinity of the generator set risk of explosions 19 If you notice abnormal behavior by the generator set stop the unit locate exami
25. al and the charger s negative cable to the battery s negative terminal Recharge battery with a current equivalent to 1 10 the nominal capacity Ah Battery is fully charged when acid density is 1 28 Before completing recharging process turn off charger before disconnecting battery and check electrolyte level 12 If the battery is discharged and you want to perform an emergency startup with the battery from another generator first check the tightness of the discharged battery s terminals Stop the engines of both units and connect the two positive terminals of the batteries first and then connect the negative terminal of the charged battery to a metal area on the disabled unit ground Start up the auxiliary unit and then the unit being repaired Disconnect the cables in reverse order to avoid a short circuit Finally fully charge the battery AN While performing preventive maintenance tasks it is advisable to wear protective eyewear and gloves during all operations involving AN Remember to always perform all operations with the utmost precaution and safety as indicated in this manual Pay special attention to the risk of short circuits that could be caused by coming in contact with the unit s metallic objects f 95115 GESAN 7 3 MAINTENANCE CHART FREQUENCY MAINTENANCE OPERATION Perform a mains failure simulation the unit should supply power to consumers for one hour For parallel units check
26. ck the exhaust passage the cooling of the alternator and the radiator air output Insufficient ventilation could produce an increase in the atmospheric temperature of the premises and cause the generator to lose engine power or even shut down 4 2 4 Fuel In keeping with current legislation special attention should be paid to the storage of fuel which is classified as a hazardous product The installation of the generator will include a day tank and an optional fuel storage tank Depending on the output of the generator the fuel tank may be external instead of being built into the base frame The tank should be installed within a maximum distance see the engine manufacturer s manual The installation will be carried out according to current legislation The unit may include a self suction eccentric fuel transfer pump SAB BE with self adjusting blades Includes a recirculation bypass valve The pump has an internal removable 352 micron filter which must be used Image 15 SAB BE PUMP PARAMETER VALUES OUTPUT ENGINE SPEED FUEL SUPPLY FREQUENCY COOLING LINE IN OUT PROTECTION LEVEL MAX AIR FLOW PUMP INTENSITY ASPIRATION BYPASS PRESSURE From 2 to 2 5 bar NU Note The pump will function if the generator set is running it has an ON OFF switch located on the door of the unit s electrical panel 4 2 5 Exhaust Given the importance of complying to environmen
27. creen will cycle through the active alarms Shutdown Warning Shutdown Higt temperature Low coolant level Emergency stop The alarms do not entail generator unit shutdown aw 11 1109 9811815 0i 281 GESAN INCIDENT ALARM DESCRIPTIONS ALARM Warning Alternator voltage not detected Charge fail Warning Low battery volts Battery voltage beyond established limits ALARM Warning High battery volts ALARM mE After shutdown command engine continues running Fail to stop Could also indicate faulty oil pressure sender ALARM Warning Fuel level below established limits Low fuel level ALARM Warning Low oil pressure below established limit Low oil pressure ALARM Warning High temperature ALARM Warning Low coolant temp ALARM Warning Overspeed ALARM Warning Underspeed ALARM Warning Over frequency ALARM Warning Under frequency ALARM Warning AC overvolts ALARM Engine temperature beyond established limits Engine speed beyond established limits Alternator frequency beyond established limits Alternator voltage beyond established limit Warning AC undervolts ALARM Warning Intensity of the alternator output beyond established limits High current GESAN INCIDENT DESCRIPTION OF SHUTDOWNS ALARM Shutdown Engine does not start three attempts ma
28. d in a enclosed space it is recommended to use an open skid model and soundproof the work area in keeping with the current fire prevention regulations The following image shows a typical installation of an open skid unit in a closed space Image 14 DETAILED VIEW OF INSTALLATION OF AN OPEN SKID UNIT 1 Air intake grill Will be at least 1 4 times the surface area of the engine s radiator panel 2 Smoke exhaust line This will be explained in more detail later 3 Silencer Must be firmly installed and fastened to a stable structure 4 Smoke exhaust outlet Smoke must flow out through a point which impedes its reentry into the space where theworking unit is installed 5 Radiator air outlet grill Will be at least 1 25 times the surface area of the engine s radiator panel 6 Channeling duct for cooling air Prevents re entry of hot air into the space where the unit is installed 7 Optional fuel tank The tank may or may not be supplied by GRUPOS ELECTR GENOS GESAN S A 8 Auxiliary fuel pump SAB BE system Optional accessory for filling of the electrical generator s day tank from large capacity tank 9 Fuel line adequate for transporting fuel and complies with current regulations GESAN 4 2 3 Ventilation and cooling The heat produced by the generator s thermal engine must be evacuated from the premises The heat is generated by the cooling of the cylinders the radiation from the engine blo
29. d of the emergency situation has been confirmed GAUGES INDICATING ENGINE PARAMETERS Oil pressure Intensity of battery voltage Engine temperature Activated by temperature and fuel button when generator set is stopped When the generator Fuel level is operating the gauges show the corresponding levels DIAGNOSTIC BUTTON Allows engine parameters to be checked when generator set is stopped electronically controlled engines Also gives a readout of the generator s different alarms DIFFERENTIAL Protection against earth leakage of one phase setting off the generator s set primary protection switch EJUS f 331 GESAN 6 2 GECO ANALOG CONTROL MODULE TEST SERV 2 TEST AUTO 19 2 27 OFF RESET i m z a SERV 1 START i SERV 2 START Image 18 GECO DIGITAL CONTROL MODULE f 92215013 eue GESAN The following is an explanation of each of the items shown on the GECO control module this module is for generator units with without ATS NUMBER SYMBOL DESCRIPTION IDENTIFICATION Startup failure No voltage or frequency detected Red LED Emergency button pushed High temperature Red LED Low coolant level Load test mode TEST SERV 2 TEST AUTO Automatic mode Different module OFF RESET operational modes OFF RESET mode SERV 1 START SERV 2 START SERV 1 START mode SERV 2 START mode Battery voltage OK Green LED Constant red batteries chargi
30. dable to turn the switch to OFF RESET and then turn the switch to the AUTO position MANUAL mode 3 different modes OFF RESET mode performs two functions the first of which is to stop the unit whether it is in manual mode MAN or automatic mode AUTO the second function is to cancel the active alarms allowing for a new startup of the generator set SERV 1 START mode 10 when turning the switch to this option the unit startup is ordered manual operation of the generator unit if it is operating in this mode and a mains failure occurs the generator set will not supply energy to the consumers SERV 2 START mode 11 when turning the switch to this option the unit startup is ordered manual operation of the generator unit and LED 17 is lit If the generator stops in this mode the loads would not be transferred to the mains power The alarms are automatically set If a TEST has been run whether in automatic mode AUTO or in manual mode MAN to stop the generator set turn the control module switch to the OFF mode 9 once the engine is stopped the switch can be set to a new operating mode Finally if the red STOP button is pressed an emergency stop will take place If the switch is turned to a position other than OFF LED indicators 15 and 1 will light up and an acoustic signal will be activated Note If the emergency stop button is pushed while the generator unit is stopped in the OFF position of the control modul
31. de Failed to start Controlled shutdown of the unit It will not be functional until the emergency stop button Shutdown has been reset Emergency stop Shutdown Oil pressure below established limit Low oil pressure Shutdown Engine temperature above established limit High temperature Shutdown Overspeed Engine speed beyond established limits Shutdown Underspeed Shutdown Over frequency Alternator frequency beyond established limits Shutdown Under frequency Shutdown AC overvolts Alternator voltage beyond established limit Shutdown AC undervolts Shutdown Faulty oil pressure sender Oil pressure sender fault Shutdown Intensity of the alternator output beyond established limits High current trip Note If the established limit for shutdown is exceeded a corresponding alarm screen will be displayed and on the configurable LED indicator 8 the common shutdown alarm will appear f 95185101 221 GESAN Typical LCD display screens Waiting in auto Indicates that the generator set will respond to either a mains failure or an active remote start Mains on load Indicates that generator set is in automatic mode and has been initiated after a mains failure has been detected Starting in auto 10s Mains on load Cranking attempt 1 Running in auto Indicates generator set running normally in automatic mode Also indicates the average Ganeratononload line to neutral voltage L N the highest of the three p
32. display appears Alternatively by holding down on v the user can autoscroll through all the instruments on a particular screen To disable scroll stop pressing the page down button and press it again for a few seconds or press When autoscroll is disabled if no buttons are pressed the display will return to the alarms page If an alarm becomes activated while viewing instruments the alarms page will be automatically displayed Instrument page content Engine speed Oil pressure Coolant temperature Engine hours run Number of starts DC battery voltage Generator AC voltage L N Generator AC voltage L L Generator Line Current Fuel level Nominal voltage L N Nominal voltage L L Nominal frequency Hz If the following appears in an instrument display this means that the engine cannot provide this parameter the control module however does provide this option If the following appears an instrument display with the generator set in OFF AUTOMATIC mode with the engine stopped this means that the control module is not connected to the engine Press this button 6 to display the given value Alarm LED Remote start on load Overload pre alarm Common alarms Common shutdown Editing the current date and time The date and time are adjustable When the battery is disconnected the date and time are frozen when
33. dule will issue a stop command to the generator unit To stop the alarm turn the control module switch to the OFF RESET position 9 Indicates overload of the generator unit LED indicator 4 will light up and the control module will issue a stop command to the generator unit To stop the alarm turn the control module switch to the OFF RESET position 9 Open the electrical panel door A and check the status of the motor guard Check the reason for the overload and reset Close the electrical panel door Put the module in AUTO mode Indicates low fuel level LED indicator 5 will be lit System warning must respond accordingly ES f 628151 01 98 GESAN 6 3 GPM 2 ANALOG CONTROL MODULE This module is for Standby by signal type generators EBHBBBB E Image 19 PLACA DE CONTROL GPM 2 f 62128140 28 GESAN SYMBOL DESCRIPTION IDENTIFICATION Flashing red light three startup failures Continuous red light voltage failure or low frequency Unit startup failure Alternator failure Flashing red light charge failed Battery charge failure Continuous red light unit stopped Flashing red light low oil level Low oil level Continuous red light unit stopped Flashing red light High Temperature Continuous red light low level Flashing red light unit overload Low fuel level Flashing red light low fuel level Flashing red light emergency
34. e the GECO control module will not give any indication of this however the unit will not start up f 62128101 28 GESAN INDICATOR LIGHTS This control module includes a 2 ampere battery charger receives power supply from external transformer connected to the mains power LED will turn on when battery voltage is correct LED is lit while batteries are charging Lit only when connection with the mains power exists LED illuminated intermittently when battery voltage is correct ALARMS The various alarms of the GECO module are LED indicators 1 through 5 There are two alarm types one which issues the stop command and one which does not if it is the first of these move the switch to the OFF position 9 and fix whatever caused the alarm and select the desired option Indicates startup failure Either voltage or frequency is not detected or the emergency stop button has been pressed in both cases the LED indicator 1 will turn on and the control module will issue a stop command to the generator unit To stop the alarm turn the control module switch to the OFF RESET position 9 Indicates low oil pressure LED indicator 2 will turn on and the control module will issue a stop command to the generator unit To stop the alarm turn the control module switch to the OFF RESET position 9 17 Indicates high engine coolant temperature low coolant level LED indicator 3 will turn on and the control mo
35. each screen menu press 17 and 16 The measurement screen displays the parameters measured by the engine if the engine uses an electronic management system many additional parameters can be displayed In addition to these parameters measurements can be displayed for fuel level oil pressure current voltage frequency run hours and battery charge level The adjustment menu screen displays the adjustment parameters already configured it is not necessary to edit any of these The history screen menu displays the log of alarms that have occurred in the generator unit It also logs the opening and closing of the mains circuit breaker as well as the starting and shutting down of the generator unit AUTOMATIC mode AUTO If a mains failure is detected the InteliGen module will open the MCB main circuit breaker Startup command is issued to generator set If generator voltage is within the established limits the following LED 7 will be lit and the controller closes the GCB generator circuit breaker Once mains power has been restored synchronization between mains and generator occurs then the MCB is closed causing the generator to discharge followed by the opening of the GCB When mains power is restored there will be a period of time during which the engine continues operating at no load to cool down before stopping completely Fault reset Not NO LOAD TEST mode Manual Press the START button EN 5
36. ed according to the european directive 2000 14 EC and in compliance with the maximum levels established by directive 2005 88 EC Image 5 INTERIOR OF A SOUNDPROOFED GENERATOR SET JEWS f SENSU 013 981 GESAN 3 2 CONTROL UNITS The unit provided may be controlled by different modules depending on the type of function it has been designed to perform The following is a generic control panel which contains all of the electrical and mechanical options available AMMETER FREQUENCY METER HOUR METER VOLTMETER LOCK VOLTMETER AUTOMATIC SWITCH CONTROL ENGINE BLOCK UNIT HEATER PILOT BATTERY VOLTMETER LOCK DIFFERENTIAL AUTO FUEL REFILL SWITCH TEMP AND FUEL GAUGE BUTTON OIL PRESSURE AMMETER ENGINE FUEL OPTIONAL BATTERY VOLTMETER TEMPERATURE OPTIONAL Image 6 GENERIC CONTROL PANEL 54 111547 ZEN p E 4 a 3 2 1 GECO GPM 2 analog control module If you purchased a generator unit with a GECO control module the electrical panel will look like the following diagram AMMETER FREQUENCY METER HOUR METER VOLTMETER LOCK VOLTMETER SWITCH ENGINE BLOCK HEATER PILOT BATTERY VOLTMETER ALTERNATOR BATTERY VOLTMETER PILOT LOCK TEMP AND FUEL GAUGE BUTTON OIL PRESSURE AMMETER ENGINE FUEL OPTIONAL BATTERY VOLTMETER TEMPERATURE OPTIONAL Image 7 ELECTRICAL PANEL OF GECO CONTROL MODULE f Saat 0 1 231 GESAN If
37. engine and alternator electrical setup a set of keys ATS upon order silencer or exhaust tube and flexible tube supplied separately for open skid units Should you have any problem with the equipment provided please contact the distributor directly GRUPOS ELECTR GENOS GESAN S A in a constant effort towards product improvement shall revise its manuals and include improvements made to the supplied units Thus the information contained in this document is subject to change without prior notice and without obligation to update 28 GESAN 2 BASIC SAFETY RULES Safety precautions and recommendations for handling the generator set supplied by GESAN 1 Do not allow the unit to be used by non authorized personnel or minors not accompanied by an adult 2 Use the necessary Individual protection equipment 3 Ground the machine and ATS panel 4 Make sure there is sufficient lighting on the control panel 5 Do not install the open skid electrical generator outdoors risk of electrocution and non functioning 6 The connection should be made by a qualified electrician in accordance with current norms and regulations An incorrectly made connection can cause electrical feedback with electrocution hazards for anyone working with the mains power supply The mains connection should always be made using an automatic transfer switch ATS if none has been supplied contact your distributor or GRUPOS ELECTROGE
38. g temperatures above Serial no 164936 Manufacture date 01 02 06 E E E E 5 Li LH Li 010300VO04 060350ST010 Pol Malpica Alfind n C Encina 8 50171 La Puebla de Alfind n ZARAGOZA SPAIN www gesan com www gesan es Image 25 IDENTIFICATION LABEL 1 119 5 f 95115 11 51 GESAN LABELED ITEM DESCRIPTION D V gt Engine manufacturer is V olvo P erkins or C ummins gt The generator set is designed to operate at 60 Hz response times per ISO 8528 E E PE 5 6 7 ES EN CE marking indicates that generator set complies with the relevant directives GESAN PLACING IN OPERATION 1 Make sure Battery Shutoff switch is CLOSED 2 Check engine s water and oil levels 3 Connect earth pin to a suitable point on the ground 4 Make sure electrical power circuit breaker is OPEN 5 Connect cables to connection terminals on circuit breaker 6 Start up ELECTRICAL GENERATOR 7 sure Voltage and Frequency are correct 8 Set Electrical Power switch to CLOSED position Image 26 Placing in operation Image 29 Undefined warning notice Image 32 Lifting point Image 35 Noise output 90 dB Image 38 Coolant flush CAUTION THIS GENERATOR SET COULD START UP WITHOUT PRIOR WARNING To perform MAINTENANCE turn the BATTERY SHUTOFF SWITCH to the OPEN position Image 27 Caution with generator startup Image 30 Electrical hazard
39. hase currents the nominal 1 4 230 240A 50Hz frequency average line to line voltage L L and total kilowatts L L 440 133kw Measurement parameter display screens Coolant temperature Coolant temperature in degrees C celsius and degrees Fahrenheit F 60 c 140 F Oil pressure Displays engine oil pressure in Bar PSI and kPa 6 Bar 87 PSI 600 kPa Generator amps 11 12 13 238 241 241 All three generator line currents Event log Lo view the event log press the following button repeatedly Register of shutdown alarms occurring in the generator unit the most recent occurrences can be stored A screen similar to this is shown Event log 21 15 00 10 th september 2003 Low oil pressure Shutdown On September 10 2003 at 21 15 the unit detected that the oil pressure was below the minimum level and has shut down the generator JUJJA GSJ IU 28 GESAN To move from one event to the next press v To exit the main screen press Note Warning alarms are not logged Displaying information Pressing this button Page order Status display Instrument display Alarms display Event log It is possible to scroll through the different display screens by pressing the next page button Once selected the instrument will remain on the screen until the user selects a different instrument or after a period of inactivity for the control module at which point the default
40. lete safety while performing the electrical installation 2 Set the control module switch to the OFF position 3 Make sure the emergency button has been pressed 4 Verify that the battery is disconnected 5 Swich off main power 6 Before beginning the installation of the unit provided make sure that it meets your particular needs for voltage and frequency 7 Handle cables with maximum precaution as they may carry a charge A 8 The installation of the electrical generator must be performed correctly and the ATS ground connection should be identified by the following icon The unit manufactured by GRUPOS ELECTROGENOS GESAN S A may or not be supplied with ATS depends on electrical configuration see section 3 3 if it is not supplied it must be added by the customer The ATS is comprised of contactors or a motorized switch supplier The ATS will prevent simultaneous supply by the mains and the electrical generator The following diagram shows the ATS setup GENERATOR MAIN SET POWER SUPPLY AUTOMATI TRANSFER SWITCH ATS CONSUMERS Image 16 ATS SETUP 1 1195 ISON ENA OI 281 GESAN The electrical installation of the ATS is performed in two separate steps first the installation of the CONTROL section control and management of mains and ATS and second the ELECTRICAL POWER section transmission of electrical energy The following diagram shows the connections of a ty
41. mains to the units ATS as well as to the generator set see section 4 Installation The following is a description of the different variable elements according to the generator set chosen 6 1 ELECTRICAL PANEL COMPONENTS AMMETER Measures the Intensity A by means of a switch of the different phases of the generator set FREQUENCY METER Indicates the frequency of the generator set Hz VOLTMETER Indicates the voltage V of the main power supply or generator set depending on the position of the voltmeter switch VOLTMETER SWITCH This switch allows for voltage measurement by phase of the main power supply or the generator set HOUR METER Indicates number of hours worked by the generator set HORAS The two digits in red on the right indicate hundredths of hours Hours are indicated in white from the third digit on V uf 7 1 195 GESAN BATTERY VOLTMETER Indicates current voltage of battery ENGINE BLOCK PILOT LIGHT WARMING UP Amber pilot light Indicates engine block heating system is turned on Turns on and off automatically according to the needs of the thermostat BATTERY VOLTAGE FAILURE PILOT LIGHT GECO MODULE ONLY Red pilot light Indicates alternator battery charge failure EMERGENCY STOP BUTTON Pressing this button brings the generator set to an immediate stop To cancel turn to the left when the en
42. mpts lasting 10 seconds each with a 10 second pause between each After three unsuccessful startup attempts LED indicator 1 will turn on If the unit was operating in automatic mode and the mains failure is resolved once the external signal disappears 60 seconds will pass in order for the engine to be cooled during these 60 seconds the LED indicator 10 will flash and later it will be continuously displayed and the engine will stop with the LED indicator light remaining for 20 seconds If the mains power falters during the shutdown sequence the operating cycle will be repeated thus guaranteeing adequate electrical supply No load test mode Manual When key is turned to the manual mode position LED indicators for low oil level d 3 and alternator battery charge indicator ERA 2 will be turned on To start up the unit press the START button 13 If the key selection has been made on the generator unit and this button is not pushed in 20 seconds the control module will shut off the system the startup signal will be cut off when LED indicators for low oil level 3 and alternator battery charge 2 turn on the startup signal will also be cut off when the frequency exceeds 20 Hz Load test mode Manual Must be done using the external ATS controller with the control module in automatic mode AUTO TEST 9 STOP B H BH amp Y 715199 f 6212815 033 22 INDICATOR LIGHTS
43. ne and resolve the potential failure of the unit prior to restarting Contact our technical services department if needed 20 Keep the unit at least one meter away from buildings or other units 21 Be cautious when switching or installing batteries as they contain acids which are highly hazardous Avoid spills and use protection to avoid contact with the skin and eyes In case of contact rinse thoroughly with water and contact a doctor immediately 22 In case of ingestion of battery acid drink large amounts of water and milk and contact a doctor immediately 23 Use only distilled water in the battery tap water reduces its life expectancy 24 battery is filled above the maximum level the electrolytes will spill out if this happens clean the area quickly to avoid corrosion of the parts it has come in contact with 25 Frequently clean the unit to avoid obstructions or the entry of foreign elements into the unit dust moisture etc 26 Regularly inspect the unit s electrical cables 27 Prolonged contact with used oil can cause skin cancer Wash your hands after working with the generator 28 Avoid oil spills on both the inside and outside of the generator In case of an oil spill on the inside of the unit clean it properly as it could potentially become a flammable material av 21409 f 98 GESAN 3 DESCRIPTION OF GENERATOR SET General overview of the generator set and its different configurations manufactured by
44. nected Make sure that the fuel tank is empty Place the open arms of the forklift below the chassis at an equal distance with respect to the lifting frame With a hoist raise the unit using the lifting frame eyebolt The image below shows a drawing of a generator unit which includes a frame with a single lifting point Image 13 LIFTING FRAME f 95185101 221 GESAN 4 2 INSTALLATION This manual describes the installation of a generic generator set comprised of a diesel engine an alternator and an electrical panel Our technicians can advise you on each of the specific applications 4 2 1 Premises The following considerations must be kept in mind the fuel supply ventilation of the premises the output and direction of the exhaust gases and the noise produced Dimensions The dimensions should allow for the various required maintenance or disassembly operations A minimum of one meter should be left on all sides of the generator to allow for the doors to be opened Openings The premises should have an entrance that is large enough for the generator to pass through and allows for ventilation fresh air intake hot air exhaust with the appropriate surface area based on the generator s output the premises cooling system and the soundproofing system used 4 2 2 Start of installation GRUPOS ELECTR GENOS GESAN S A does not recommend installing canopied units in closed spaces If the unit must be installe
45. ng Battery charging Flashing red light batteries fully charged Yellow LED on indicates Mains contactor contactor closed Consumer power supply consumers supplied Yellow LED on indicates Generator contactor contactor closed Generator voltage and frequency Green LED indicates correct correct voltage and frequency 2 2 1 1195 9 9 8 GECO module has six operating modes differentiated automatic mode AUTO and manual mode which can be configured using the module switch numbers 6 11 on the control module s descriptive panel AUTOMATIC mode 8 normal operating mode When mains failure occurs the GECO module registers this by turning off LED indicators 14 and 13 at which point the mains contactor closes LED 15 turns off and the command is sent to turn on the unit There will be a maximum of three startup attempts lasting 20 seconds each with a 10 second pause between each Once the unit has started up if the generator set voltage is correct LED indicators 19 and 18 will be turned on at which point the generator s set contactor closes and LED indicators 17 and 16 will be turned on and the customer s installation receives a power supply until the mains power returns If all three startup attempts have been unsuccessful LED indicator 1 will be lit and an acoustic signal will be given lasting 120 seconds Upon re
46. ny reason the installation is not possible within the first sixty days following the invoice date the manufacturer must be informed thereof in writing Thus no warranty claims shall be accepted if the manufacturer is not in possession of the aforementioned correspondence The warranty of the generator set will cover any faulty components or assembly not caused by improper use han dling or modification The warranty does not cover breakdowns caused by connecting the generator set to devices not installed or supplied by the manufacturer Also excluded are breakdowns and damages caused by prolonged or improper storage should this occur please see the manufacturer s user manuals The warranty for the generator set shall cover ONLY the replacement parts and labor necessary for the repair of the generator by personnel authorized by the manufacturer Traveling kilometers traveled and other expenses deriving from the repair of a generator under warranty are excluded from the warranty coverage and in no case shall the manufacturer be responsible for these covering these expenses which shall be paid in cash The decision to accept or reject a warranty shall be made by the manufacturer In the case of engine and alternator breakdowns the warranty shall be granted by the provider of said components according to the particular warranty conditions of those components The manufacturer reserves the option to request that the faulty element be returned In s
47. on Green LED Button for switching to NO LOAD TEST mode ENCE sp Button for switching to LOAD Green LED available on model TEST mode 5320 only Button for switching to AUTOMATIC mode ads Button to silence alarms Control module LED test Sese Button for starting up generator Turned on when generator set is Green LED available Configurable LED indicators Red LED Warming 10s Screen indicating the status of the L N 240V DA 50Hz generator set BN 285 Button to scroll to next page of screen menu Green LED available on model LED lit Mains power available 5320 only Left LED indicator mains closed Right LED indicator Generator closed Status of ATS for mains and generator set LED lit Generator set is supplying loads for consumers Status of the electrical f 9 9 8 Deep Sea 5320 control module is an automatic module that controls the main power supply if a mains failure occurs generator set will start up Loads are transferred once the mains supply fails This control module also gives the option of manual startup The user can also control all of the generator unit s parameters as well as the status of mains power supply AUTOMATIC mode AUTO This is the normal operating mode The automatic mode is activated by pressing the button 4 at which point the LED at the top of the button 2 will turn on indicating that it is
48. ondition Make sure that vibration and noise levels comply with the current regulations Make sure noise emission level is compliant with the current regulations Check the engine manufacturer s manual for specific tasks EVERY 3 YEARS Replace startup batteries JEWS f SENSU 013 981 GESAN 8 TROUBLESHOOTING INCIDENT LIKELY CAUSE SOLUTION Starter does not turn 2 Replace starting system 2 Defective starting system 3 Contact technical svcs 1 Faulty voltage detector on cont alode 1 Contact technical svcs Starter functioning properly 2 Low fuel level 2 Refill fuel tank Stops with cause 1 Emergency has occurred 1 Take appropriate measures 1 Emergency not indicated due to _ Stops for no apparent reason faulty LED indicator 1 Contact technical svcs 1 P Does not stop when emergency 1 stopping system 5 2 Contact technical svcs 1 Faul uni 1 P Ger ratordoesmobstopwhem in aulty control unit ress emergency stop button 2 Defective stopping system 2 Contact technical svcs 1 Overspeed High voltage at no load 1 Contact technical svcs 2 Alternator failure 1 Underspeed Low voltage at no load 1 Contact technical svcs 2 Alternator failure 1 Heavy load 1 Adjust unit s loads voltage but low when on 2 Underspeed on load 2 Contact technical svcs 3 Alternator failure 1 Voltage meter damaged Voltage unstable 2 Engine unsteady 1 Contact technical svcs 3 AVR
49. operational 5320 If the mains power supply fails for longer than the units programmed period the LED ERE 12 indicating that the mains power is available will be turned off 5310 If a mains failure occurs the external management system should send a startup signal to the generator set at which point the LED indicating remote startup active 7 turns on and the startup process of the generator set begins The engine will start if it should fail there will be a maximum number of startup attempts 3 If all three startup attempts have been unsuccessful the information screen will display a startup alarm Shutdown Faiilede to start When mains power is restored or when the remote startup signal disappears there will be a period of time in which the engine will continue operating at no load to cool down before stopping completely If a mains failure occurs during the no load operating period cool down period the generator set would begin the startup process again Press 1 or the emergency stop button to intentionally stop the unit NO LOAD TEST mode Manual The no load Test mode is activated by pressing the button 2 at which point the LED at the top of the button will turn on indicating that it is operational Press le 6 to start up the unit If a mains failure occurs or a remote startup signal is received loads will be transferred to the generator set 5320 the unit will continue operating with a
50. pical ATS manufactured by GRUPOS ELECTROGENOS GESAN S A CONTROL CONNECTIONS ON CONTROL PANEL GECO module only KM2 e ENS d Z ELECTRICAL POWER CONNECTIONS ON CONTROL PANEL Image 17 DIAGRAM OF CONTROL PANEL 1 4195 95 8501 98 GESAN 4 2 7 1 Installation of CONTROL section A The installation of the control section can be done in three different ways 1 ATS supplied by GESAN 2 ATS not supplied by GESAN 3 Unit is the Standby by signal type 1 ATS provided by GRUPOS ELECTROGENOS GESAN S A Connect the terminals R S T N on the control panel installed on the generator and the terminals numbered 37 40 41 and 44 for the GECO module also connect 45 46 and 47 to the terminals on the ATS panel with the same numbering CAUTION Do not mistake control terminals R S T N with the electrical power terminals R S T N see the connections diagram preceding the installation instructions for the control and electrical power sections In making these connections you must use 8 wire conductor or 11 wire for the GECO module of 1 5mm the length of which will depend on the distance separating the two panels this cable is not provided with the generator set The maximum distance between the electrical panel and the and the ATS panel should be 25m for a 1 5mm section and a voltage of 650 kVA In case of higher voltage use the same maximum distance and a 2 5mm section 2
51. ructions the manual has been provided together with this document Check your alternator manual for care instructions the manual has been provided together with this document 1 1997 5 STARTUP To start up the generator set follow these steps listed below 1 2 3 4 5 6 7 Check levels oil coolant and fuel Turn the battery shutoff switch to the ON position Release the emergency shutoff switch if it has been pressed Connect to the mains power and verify that the voltage indicator is giving an adequate reading Check the automatic switch or motor guard levers should be raised After completing the pre startup tasks make sure that the generator s control module switch is in the desi red position For this reason the user should carefully read about the operation of the control module in section 6 ofthe OPERATION MANUAL It is recommendable to run a simulation of mains failure to verify that the unit is functioning properly Note It is not advisable to operate the generator set at low load for extended periods of time The generator is considered to be running at low load when it is below 3096 of the unit s nominal power 1 4195 f 953 GESAN 6 OPERATION MANUAL The generator set you purchased was designed for standby use which means that it will mainly be operational when the mains voltage is inadequate Therefore it is necessary to connect the outside
52. stop Flashing red light overspeed Green LED Unit warming up Yellow LED Flashing red light cool down period Stop signal Continuous red light stop command issued Low level High coolant Temperature Emergency stop Overspeed Remote startup mode CoN oun oN Flashing blue light maintenance required Maintenance signal Maintenance reset button Contact block button Unit startup button Key position for stopping unit Automatic mode Flashing or continuous red light user defined Programmable alarm The GPM 2 control module has three positions STOP automatic AUTO and manual E q MAN Key selectable numbers 14 through 16 of the descriptive chart on the control 51 module JEWS 981 GESAN AUTOMATIC mode AUTO When key is turned to the automatic mode position unit will sit idle until receiving an external startup command If mains failure occurs the external mains monitoring system will issue a signal to the electrical generator which will begin to operate supplying the necessary electricity At the moment in which the external startup signal is received while the key is in the AUTO position the LED indicator for low oil level d will light up as well as the alternator battery voltage indicator ERA and AUTO TEST AUTO LED TEST 9 numbers 3 2 and 8 of the descriptive panel on the control module respectively There will be a maximum of three startup atte
53. tal regulations special attention must be given to gas emissions Preventable load loss insulation suspension sound levels and air contamination should all be taken into account The compensators and flexible tubing used in the installation will absorb the displacement of the unit due to dilations and vibrations The units supplied by GRUPOS ELECTR GENOS GESAN S A may or may not include a rain cap The units are equipped with two holes on the underside to prevent internal water accumulation The potimun muffler locations are first directly behind the exhaust manifold and secondly at 2 5 or 4 5 of the total exhaust system length The reason for this are the existing standing waves especially for long exhaust systems when the natural tube frequency is in resonance with the fundamental engine frequency or one of its harmonics The worst muffler locations in order of valve are 1 3 3 5 or at the end of the system The best muffler locations in order of values are The worst muffler locations in order of value are L total exhaust system length elbows may be considered as straight portions Note In installations where it needs long exhaust system It will must have bigger diameter If the installation isn t correct 4 2 6 Generator startup Startup failure entails the stopping of the motor and as a result of the entire generator unit The intention is to ensure correct startup of the generator set by preheating the entire unit
54. turn of the mains power LED indicator 14 on the control module will be lit and the units shutdown sequence begins which lasts approximately 60 seconds in order to check the stability of the mains power following the return of the mains power the generator s set contactor will be disconnected which in turn shuts off LED indicators 17 and 16 followed by the closing of the mains power contactor and the illuminating of LED indicators 17 and 16 From this moment the unit will continue operating for 120 seconds at no load before stopping completely to cool the engine If the mains power falters during the shutdown sequence the operating cycle will be repeated thus guaranteeing adequate electrical supply On this control module in automatic mode two additional selections can be made in addition to the automatic option seen previously Load TEST MODE 6 with the switch turned to this position a simulation is made of mains failure and the load is transferred to the generator set If the switch is turned to another option while correct power and intensity levels exist the loads will be transferred to the mains power No load TEST MODE 7 this option simulates a mains failure no loads are transferred to the generator set If a mains failure occurs during this operation the loads will be transferred to the generator unit This mode will terminate if another option is selected Note For terminating test modes it is recommen
55. uch case all costs related to said return shall be covered by the customer The warranty for a repair made during the warranty period shall have the same expiration date as the warranty for the generator set The warranty does not cover damage caused by terrorist attacks natural disasters sabotage or incidents of a similar nature If any of the provisions set out does not comply with the legislation of a certain country the importer is required to notify the manufacturer thereof prior to carrying out the sale transaction f 9 9 8 11 NOISE LEVEL GESAN Electrical Generators produce different acoustic levels depending on the output and soundproofing of the generator set The noise output is indicated on a sticker affixed to the unit s base frame Note If you work near the unit for any extended period of time it is advisable to use hearing protection 12 DECLARATION OF CONFORMITY GRUPOS ELECTR GENOS GESAN S A shall deliver a CE Declaration of Conformity form along with the unit in compliance with the referenced regulations or standardized documents 13 APPENDIX 1 FIGURES Detail of the unit s Identification label Model DVAS 360 Nominal output 260 kW Power factor Nominal frequency 50 2 GESAN Nominal voltage 400 230V Nominal figures reduce E Product class in altitudes above 1 000m Weight 4 499 Kg and surroundin
56. values If it is below the minimum add engine oil NOTE With the GPM 2 and INTELIGEN modules at 50 hours run notice will be given to change the oil The recommended oil is 15W40 2 The radiator water level should be adequate 3 The fuel level in the tank should be sufficient for the service to be performed The generator control panel is equipped with a fuel gauge which will be functional whenever the electrical panel is receiving power 4 Always refuel in a well ventilated area with the engine stopped 5 Closely inspect the connections and the electrical circuit for both the mechanical and electrical sections 6 Check carefully for possible liquid leaks If a leak is detected find its source and resolve the problem If your unit has a drip pan drain the pan see section on DRIP PAN 7 The air inlet and outlet vents should be completely unobstructed to allow for free circulation of cooling air 8 Check the state of the unit s radiator and clean if necessary 9 Make sure the exhaust tube is not obstructed 10 Check the battery s connection terminals and electrolyte level if necessary add demineralized or distilled water Acid should never be added The battery should be recharged if the terminal voltage is below 12 3 V 11 If the battery needs recharging after being taken out of the unit remove the vent caps and charge battery with direct current only Connect charger s positive cable to the battery s positive termin
57. y pressing the button 4 The LED at the top of the button will turn on indicating that it is operational 5220 If the mains power supply fails for longer than the unit s programmed period the LED 11 indicating that the mains power is available will be turned off 5210 If a mains failure occurs the external management system should send a startup signal to the generator set at which point the LED indicating remote startup active 7 turns on and the startup process of the generator set begins vi Once the generator unit is up and running the display 6 lights up If a startup failure occurs there will be a maximum number of startup attempts 3 after three failed startup attempts the flashing stop signal 59 will appear along with the startup failure indicator When mains power is restored or when the remote startup signal disappears there will be a period of time in which the engine will continue operating at no load to cool down before stopping completely If a mains failure occurs during the no load operating period cool down period the generator set would begin the startup process again e Press 1 or the emergency stop button to intentionally stop the unit NO LOAD TEST mode Manual The no load test mode is activated by pressing the button 2 at which point the LED at the top of the button 2 will turn on indicating that it is operational Press 5 to start up the unit If a
58. you purchased a generator unit with a GPM 2 control module the electrical panel will look like the following diagram AMMETER FREQUENCY METER HOUR METER VOLTMETER LOCK VOLTMETER SWITCH ENGINE BLOCK HEATER PILOT BATTERY VOLTMETER LOCK TEMP AND FUEL GAUGE BUTTON OIL PRESSURE AMMETER ENGINE FUEL OPTIONAL BATTERY VOLTMETER TEMPERATURE OPTIONAL Image 8 CONTROL PANEL OF THE GPM 2 CONTROL MODULE 01392 GESAN 3 2 2 DEEP SEA digital control Module If you purchased a generator unit with a DEEP SEA control module the electrical panel will look like the following diagram ENGINE BLOCK HEATER LIGHT YELLOW AMMETER DIAGNOSTIC BATTERY VOLTMETER BUTTON Image 9 CONTROL PANEL OF THE DEEP SEA CONTROL MODULE Note The button on the control module performs the same function as the diagnostic button while in OFF AUTO mode f 921251013 921 GESAN 3 2 3 INTELIGEN digital control module If you purchased a generator unit with an INTELIGEN control module the electrical panel will look like the following diagram AMMETER VOLTMETER FREQUENCY METER LOCK Gomap InteliGen HOUR Ba ENGINE BLOCK AUTO HEATER PILOT FUEL REFILL SWITCH YELLOW OPTIONAL PILOT ON SLAVE MASTER GREEN LIGHT SWITCH OPTIONAL LOAD AMMETER FUEL GAUGE Image 10 CONTROL PANEL OF THE INTELIGEN CONTROL MODULE 1 4195 95 8501 98 GESAN
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