3.- installation of the electrical generator
Contents
1. in writing via fax or email The following information must be included MODEL SERIAL NUMBER and INSTALLATION DATE o 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 any 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 does not possess the aforementioned correspondence 8 The warranty of the electrical generator will cover any faulty components or assembly not caused by improper use handling or modification The warranty does not cover breakdowns caused by connecting the electrical generator to devices not installed or supplied by the manufacturer Also excluded are breakdowns and damages caused by prolonged or improper storage In the latter case check the manufacturer s user manuals e The warranty for the electrical generator 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 e The dec2. IN x Jm VI S M Ya ENERATOR SES 032593 MANUAL Y GESAN Serie Rental RENTAL SERIES abLacgrpiceaAL ozilzi NIO GESAN ti n TALLATONOFTHEELECTREALGENERTOR O TTT NM mo OO RN c INN CIT XI MER EE amaron or me I w Tre mr O DM NN woe A LTT ormone ig O I e TE MATERNI cern GENERATOR DURING MAINTENANCE MAINTENANCE CHART c it VEAL SS GESAN zl G 1 1 WELCOME Thank you for purchasing a GESAN electrical generator The purpose of this manual is to familiarize the user on how to use and work with the electrical generator its components and maintenance We recommend carefully reading the manual prior to working with the equipment in order to ensure proper use Save this manual for future reference and if you ever decide to sell the electrical generator be sure to include the manual along with the unit The following is a general description of the unit and the necessary information for installation operation and preventive maintenance Additionally you should have received a specific user manual for the engine and alternator electrical setup and a set of keys Should you have any problem with the equipment provided please contact the distributor directly GRUPOS ELECTROGENOS GESAN S A as a part of its dedication to constant product improvement will revise its manuals and incorporate the improvements made to supplied units Thus the inform
3. L CITRICAL 92 NERATOR 4 INSTALLATION OF THE ELECTRICAL CENERATOR 4 1 UNLOADING AND TRANSPORT The unloading and transport of the unit should only be done by qualified personnel observing certain minimum safety conditions The ground must be capable of supporting the full weight of the Generator and the forklift Make sure that the battery is disconnected e Make sure that the fuel tank is empty e Place the open arms of the forklift below the chassis at an equal distance with respect to the lifting frame e With a hoist raise the unit using the lifting frame eyebolt The image below shows a generator unit that which includes a frame with a single lifting point J Image 9 LIFTING FRAME RENTAL SERIES E SSCS SICA ODS GESAN If your unit includes a trailer one of the following may apply Trailer 1 Site trailer Connected with a DIN hitch ring and safety chains to the rear of the towing vehicle Use of this trailer is not authorized on public roads Use the safety brake whenever necessary Trailer 2 Road trailer Keep in mind the legal considerations detailed in point 3 3 AN Always perform the following precautionary steps Make sure the hitch ring and coupling connecting the towing vehicle to the trailer have the adequate towing capacity supporting a weight equal to or greater than the gross trailer weight Make sure there is no wear or damage to the hitch system or coupling never tow the genera
4. Fax 34 976 107 366 50171 LA PUEBLA DE ALFINDEN Zaragoza ESPANA www gesan com export gesan com info gesan com V 2 00
5. canopy See details on part 11 Image 3 INTERIOR OF A SOUNDPROOFED ELECTRICAL GENERATOR RENTAL SERIES ELECTRICAL GENE 3 2 CONTROL UNITS to perform AVE OT GESAN The unit provided may be controlled by different modules depending on the type of function it has been designed The following is a generic control panel which contains all of the electrical and mechanical options available AMMETER VOLTMETER FREQUENCY METER SJ NI NM I N 2 IR HOUR METER LOCK HEURES AUTOMATIC EMERGENCY CONTROL UNIT STOP EARTH LEAKAGE CIRCUIT BREAKER LOCK AUTO FUEL REFILL SWITCH OIL PRESSURE BATTERY ENGINE TEMP GAUGE VOLTMETER OPTIONAL OPTIONAL FUEL GAUGE GAUGE Image 4 GENERIC CONTROL PANEL m EIN PAL 324125 GESAN L CIRICAL Salso u 3 2 1 GPM 2 analog control module If you purchased a generator unit with a GPM 2 control module the electrical panel will look like the following diagram AMMETER VOLTMETER FREQUENCY METER AU HOUR METER LOCK HEURES A VOLTMETER amm O SWITCH EMERGENCY STOP EARTH LEAKAGE CIRCUIT BREAKER LOCK TEMP AND FUEL GAUGE BUTTON OIL PRESSURE BATTERY ENGINE TEMP FUEL GAUGE GAUGE VOLTMETER GAUGE OPTIONAL OPTIONAL Image 5 CONTROL PANEL FOR THE GPM 2 CONTROL MODULE RENTAL SERIES ar ZLZSOTRICAL OSI GESAN 3 2 2 DEEP SEA digital control module If you purchased a generator unit with a DEEP SEA control module models 5210 and
6. 5310 the electrical panel will look like the following diagram ENGINE BLOCK HEATER LIGHT YELLOW EMERGENCY STOP ELDON XXXXXX DIAGNOSTIC BUTTON EARTH LEAKAGE AMMETER CIRCUIT BATTERY BREAKER VOLTMETER Image 6 CONTROL PANEL FOR 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 a Sa ANE 3231123 GESAN L ZCITIRICAL Say SANTOS u 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 EOS A MAS fe 2 EARTH LEAKAGE p gt I CIRCUIT BREAKER LOCK ap InteliGen HOUR METER rr O t EN GREEN FUEL ENGINE BLOCK AUTO FUEL oo BUTTON HEATER PILOT REFILL SWITCH lo YELLOW OPTIONAL EMERGENCY ON GREEN SLAVE MASTER STOP LIGHT SWITCH OPTIONAL e e 4h 3 LOCK LJ LOAD FUEL M AMMETER GAUGE O po Image 7 CONTROL PANEL FOR THE INTELIGEN CONTROL MODULE RENTAL SERIES ar abL2acgrpilcejLgogzilzifIO GESAN 3 3 TRAILER The generator can be supplied with a trailer for transporting the unit e Site Trailer for private use areas only Includes DIN hitch ring safety brake and jockey wheel Note Ask about the possibility of using trailer with drip pan Image 8 TRAILER RENITALESERICO GESAN
7. D TH IS E LECT RICAL 2 Check engine s water and oil levels G E N E RATO R CO U LD 3 Connect ground wires to a suitable point on the ground START U P WITHOUT PRIOR l 4 Make sure electrical power circuit breaker is OPEN WARN IN G 5 Connect cables to connection terminals on circuit breaker J 6 Start up ELECTRICAL GENERATOR f To perform MAINTENANCE switch the T Make sure voltage and frequency are correct BATTERY ISOLATOR to the OPEN position 8 Set electrical power switch to CLOSED position M j Image 16 Placing in operation Image 17 Caution with generator startup Image 18 General warning Image 19 Undefined Warning Notice Image 20 Electrical Hazard 230 Volts Image 21 Electrical Hazard 400 Volts Image 22 Lifting point Image 23 Possible battery leakage Image 24 Electrical grounding Da Image 25 Noise output 90 dB Image 26 Noise output 114 dB Image 27 Use of hearing protection required A Image 28 Coolant Flush Image 29 Oil draining Image 30 Fuel draining BATTERY ISOLATOR Image 31 Battery isolator RENTAL SZINZI GESAN SL3 Ci CAL OSITOS 14 APPENDIX 2 IMAGE INDEX e _ 3 UNITS WITHOUT DRIP PAN Image 2 Image 2 DETAILED VIEW DETAILED VIEW OF IMAGE 1 IMAGE 1 e a image 5 CONTROL PANEL FORTHE OPM Z CONTROL MODULE e image 6 CONTROL PANEL FORTHE DEEP SEACONIROLMODULE o GESAN Poligono Malpica Alfind n c Encina n 8 Tel fono 34 976 107 332
8. L mode button Green LED Settings a ee AUTOMATIC mode button Green LED Settings ENTER Startup button for Electrical generator MEM When lit indicates correct readings for Green LED electrical generator Configurable LED indicators Bar Rpm L1 L2N Screen indicating the status of the B ui EE Down button on the screen menu Event Log button LED lit Electrical generator is supplying Green LED consumers RENTAL gt GESAN ZL ZCIMICAL O Startup If the LCD screen is off press 1 to connect the control module and the LCD screen will turn on Press the button 2 and the LED in the top part of the button will turn on indicating that the unit is operating Press 5 briefly to start up the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT There is a maximum of 3 startup attempts after which the flashing stop symbol bY will be displayed along with the startup failure indicator a The status screen of the Deep Sea 5210 Control Module will indicate all of the possible events of the electrical generator This image shows all of the symbols displayed on the LCD screen 8 kW kVAr Cos SO O GEA TI x The LCD display 8 will normally look similar to this Example of the screen indicating the voltage readings for each phase of the electrical generator Stopping the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE U
9. 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 values If it is below the minimum add engine oil Note With the GPM 2 and InteliGen modules after running 50 hours notice will be given to change the oil The recommende oil is 15W40 2 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 7 The air inlet and outlet vents should be completely unobstructed to allow for free circulation of cooling air 8 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 9 If the battery needs recharging after being taken out of the unit remove the vent caps and charge battery with direct current only Connect the
10. NIT Press 1 to stop the unit The unit will be stopped immediately RENTAL SERIES E OO OA GESAN DESCRIPTION Indicates that the screen display information refers to the electrical generator Indicates that the event log reading is being accessed Flashing Indicates that the programming mode is being accessed Indicates that the electrical generator is idle Indicates that the electrical generator s system date and time is being shown This icon indicates a stoppage or alarm Warning Y Stoppage bY Indicates the percentage of fuel remaining in the generator s tank 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 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 Bar Rpm psi Hz Kpa Ep f a E displayed ae ee ndicates measurement of phase neutral voltage L1 L2N L2 L3N L3 L1 N Bar rpm PSI Hz kPa indicate measurement units for the corresponding parameter The lock icon indicates keypad is locked a SANS Da SS GESAN ZLS GAL OZNI To view the different parameter readings press v and the LCD indicator 8 w
11. ON Fuel level below minimum Low battery voltage Emergency stop Engine overspeed Low oil pressure High engine temperature If engine does not start after 3 attempts the unit will be stopped and this icon will be displayed Low engine speed Alternator frequency beyond established limits lt TUAIC lt SX lt N Alternator voltage beyond established limits If it is detected that the generator s output current exceeds the established value for an extended period of time this warning will be displayed If the cutoff point for overcurrent is exceeded by 10 for one hour the unit will be stopped gt 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 RIONI ALETSERICO GESAN SC JFICAL OZNI Event log To view the event log press the following button repeatedly 10 This icon will flash WU l A screen similar to this will be shown On november 1 2002 at 08 17 the system detected that the oil pressure was below the minimum level and 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 Adjust date and time The date and time are adjustable When the battery is disconnected the date and time are frozen when the b
12. OZNI ow LABELED ITEM DESCRIPTION D Engine uses diesel fuel at 1 500 rpm P gt Engine manufacturer is P erkins V olvo C ummins or Deut Z DPR 100 R gt The electrical generator is soundproofed rental series 100 gt Commercial name 400 230 V Indicates electrical generator output voltage Indicates nominal frequency Hertz The electrical generator s control panel contains five electric gauges SE 2M Ammeter frequency meter and voltmeter and two mechanical gauges Engine temperature and fuel level Built in control panel Indicates control panel built into electrical generator Nominal power 80 kW Nominal output of engine expressed in kW Power factor 0 8 Indicates power factor of alternator Nominal frequency 50 Hz Nominal frequency of electrical generator Hertz Nominal voltage 400 230 V Nominal frequency of electrical generator Volts When withstanding an overload engine will perform according to catalogued Product class G1 response times per ISO 8528 Weight 1 640 kg Total weight of electrical generator Serial no 169216 Serial number of generator manufacture T PmPIPIFPF Manufacture date 30 03 06 Manufacture date of electrical generator CE marking indicates that electrical generator complies with the relevant standards V RENTAL SERIE E OO OSI GESAN IMPORTANT CAUTION da I Bos gt PLACING IN OPERATION 1 Make sure Battery Isolator switch is CLOSE
13. SCRIPTIONS ALARM Warning Charge fail ALARM Battery charge alternator voltage not detected 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 Low fuel level Low fuel level ALARM Warning Low oil pressure Low oil pressure ALARM Warning High temperature ALARM Warning Low coolant temperature ALARM Avertissement 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 limits Warning AC undervolts ALARM Warning Intensity of the alternator output beyond established limits High current RENTAL 934412 Z ar FIECTRICAMC ENERATOR GESAN INCIDENT DESCRIPTION OF SHUTDOWNS ALARME Shutdown Engine does not start three attempts made Failed to start ALARME Controlled shutdown of the unit It will not be functional until the emergency stop button Shutdown has been reset Emergency stop ALARME Shutdown Low oil pressure Low oil pressure ALARME
14. Shutdown High engine temperature High temperature ALARME Shutdown Overspeed ALARME Shutdown Underspeed ALARME Shutdown Over frequency ALARME Shutdown Under frequency ALARME Shutdown AC overvolts ALARME Shutdown AC undervolts ALARME Shutdown Faulty oil pressure sender Engine speed beyond established limits Alternator frequency beyond established limits Alternator voltage beyond established limit Oil pressure sender fault ALARME 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 RENTAL SERIES GESAN Lisi CAL SSI Sie vii Typical information screen messages Indicates electrical generator running normally in automatic mode Also indicates the average line to neutral voltage L N the highest of the three phase currents the L N 230V 240A 50Hz nominal frequency average line to line voltage L L and total kilowatts L L 440V 133kW Running in auto Generator on load 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 Generatos amps lip ZAS 238 241 241 Al
15. TH LEAKAGE CIRCUIT BREAKER ELCB Protection against earth leakage of one phase setting off the electrical generator s primary protection switch Configured to be activated when voltage is exceeded by 3 mA with a time delay of Os Includes a TEST button for checking the state of the ELCB It is the installer s responsibility to adjust and seal the ELCB according to the current regulations y RENIAL 3313133 B I GESAN LECIRICAL GENEROS 6 2 GPM 2 ANALOG CONTROL MODULE STOP A a x LI y i NN n fy A B bu 5 f EBHBBBB IBEBE Lu Image 10 GPM 2 CONTROL MODULE RENTAL SERIES ar abL2acgpilejsLgogzilmifIO GESAN SYMBOL DESCRIPTION IDENTIFICATION Flashing red light three failed startup Unit startup failure attempts alternator failure Continuous red light voltage failure or low frequency Flashing red light battery charge Battery charge alternator alternator failure failure Continuous red light unit stopped indicates contact Flashing red light low oil level Low oil level Continuous red light unit stopped indicates contact rend Low level high coolant Flashing red light high temperature temperature Continuous red light low coolant level Flashing red light unit overload Red low fuel level Low fuel level Continuous flashing red light stopped warning Flashing red light emergency stop Continuous red light engine overspeed Remote
16. ation contained in this document is subject to change without prior notice and without obligation to update RIONI 2 ile a Sao rit ei t OO GESAN 2 BASIC SAFETY RULES Safety precautions and recommendations for handling the electrical generator supplied by GESAN 1 Do not allow the unit to be used by non authorized personnel or by minors without adult supervision 2 Use the necessary Individual protection equipment 3 Ground the machine 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 inoperability 6 The connection should be made by a qualified electrician in accordance with current norms and regulations An improper connection can cause electrical feedback with electrocution hazards for anyone working with the mains power supply 7 The supply line between the electrical generator and the consumers should be protected by means of a circuit breaker for protection against earth leakage ELCB 8 Do not operate the unit with the doors open Risk of electrocution burns or entrapment 9 The exhaust system produces enough heat to ignite certain materials 10 Do not inhale exhaust gases produced by the unit 11 Do not touch the engine nor the exhaust while the electrical generator is operating as this could produce severe burns 12 Ensure proper ventilation in the area where the generator is installed in order to guarantee
17. attery 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 oj 1 and DS 10 simultaneously This icon ES will flash indicating that configuration mode is active The calendar will be shown mu eu a it Seo TniocAL GSS UT GESAN LIST OF POSSIBLE ALARMS e gt C Eee gem 6 7 8 9 B gt 23 sali o 5 1 gt eee n DI 2 zs 2 20 a so RENTAL SERIES GESAN LECINICAL Sal ii tivson 6 4 DEEP SEA 5310 DIGITAL CONTROL MODULE Deep Sea Electronics Model 5310 RUNNING IN AUTO Warming 10s ES L N 240V DA 50Hz Ea a ci af Q o Q i Image 13 DEEP SEA 5310 CONTROL MODULE 1133 ar J gt SSO TIC Salite Uit GESAN NUMBER SYMBOL DESCRIPTION IDENTIFICATION Stop button Green LED MANUAL mode button Green LED Settings nnd AUTOMATIC mode button Green LED Settings ENTER Button to silence alarms control module LED test SIGSIEECO Button for starting up electrical generator When lit Indicates correct readings Green LED for electrical generator Configurable LED indicators Red LED Screen indicating the status of the RUNNING IN AUTO Warming 10s L N 240V DA 50Hz electrical generator AA MN Button to
18. charger s positive cable to the battery s positive terminal and the charger s negative cable to the battery s negative terminal Recharge battery with a current equaling 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 10 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 11 Installation of the fuel filter in all units means that the operator must constantly monitor the water buildup and drain as it becomes filled This does not entail an inconvenience but rather simply keeping an eye on the transparent tank in order to know when to drain If the filter were to become worn out it should be replaced 12 The oil draining pump improves the draining process saves time and facilitates maintenance 13 The fuel tank includes a drain hatch to provide quick access and a safety valve to prevent fuel from being
19. d has been designed for manual service and thus starting and stopping the unit will be done manually The following is a description of the different elements according to the electrical generator chosen 6 1 ELECTRICAL PANEL COMPONENTS AMMETER Measures the Intensity A by means of a switch of the different phases of the electrical generator FREQUENCY METER Indicates the Frequency of the electrical generator Hz VOLTMETER WITH ATS Indicates the Voltage V by means of a switch of the different phases of the electrical generator HOUR METER ndicates number of hours worked by the electrical generator LLLLLLI The two digits in red on the right indicate hundredths of hours Hours are indicated in white from the third digit on HORAS mi eu RENTAL SERIES E BaLaACIMICAL OSI GESAN EMERGENCY STOP BUTTON Pressing this button brings the electrical generator to an immediate stop To cancel turn to the left when the end of the emergency situation has been confirmed On soundproofed units the emergency stop button is installed apart from the electrical panel built into the canopy N GAUGES INDICATING ENGINE PARAMETERS Oil pressure Intensity of battery voltage Engine temperature Fuel level DIAGNOSTIC BUTTON Allows engine parameters to be checked when electrical generator is stopped electronically controlled engines Also gives a readout of the generator s different alarms EAR
20. e 7 button 10 to confirm the value entered and select the day The day will begin to flash 2 again to adjust to the desired setting Press the 10 button to confirm the selection made and select the month The value will start to flash 2 again to adjust the month Lastly set the correct year by pressing the 10 button The year will start to flash Press 2 pour r gler la valeur d sir e Press 4 to save the changes made to date and time The screen will display the date and time 3 SIL elie le entered 19 sep 2003 10 00 RENTAL SERIES GESAN LS ST CAL GSI Sivvior 6 5 INTELIGEN DIGITAL CONTROL MODULE Comap InteliGen Image 14 INTELIGEN CONTROL MODULE lit Lu Ly l_ i ul V E y TRIGAL G LU 2 Lu im SINTO GESAN SYMBOL DESCRIPTION IDENTIFICATION Deactivates audible alarm OFF MAN AUT TEST Scrolls through different operating modes OFF MAN AUT TEST Fault vw 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 Electrical generator failure State of GCB Green when 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 d
21. evels Sales reference LWA dBA 7m DPR 20 90 70 DZR 30 S E DZR 40 0 DRE 7 3 7 DPR45 294 6 DPRO 94 66 DPR8O 9 6 DPR100 297 69 DVR1M0 To 69o DvR10 9 897 69 97 DVR20 97 69 DVR20 9 69 DVR30 097 6 DVR375 97 69 DVR410 98 70 DVR80 20294 62 Note If you work near the unit for any extended period of time it is advisable to use hearing protection RENTAL SERIES E aLaACIMICAL OSI GESAN 12 DECLARATION OF CONFORMITY GRUPOS ELECTROGENOS 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 nameplate DPS 100 400 230V 50Hz 3E 2M PRO60300 Nominal output 8260 kW Power factor 00 Nominal frequency 50 Hz Nominal voltage 400 230 V Nominal figures reduce in Product class altitudes above 1 000m and surrounding temperatures above 40 C Weight 1 640 Kg Serial no 169216 E E EB E al a a al Manufacture date 30 03 06 010300VO04 060350ST010 Pol Malpica Alfind n C Encina 8 50171 La Puebla de Alfind n ZARAGOZA SPAIN WWW gesan com www gesan es Image 15 NAMEPLATE c RENTALESIERICO GESAN L Ci t
22. extracted through the outlet on the base fra 14 The radiator is drained through the base frame outlet 15 For maintaining the canopy we recommend cleaning periodically to avoid dirt buildup The unit s galvanized canopy prevents corrosion and rust A Note While performing preventive maintenance tasks it is advisable to wear protective eyewear and gloves during all operations involving the handling of battery acid Note 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 RENTAL SERIES E abLzgrpicej gzlizixrOi GESAN 7 3 MAINTENANCE CHART FREQUENCY MAINTENANCE OPERATION Check fuel level on the main tank Check coolant fluid level Check the oil level see engine s user manual Drain water separator filter Make sure the radiator inlets and outlets are unobstructed DAILY Inspect the air filter service indicator Make sure the electrical generator s outlet cables are in perfect condition Make sure machine is properly grounded and that the earth leakage circuit breaker is working press test button Perform a general inspection and make sure there are no fluid leaks Check the engine manufacturer s manual for specific tasks EVERY 50 HRS l l WEEKLY Water and sediment in fuel tank Drain Review the connections
23. failure Low oil pressure and the control module issues unit stop command If light is continuous indicates low Low level coolant level and module issues unit stop command 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 unit stop command If light is flashing indicates WARNING Low fuel level If light is flashing module issues unit stop command If light is continuous module issues unit stop command indicating an emergency stop emergency button activated If the light is flashing module issues Overspeed unit stop command indicating engine high speed High coolant temperature Emergency stop If the light is continuous indicates WARNING 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 RENTAL SERIES z Y GESAN ZL Z3CIMRISAL GASTO DAE Deep Sea Electronics AS kW kVAr Cos RO C DES Y erm BEBE ian DEBEO va sim BIO v Image 11 DEEP SEA 5210 CONTROL MODULE Deep Sea Electronics sn HEB va SLI GOOG V Image 12 DEEP SEA 5210 CONTROL MODULE RENTAL SERIES E abLzcgrpicej ogzlizixrOi GESAN NUMBER SYMBOL DESCRIPTION IDENTIFICATION Stop button Control module connection Green LED MANUA
24. ill display these readings in the following order RPM of generator frequency Hz Line Neutral AC voltage of generator Line Line AC voltage of generator Oil pressure Coolant temperature Fuel level 96 Engine operating hours DC voltage of battery AC line current Total kW Voltage V Phase angle cos The following is an example of what the LCD screen 8 will look like when the various parameters are displayed SCREEN SEQUENCE DESCRIPTION Sem Dt Initial screen in which engine speed and generator frequency are measured To measure the next parameter press v i eE Then the second measurement screen appears indicating the voltage readings between each phase and neutral L2 N 2315 V em E VL To measure the next parameter press v 3070 IO The third measurement screen will appear indicating the voltage Y readings between phases uius 4010 Y E Hd y ESA To measure the next parameter press v Pressing v afterwards we move from one parameter to the next in the order specified on the previous page WARNING STOPPAGE DESCRIPTION Turns on to indicate a set alarm displayed along with the icons detailed on the preceding page Warning state DI Stoppage I LCD screen will appear as follows when a configurable alarm is activated RENTAL SERIES E aLaACIMICAL OSI GESAN ALARMS The following chart describes each alarm NUMBER SYMBOL DESCRIPTI
25. ision 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 such case all costs related to said return shall be covered by the customer e The warranty for a repair made during the warranty period shall have the same expiration date as the warranty for the electrical generator e The warranty does not cover damage caused by terrorist attacks natural disasters sabotage or incidents of a similar nature e 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 RENTAL SERIES GESAN SL3 Sic Sa Iai Oss 11 NOISE LEVEL GESAN Electrical Generators produce different acoustic levels depending on the output and soundproofing of the electrical generator The noise output is indicated on a sticker affixed to the unit s base frame Each electrical generator is provided with a sticker indicating the level of noise output produced see APPENDIX 1 FIGURES The noise level has been measured according to the European Directive 2000 14 EC and in compliance with the maximum levels established by the directive 2005 88 EC Noise l
26. l three generator line currents Event Log To view the event log press the following button repeatedly O 11 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 september 2003 Low oil pressure Shutdown On September 10 2003 at 21 15 the system detected that the oil pressure was below the minimum level and shut down the generator To scroll from one event to the next press v 10 To exit the main screen press 11 Note Warning alarms are not logged RIONI 2 ile a Sao rit oei t GSN GESAN Displaying information Press this button O 11 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 v 10 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 display appears Alternatively by holding down on v 10 the user can autoscroll through all of the instruments on a particular screen To disable scrolling stop pressing the page down button then either press it again for a few seconds or press 11 When autoscroll is disabled if no buttons are pressed the display will return to the alarms page If an alarm becomes activa
27. of the startup battery clean and cover with vaseline Change the filtering element of the water separator filter EVERY 250 HRS Start up the engine 3 times noting the voltage readings each time Make sure battery voltage is EVERY 6 MONTHS correct on each startup Make sure all of the electrical panel lights are functioning properly Check the state of all of the gauges and indicators on the electrical panel Clean the interior of the electrical generator Check the engine manufacturer s manual for specific tasks Make sure there are no leaks in the coolant tubes Make sure that all of the unit s alarms display correctly Thoroughly clean the engine radiator Check the engine manufacturer s manual for specific tasks EVERY 500 HRS YEARLY Fully charge the battery and check the electrolyte level Thoroughly clean the generator unit Clean the control panel and tighten its connections EVERY 1000 HRS Clean the electrical power panel and socket panel and tighten its connections YEARLY Make sure the control apparatus measurements given are correct For units with trailer take to specialized maintenance shop annually Check the alternator manufacturer s manual for specific tasks Check the engine manufacturer s manual for specific tasks Check the condition and tightness of the antivibration feet EVERY 3000 HRS EVERY 2 YRS Change coolant does not apply to the oil cooled DZR
28. r unit RENTAL SERIES a SSC TRIO OSI GESAN Startup Press the START button 5 to start up the electrical generator When the generator voltage is within the 7 will be lit Next press the GCB ON OFF button 10 The loads will be transferred directly to the electrical generator To stop the unit press STOP Es 6 established limits the LED indicator LOAD TEST Mode Manual This operating mode is used to allow the electrical generator 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 12 and then press the GCB ON OFF button 10 At this time synchronization occurs between the electrical generator and the mains for 60 seconds to assume the loads e OFF mode The electrical generator will not start Even if we press the buttons START 5 STOP 6 GCB ON OFF 10 the generator will not respond mi en N st FTA D353 35 GESAN L CINICAL OSITOS 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 STOP position Press the emergency stop button Open the battery isolator 7 2 DURING
29. range Notes Check your engine and alternator manuals for specific maintenance tasks Make sure maintenance is performed by qualified personnel Be sure to comply with local legislation on environmental protection Batteries filters and used fluids as well as replaced electrical material and packaging should be taken to an authorized recycling center When cleaning the generator do not use pressurized water as it could damage components Ba TEAL Darth Sa GESAN LSECIURICAL Say 8 TROUBLESHOOTING Defective battery SOLUTION Replace the battery Starter does not turn Battery isolator open Close battery isolator Defective starting system Contact technical services Faulty voltage detector on control Contact technical services module Starter functioning properly Engine does not start Lacking fuel Refill the fuel tank Stops with cause Emergency has occurred Emergency not indicated due to faulty Stops for no apparent reason LED indicator Contact technical services Press emergency stop button Take appropriate measures IN THE ELECTRICAL PANEL Ue NOL SIOP wiem emergengy Defective shutdown system occurs Contact technical services Engine starts Faulty control unit Press emergency stop button Generator does not stop when in stop position Defective shutdown system Contact technical services i Excessive speed High voltage at no load l Al
30. scroll to next page of screen menu Electrical generator is supplying LED consumers RENTAL SERIES GESAN L CITRICAL OI SAVIO Startup If the LCD screen is off press 1 to connect the control module and the LCD screen will turn on Press the button 2 and the LED in the top part of the button will turn on indicating that the unit is operating Press 5 to start up the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT There will be a maximum of 3 startup attempts after which the information screen will display a startup alarm Shutdowm Failed to start Stopping the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Press 1 to stop the unit The unit will be stopped immediately RENTAL SERIES a CFLECIRICAL GE TERATOR GESAN ALARMS 5 to silence the audible alarm and the common alarm LED By default the information screen will display the following message Generator on load L N 230v 240A 50Hz L L 400v 133kW If an alarm occurs the screen will display the following Shutdown Example High engine temperature The warning alarms do not entail generator unit shutdown If shutdown occurs while a warning is active the screen will cycle through the active alarms Shutdown Warning Shutdown High temperature Low coolant level Emergency stop INCIDENT ALARM DE
31. startup mode Green LED Unit heating Yellow LED Flashing red light imminent stoppage Stop signa Continuous red light stop command Emergency stop overspeed Flashing blue see maintenance section Maintenance signal Key position for stopping STOP unit Automatic mode AUTO Flashing or continuous red light user defined SDP Alo O ONI OAA ON Programmable alarm The GPM 2 control module has three positions STOP automatic AUTO and manual MAN Key selectable numbers 14 through 16 of the descriptive chart for the control module GESAN L 2CITIRICAL O Startup When the key is turned to Manual Mode position LED indicators for low oil level d 3 battery charge alternator LER 2 and preheating 00e 9 will be turned on and after 10 seconds the LED indicator 9 will be turned off at which point the START button starr 13 can be pressed to start up the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Note While the key is in the MAN position if the button 13 is not pressed within 20 seconds the control module will shut down the system Stopping the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Turn the key to the central STOP position INDICATOR LIGHTS AUTO Indicates remote startup continuous green light turns on when unit is operating remotely TEST Indicates heating of the uni
32. sufficient flow of coolant air 13 Do not refuel while the engine is running or in poorly ventilated areas 14 Know how to stop the unit in case of emergency 15 The fuel used is flammable and volatile 16 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 17 Do not smoke or bring any flames or sparks in the vicinity of the electrical generator risk of explosion 18 If you notice abnormal behavior by the electrical generator stop the unit and locate examine and resolve the potential failure of the unit prior to restarting 19 Keep the unit at least one meter away from buildings or other units 20 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 21 In case of ingestion of battery acid drink large amounts of water and milk and contact a doctor immediately 22 Use only distilled water in the battery tap water reduces its life cycle 23 If a 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 24 Frequently clean the unit to avoid obstr
33. t continuous yellow light turns on when unit is being heated Wait before starting up the unit Indicates stop signal STOP M 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 electrical generator must be running Turn the key to the STOP position while pressing the button Ra 12 until the control module becomes completely deactivated a RENTAL SERIES a abLzgrpicej gzizixrOi GESAN ALARMS The following is a chart describing the possible alarms of the GPM 2 module NUMBER SYMBOL DESCRIPTION IDENTIFICATION Unit startup failure If the light is flashing an audible signal will be given and generator is shut down If light is continuous indicates low Alternator failure frequency If it runs below nominal level for over 30 seconds unit is shut down If light is continuous and the engine Contact is stopped indicates contact not an alarm Battery charge alternator If light is flashing indicates failure and the control module issues unit failure stop command If light is continuous and the engine Contact is stopped indicates contact not an alarm If light is flashing indicates
34. ted the unit should always be started up at no load Make sure that there is nothing obstructing the ventilation ducts and that there are no foreign objects inside the unit Make sure the fluid levels of the electrical generator are adequate for the service the unit will be providing and that there are no leaks or spillage 4 2 4 Electrical connection The connecting of cables that supply consumers must be performed by qualified personnel these conductors should be connected to terminals U V W and N or L1 L2 L3 and N or to the socket panels The four pole circuit breakers have copper bus bars to facilitate the connection with conductors and prevent deterioration produced by repeated connecting Depending on the options selected sockets may or may not have individual protection which is distinguished from the general unit protection by the use of an individual circuit breaker for each socket RENTAL SERIES a abLzcgrpieaAL852zizixrO0 i GESAN 4 3 STORAGE If you think your generator will be inactive for a long period of time follow these instructions 1 Press STOP on the control module 2 Press the emergency stop button to avoid future involuntary startups when connecting 3 4 Leave the battery disconnected 5 6 7 8 uu Empty the fuel tank Make sure the internal protection valve is in the correct position a Avoid storing the unit in areas with high dust accumulation or excessive moisture a Do not use pressuri
35. ted 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 96 Nominal voltage L N Nominal voltage L L Nominal frequency Hz If the following appears in an instrument display 4 this means that the engine cannot provide this parameter the control module however can display this instrument If the following appears in an instrument display with the electrical generator 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 RIONI ALETSERICO GESAN ZLS GAL OZNI Alarm LED Remote start on load Overload pre alarm Common Common Editing the current 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 stepst 11 simultaneously then enter the correct PIN number 3 or RENTAL SERIES E SSC TSI OSNES GESAN Press th
36. ternator failure Reduced speed Low voltage at no load Alternator failure High load Contact technical services Contact technical services Adjust the unit s loads Correct voltage but low when on load Underspeed on load Contact technical services Alternator failure Voltage meter damaged Voltage unstable Engine unsteady Strange noise inside the unit Various causes Contact technical services Make sure nothing is preventing the unit from functioning properly Unit in operation Contact technical services Remove obstructions from internal and external ventilation openings De O De LUI H SA LU O LU O E lt 2 De Oo Ventilation openings obstructed High alternator temperature Possible overload Check loads 9 PROTECTION FROM THE ENVIRONMENT Once the electrical generator 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 being taken for ecological recycling RENTAL SERIES E SSCS SICA OSNES GESAN 10 WARRANTY The electrical generator warranty covers an entire year starting from the date it is installed This should be communicated to GRUPOS ELECTROGENOS GESAN S A hereinafter the manufacturer
37. tor if there is excessive wear or if any piece is damaged Make sure the coupling is properly fastened to the towing vehicle Check the condition of the trailer s tires Connect the safety cable to the bumper or rear part of the towing vehicle never attach it to the generator unit or to the hitch ring itself Check to make sure the brake systems on both the trailer and towing vehicle are in perfect condition Make sure the trailer s turn signal indicators and brake lights are correctly installed and functioning properly After each transport apply a light coat of grease to both the towing vehicle s coupling and the trailer s hitch ring before towing again Install safety chains on units with site trailer RENTAL SERIES GESAN S3L3 Sit CAL OSITOS 4 2 INSTALLATION OF PORTABLE UNITS Portable units are defined as those moved to different work sites at least twice yearly 4 2 1 Placement This type of unit must be installed in well ventilated areas in order to ensure sufficient flow of coolant air and preventing combustion smoke from sitting in the engine s exhaust The unit must be placed in a location that can safely bear the full weight of the generator unit and guarantee its stability both horizontally and vertically It should always remain at a distance that allows access to the interior of the electrical generator at least 1 meter away from any building or wall Avoid installing in areas with mois
38. ture or locations where water could get into the interior of the unit Note Exhaust can be supplied with optional spark arrester in the exhaust tube for Ex zones 4 2 2 Fuel As diesel fuel is used keep in mind the safety instructions previously mentioned in point 2 BASIC SAFETY RULES Before operating check the fuel level to ensure that the tank has the amount needed by the generator unit for an entire work day There is a optional of quick conectors for external fuel tank We can connect them with conductors through canopy fuel point for replenishing the generator base tank You should consider this series of points 1 In order to connect or disconnect you should move backwards the female lock fitting 2 Make sure that the external tank aspiration circuit does not contain air 3 In the external tank the aspiration connector should be male and the return connector female both are 3 8 BSP connectors 4 Return should be correctly connected 5 Connectors have to be watertight they lock when they are disconnected 6 The distance between tank and genset has to be as shorter as possible If you observe engine anomalous behaviour lack of power for aspiration problems you should have to reduce distance or increase the hose diameter 4 2 3 Prior to starting generator Before starting up the generator inspect the consumer power supply conductors to make sure they are in perfect condition and that the consumers are disconnec
39. uctions or the entry of foreign elements into the unit dust moisture etc 25 Regularly inspect the unit s electrical cords 26 Prolonged contact with the used oil can cause skin cancer Wash your hands after working with the generator 27 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 RENTAL SERIES GESAN L CIRICAL oa l3 tion 3 INSTALLATION OF THE ELECTRICAL GENERATOR General overview of the electrical generator and its different configurations manufactured by GRUPOS ELECTROGENOS GESAN S A Note this image corresponds to the detailed view of Image 2 Image 1 ELECTRICAL GENERATOR WITH CANOPY AND OPTIONAL TRAILER FOR UNITS WITHOUT DRIP PAN 1 2 3 4 5 6 7 8 ONES El Coolant tank hatch Side access door Fuel tank cap omoke exhaust Engine Antivibration feet Base frame Capot oo ee RENTAL SE 0 foe RICO E CIRCA GAL NI GESAN m Image 2 DETAILED VIEW OF IMAGE 1 9 10 11 12 13 14 15 16 17 Electrical panel door Ventilation grill Lifting frame and eyebolt Electrical control panel Alternator Electrical power panel Battery Fuel tank Retention bath RENTAL SERIES GESAN ZLZCIMICAL Garlzitivso i 3 1 SOUND INSULATION The supplied unit is soundproofed and includes sound insulating
40. uring synchronization with mains MCB on off Flashing Red LED indicates alarm State of mains power Green if mains power is 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 Selects on screen value Cycles through display screens Button to cycle through the MEASUREMENT menus ADJUSTEMENT HISTORY Dallas RENTAL SERIES GESAN BC IRICAL OSITOS The InteliGen module contains the following three menu screens Measurement Adjustment Can be selected using the following button History To display the different instruments on 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 generato
41. zed water when cleaning the unit a Check your engine manual for care instructions the manual has been provided along with this booklet a For alternator care instructions please check your alternator s manual which has been provided along with the document you are now reading 5 STARTING AND STOPPING THE UNIT To start up the electrical generator follow the steps listed below 1 Check the levels of oil coolant and fuel 2 Close the battery isolator 3 Release the emergency shutoff switch if it has been pressed 4 Check the electrical generator s automatic switch levers should be in the lowered position 5 To perform the startup of your electrical generator please refer to point 6 OPERATION MANUAL taking into account the control panel model of your unit 6 Once the unit has been started connect the electrical generator s automatic switch 7 Make sure the earth leakage circuit breaker ELCB is functioning properly by pressing the TEST button 8 Turn on the electromagnetic circuit breaker once again and use the electrical generator normally To stop the unit 1 Disconnect the loads 2 Turn off the electromagnetic circuit breaker 3 Leave the engine running at no load for 2 minutes to cool down the generator unit 4 Stop the engine completely by switching the control module switch to the OFF position MITA xi GESAN L CITIRICAL 92 NERATOR 6 OPERATION MANUAL The generator you purchase
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