IS 2.7 B - COD 43256 - Mase Generators of North America
Contents
1. O 15 E 5 5 2 gt Y M3 ra ENE e D N m i 1 Sea drainage nozzle Zz Silencer 5 Anti sifon valve Drainage A i 45 50 IS 10 2 5 uffler B oi 16 e a 6 Water filter y 7 System general choke Dimension mm 3 Sea intake 9 Drain system choke 10 Draining pipe Generator downside water line GB 22 mess IS 2 7 TYPICAL INSTALLATION WITH GENERATOR AND SEPARATOR ABOVE THE WATERLINE Jy L 1000 eu O Qu NM N up A 2 b C 4 O GENERATOR E NO oO Y 2 O Ww S X 0 D aft O A qeu me x lt E a 4 Pa L MAX D Pt s o 622 a E A ee O 0 O HE 5 dE O Q ln uo E LO CLS e 9 2 x lt OT lt EZ Bc 6 ___ 8 1 Sea drainage nozzle gas c2. GB 26 mase GENERATORS CONNECT AN EXTERNAL BATTERY PACK TO CBU Itis possible to connect a 12 24V external battery pack to CBU and show Voltage on display CBU generator control module CN4 connector Molex 12 polesfemale holder onboard module external battery pack 12 24 not included B fuse 1A not included C cable terminal Minifit female not included On the rear side of CBU module connect battery EXT to CN4 connector using following terminals ref C at n 6 Vext and at n 12 Vext ATTENTION It is possible to have this type of connection only on the main CBU module START 20 a mH E T ee COM LCD 456 ALLACCIAMENTO CONNECTION P2 F2 P1 F1 eene L1 LO GRD 120V T 60 Hz IS 2 7 B 3 7 3 A C CONNECTION This connection can be made by means of the terminal board ref 1 Generator earthing High voltage may cause serious injury or death Electroconduction is possible whenever electricity 1 present De energise the main magnetothermal switches of all the power outputs before repairing the equipment Configure the installation for earthing of the generator and the electrical circuits when in use Avoid contact with the electrical conductors or equipment when standing in water or on wet ground since there 1 a higher risk of electroconduction in
3. 16 mase IS 2 7 B 2 2 REMOTE COMMAND AND CONTROL PANEL STANDARD VERSION Each generator 1 fitted with an instrument panel for commands and controls with the following components 1 STARTBUTTON 2 STOPBUTTON 3 MENUNAVIGATION BUTTON 4 MENUNAVIGATIONBUTTON 5 MENUSELECTIONBUTTON 6 DISPLAY GB 17 IS 2 7 ma e 2 3 TECHNICAL CHARACTERISTICS TABLE O GENERAL yg MAX POWER LTP 122 J J kW CONTINUOUS POWER PRP 19 J kW A RATED VOLTAGE ORO RATED FREQUENCY GRADE OF PROTECTION TEMP OF USE _______ o 40 104 o OS MIN TEMP OFUSE 5 28 MAXALTITUDEOFUSE 1000 3280 m f _ 3 min A HARE apg Ts HH DIMENSIONS mmi H _ 465 123 MASS gt 65 13 Tbs 4 STROKE MANUFACTER YANMAR O MODEL LV48 NENNEN DISPLACEMENT 211 129 MAX POWER _ 47 346 PAR n OFCYLINDERS CYLINDERS HEAD MATERIAL ALUMINUM ___ RATED SPEED J 3600 rpm SPEED CONTROL CENTRIFUGAL MECCANICAL INDUCTION SYSTEM J NATURA FUEL A
4. NR 3 Sea drainage nozzle water Ae Melo A 01 45 650 IS 10 2 7 B ei 16 Water filter C i 25 6 System general choke D 40 Dimension mm Sea intake O Drain system choke KC i 1 Pus enerator upside water line 9 Draining pipe TYPICAL INSTALLATION WITH GENERATOR AND SEPARATOR BELOW THE WATERLINE i 1000 C uy E O 4 M C 0 5 T Z O 0 C5 LO Y A O Me F 9v NAM jo 29 E Y VM NO 77 lt L Y y a ra rn 5 GENERATOR Y A ea WI o 0 Ba u 00 mm N cp 2 O LO E G 77 D AE E pe Ln T Lf 25 gt LB lt B y 0 1 Sea drainage nozzle gas MM Z Lxmdust gos separator O 2 AMI S TOR 4 Draining A M E 650 IS 10 2 5 Sea drainage nozzle water Wi 14 6 Muffler D si 25 Dimension mm 7 Water filter REOS E Generator downside water line 9 Sea intake 1
5. Before starting the generator ensure that all the preliminary checks have been carried out Start Press the ON OFF pushbutton ref 1 to turn on the module It will show mase logo on display Press and hold pressed the START pushbutton ref 2 in order to preheat the glow plugs pre starting and then start the engine Release only when the engine is started paying attention to not exceed 5 seconds for each starting attempt and doing a pause of about 30 seconds between them CAUTION Repeated unsuccessful starting attempts may cause excessive accumulation of water in the exhaust system with possible serious damage to the engine In case of have difficulty in starting the engine absolutely do not persist for a long time before first having closed the seawater intake cock Ref 3 During the running in period the first 50 hours do not apply loads exceeding 70 of the rated power of the generator For more detailed information consult the manual provided by the engine manufacturer which accompanies each generator 4 4 STOPPING LHE GENERATOR Stop the generator by pressing the STOP button on the control panel ref 1 The generator can be stopped also by setting the switch ref 4 to the OFF position CAUTION Before stopping the generator it is advisable to run it for a few minutes without drawing current in order to allow gradual cooling of th
6. 40 6 20 How to order the spare parts 40 7 TRASPORT STORAGE LIFTING HANDLING AND PACKAGING 41 7 1 Transportandstorage 41 7 2 Lifting and handling of the packed generator 41 8 GUARANTEE AND RESPONSABLLITY 42 8 1 Guarantee RET 42 8 2 Limits of responsability 42 9 DISPOSAL sonata 42 9 1 Disposal of the waste materials deriving from maintenance and scrapping 42 10 WIRING DIAGRAMS 43 IS 2 7 DEFINITIONS USED The terms used are current technical terms and where considered necessary the meaning is described below Generator An assembly of an internal combustion piston engine and an alternate current synchronous 2 4 pole self excited generator joined together to create a station for self production of electrical energy User system Composed of the power supply circuits of the user equipment including the relevant sectioning handling breaking transformation protection etc devices which do not form part of the production transmission and distribution systems Category 1 electrical system A system where the rated voltage 1 greater than 50 V and smaller than 1000 V including alternate current Load A set of numerical values of electrical and mechanical magnitudes which characterise the requi
7. Check fuses Replace The engine protection module is not activated when the ON button is pressed Check fuses Replace Check battery cables and clamps and electrical connections Reconnect Check integrity of the battery Recharge or replace Check that the emergency button is in ON position Turn ON position The generator switches off during the operating period Check if a protection has been activated with symbol showed on display Remove the cause and retry starting Check if there is fuel in the tank Fill up There is a high grade of smoke at the engine exhaust Check that the oil level in the sump does not exceed the MAX index Restore level Check that the generator is not in overload Reduce the load Check calibration of the injectors Consult Service Centre The engine runs irregularly Check fuel filters Replace Bleed the air bubbles from the fuel circuit The alternator voltage is too low Check the engine rpm 3750 3780 rpm 62 5 63Hz without utilities connected Check if load is too high Reduce the load Capacitor breakdown Contact Service Centre Alternator failure Contact Service Centre Check all electrical connections Contact Service Centre Starter battery flat Check the electrolyte level in the battery Restore the level Check correct functioning of the DC alternator Check integrity of the battery The generator does not deliver power
8. 3 6 2 ELECTRIC Pump The electric pump is equipped with a protective filter ref 3 CAUTION The electric pump is cooled and lubricated with the fuel Do not activate the pump without fuel in order not to be damaged The generator is equipped with an automatic fuel bleed valve Should manual bleeding be necessary press the ON button on the control panel and wait 30 seconds before starting the generator IS 2 7 Inlet outlet pipe diameter 8 mm Filtering surface area min 500 cm Degree of filtering max 10um micron GB 25 IS 2 7 mase 3 7 ELECTRICAL CONNECTIONS QC BATTERY CONNECTION Use a 12V stand alone battery to start the generator Connect it to the generator terminals using cables of 25mm cross section for a distance up to 5m 16 4ft or cables of 35mm cross section for longer distances following this sequence of operations First connect the positive of the battery to the terminal marked on the generator ref 1 Then connect the negative pole of the battery to the terminal marked on the generator ref 2 Spread some specific mineral grease on the connectors in order to reduce oxidation or corrosion The generator is equipped with an automatic electronic recharging device for the starter battery able to deliver 10A at a voltage of 12V Install the battery in a ventilated housing separate from the generato
9. 5 SAFETY SWITCHES AND WARNING SONALS 30 5 1 Protection against short circuits and overload 30 5 2 Protection against short circuit of low voltage electrical system 30 5 3 Control panel Alarm codes 31 4 6 MAINTENANCE eren nnn 32 6 1 Preamble UR 32 6 2 Routine engine maintenance 32 6 9 Engine Ol check 32 6 4 Engine oil change 33 MES IG 39 6 6 Replacing cleaning the fuel pump filter 34 6 7 Replacing the line fuel filter 34 6 8 Bleeding the fuel system 35 6 9 Air 35 6 10 Draining the cooling system 35 6 11 Replacing the zinc anode 35 6 12 Seawater pump maintenance 36 6 13 Checking replacing the v belt 36 6 14 Alternator maintenance 37 6 15 Battery maintenance 37 6 16 List of recommended spare parts 38 6 17 Periods of inactivity oit normis 38 6 18 Period checks and maintenance 39 6 19 Anomalies causes and remedies
10. Keep the machine unit sufficiently away from a building and flam mable materials during engine running It may cause fires due to hot exhaust gas and engine body Keep sparks open flames or any other form of ignition match cigarette etc away when fueling refueling Fire and or an explosion may result FIRE In case of fire do not open sound shield or compartment Avoid serious injury or death from fire Can cause severe injury or death ser n Doves In case of fire do not open the chest Immediatelly discharge __ igre atte Extinguish the generator fire and immediately unload the whole content of the portable ire extinguisher t roug t the port or other provision INGU extinguisher through the hole indicated by the label EXHAUST SYSTEM Carbon monoxide gt Carbon monoxide Can cause severe nausea fainting or death Can cause severe injury or death The exhaust system must be leakproof and routinely inspected The exhaust system must be leakproof and routinely inspected COD 42474 Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide 1 a poisonous gas witch is present in exhaust gases Inspecting exhaust system Carbon monoxide can cause severe nausea fainting or death In addiction to routine exhaust system inspection install a carbon monoxide detector Consult your boat builder or dealer for approved de
11. USE MAINTENANCE AND INSTALLATION MANUAL Rev 3 27 03 2014 cod 43256 Modello Modelo matricola Matricula Codice Codigo GENERATORS EN Cla 2 IS 2 7 GB 2 ma e IS2 7 B This manual has to be preserved for all through life of the gen set to which ago reference Thank you for having chosen a product MASE As a leading generator manufacturer Mase Generators offers a wide range of generators with an output from 1 KVA portable generators to 1600 KVA units for special applications Founded in 1970 the Cesena based company extends over a area of 16 000 square meters including a 9 000 sq mtr manufacturingfacility Mase Generators began as a company producing 500 Watt light and compact portable generators These generators made the Mase Generators name well known throughout the world Mase Generators is a leader in high quality reliable products and innovative research performed by Research and Development Department The generator you have purchased is the fruit of years of experience in the sector and for the modern conception the strong sizing the materials employees the continuous updatings constitutes an effective answer to the operators demands of the sector This Manual instructions will furnish you useful information and precious suggestions so you can fully exploit all the possibilities that the generators offers you If any part ofthe manual resulted incomprehensible pleas
12. 2 2 Command and control panel 17 2 3 Table of technical characteristics 18 3 INSIALLATION 19 3 1 General housing characteristics 19 a o 19 3 3 Anchoring the generator 19 3 4 Ventilation 19 3 5 Cooling water 20 3 5 1 Seawater feed system 20 9 0 2 GOMpPONENIS 21 3 5 3 Typical installation with the generator above the l rucs me 22 3 5 4 Typical installation with the generator below the waterline 22 3 5 5Exhaustsystem atrocidades 23 30 FUE ON 24 SNMP 24 3 6 2Electric PUMP Mec 24 3 7 Electrical connections 25 coin 25 3 7 2Control panel connection 25 3 7 3A C CODEC HOLD ela coria 26 3 7 4Generator network switching 27 3 SEmergenty eine 27 4 USING THE GENERATOR 28 4 1 Preliminary checks piscina 28 A 28 4 3 Starting the generator 29 44 Stopping the generator 29 GB
13. Carefully read the meaning and the precautions described in this manual e If the label detaches or becomes illegible replace it with a new one which can be requested from an authorised mase dealer Danger Symbols Meaning HOT PARTS Hot engine and exhaust system ON Can cause severe injury or death Can cause severe injury or death Do not work on the generator set until it cools Do not work on generator set untill it is allowed to cool COD 42481 f A WARNING Hot engine and exhaust system y MUA Servicing exhaust system Hot parts can cause severe injury or death Donottouch hot engine parts An engine becomes hotwhile running and exhaust system components become extremely hot A WARNING ACCIDENTAL STARTING Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set Remove negative lead first when disconnecting battery Reconnect negative lead last when reconnecting Accidental starting can cause severe injuy or death battery Disconnect the battery cables before working on the generator set Disabling generator set Accidental starting can cause severe injury or death when disconnecting the battery Before working on the generator set or connected equipment disable the generaset Reconnect the negative lead last when reconnecting the battery as follows COD 42472 1 Disconnect power to battery
14. and the year of construction must always be indicated when contacting the manufacturer for information order of spare parts etc GB 15 O IS 2 7 2 GENERAL CHARACTERISTICS The generators have been designed for use in the marine field using highly reliable 3000 3600 rpm air water cooled diesel engines Particular attention has been paid to the degree of protection against external agents engine protection and protection ofthe electrical parts against overload or overheating adopting automatic systems able to stop the generator in the event of malfunctioning The generator is particularly quiet thanks to an internally insulated soundproof casing and an advanced soundproof system for combustion smoke exhaust The alternators used are the synchronous self energized type 2 1 COMPOSITION OF GENERATOR UNIT The generator unit is essentially composed by the following components Fixed frame Upper openable cowling Beside openable cowling Electric connection cowling Anchorage stirrup Emergency button Exhaust gas and cooling water connection Seawater intake connection Tank connections 10 Engine air filter 11 Check refill oil cap 12 Seawater pump 13 Water air radiator 14 Starting motor 15 rpm regulation screw 16 Battery connection lead 17 Battery connection lead 18 Remote control panel connector 19 Zinc anode 20 Fuel pump filter 21 Fuelpump
15. plug icon disappear from display If there are air bubbles in the fuel system the engine will not function regularly or will be unable to reach the rated rom may penetrate the fuel circuit through a not perfectly sealed joint pipe filters tank or when the fuel in the tank is at minimum level 6 9 AIR FILTER The IS series generators are fitted with a dry air filter ref 4 which prevents foreign bodies from entering the combustion chamber It is sufficient to clean the filter mass with diesel fuel once a year to remove any impurities CAUTION Take the liquids used to wash the filter to special waste collection centres for disposal IS 2 7 B Inlet outlet pipe diameter 8 mm Filtering surface area min 500 cm Degree of filtering 10um micron GB 35 IS 2 7 GB 0 DRAINING THE COOLING SYSTEM In order to carry out maintenance on the water air exchanger or the cooling system the seawater intake circuit must be drained Carry out this operation as follows Close the seawater intake cock ref 1 Open the drain tap ref 2 until all the water has drained out Close the drain tap Discarge CAUTION Reopen the seawater intake cock before starting the generator Sea Water 6 11 REPLACING THE ZINC ANODE A sacrificial zinc anode ref 4 has been fitted in the water air heat exchanger ref 3 to protect i
16. Check that the magnetothermal switch is in the ON position Contact Service Centre Capacitor breakdown Contact Service Centre Alternator failure Contact Service Centre Check all electrical connections Contact Service Centre 6 20 How ORDER THE SPARE PARTS In order to ensure a good functioning of the generator we recommed to use original spare parts only The spares can be purchased from the mase authorized assistence network consult the SERVICE manual enclosed with the generator You can get any futher information contacting the mase central Service 41 O IS 2 7 7 TRANSPORT STORAGE LIFTING AND HANDLING AND PACKAGING 7 1 TRANSPORT AND STORAGE Packaging Supplied directly by Mase Generators The total weight of the packed generator is given in Paragraph 2 3 Table of technical characteristics Transport During transport the generator with or without packaging must be protected against atmospheric agents it must not be turned upside down and must be protected against knocks CAUTION It is strictly prohibited to pollute the environment with the packaging Storage The generator must be stored in horizontal position and away from atmospheric agents and humidity 7 2 LIFTING AND HANDLING OF THE PACKED GENERATOR UNIT CAUTION Always check that the capacity of the lifting means and ts accessories 1 greater than the weight of the generator printed on the id
17. charger if equipped 2 Remove battery cables remove negative lead first 3 Reconnect negative lead last when reconnecting battery Follow these precautions to prevent starting of generator set by the remote start stop switch WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate generator set only with all guards and electrical enclosures in place MOVING PARTS A WARNING Rotating parts C Moving parte Can cause severe injury or death 2 A Do not operate generator set without all guards screens and covers in place do not operate this equipement whit the shield removed PREVENTING FIRE DANGER Be sure to use the proper diesel fuel Be sure to stop the engine before refueling f you spill fuel wipe off such spillage completely Never place oil or other flammable materials such as straws withered grass close to the engine during running or shortly after shutting it down Check fuel oil and engine oil for leakage from their piping lines to cause fires GB 11 IS 2 7 O DangerSymbols Meaning PREVENTING FIRE di DANGER Can cause severe injury or death Start Start the engine only from a starter switch without any load or in neutral posi tion of the clutch of machine unit The machine unit suddenly starts to move or generates power to cause serious personal injury
18. tension or towards the inside to decrease it Tighten the screws and check the tension The belt tension is correct when it sags about 5mm ref 3 under a thrust force of 8kg 17 7165 INFORMATION prevent the belt from idling do not spill oil on it If oil is spilled clean it off with petrol IS 2 7 B GB 97 IS 2 7 mase lt ALTERNATOR MAINTENANCE The alternator used on this model generator is type synchronous self excited This type of brushless alternator without manifold does not require any particular maintenance Periodic inspections and maintenance are limited to eliminating any traces of moisture and oxidation which may damage it 6 15 BATTERY CHARGER Before installing a new battery it is important that it first be fully chargedto charge it completely The battery must be activated by personnel who has sulphuric acid for batteries and suitable equipment available At least once a month check the level of the electrolyte and if necessary top up with distilled the generator is not used for a long period of time it is advisable to disconnect it and store it in a dry place ata temperature above 10 C 50 F and to carry out a full recharging cycle once a month When topping up the batteries with distilled water wear rubber gloves and protective goggles to prevent accidental contact of sulphuric acid with the skin In the event of accidental contact thorough
19. the operating life cycle of the generator and is necessary to inform both those who effectively carry out the different operations and those who coordinate the activities to arrange the necessary logistics and to regulate access to the place where the generator will be installed and operated This manual was drawn up by the manufacturer with the purpose of providing essential information and instructions for proper use and maintenance in conditions of safety It constitutes an integral part of the generator equipment and must carefully be protected from any agent which may damage it for the entire life cycle of the generator The manual must accompany the generator if transferred to another user or owner It is opportune to remember the supplied generator group needs installation The technician will release at the end of the work a declaration to the meaning of the normative applied The manual defines the purpose for which the generator was constructed and contains all the information necessary to guarantee safe and proper use Constantobservance ofthe instructions contained in this manual guarantees the safety ofthe operator protection against damage to persons or things operating economy and a longer life of the generator The drawings are provided by way of example Even if the generator in your possession differs from the illustrations contained in this manual in elements of little significance for example the colour the safety of the ge
20. 0 Drain system choke 11 Draining pipe GB 23 O GB IS 2 7 3 5 5 EXHAUST SYSTEM The generator combustion gas water exhaust system must be independent of that of the main engines See installation diagrams CAUTION The pipe length from the highest point of the exhaust pipe to the exhaust must not exceed 2m 6 6 ft This is to prevent that when the generator is switched off the water that is left in the exhaust pipe flows back to the engine after having filled the barrel exhaust Barrel exhaust capacity 3 5 litres 0 92 gal Attenuates the exhaust noise and prevents water backflow to the engine It is recommended to install the exhaust not more than 1m 3 3ft from the generator and to position it at a height equal to or lower than that of the generator base Silencer Further reduces the noise It is recommended to install it at a distance of not more than 1m 3 3ft from the sea exhaust union Sea exhaust union It must be installed in such a position that it is always above sea level Water gas separator Separates the water from the gas reducing the noise at the exhaust and eliminating the typical pulsating effect of water mixed with gas Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected COD 42474 Carbon monoxide may cause strong nausea fainting or death Do not use copper pipes in diesel exhaust
21. 86 Cod 41650 WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected COD 42474 Cod 41961 In case of fire do not open sound shield or compartment Avoid serious injury or death from fire Shut down engines generator sets and blowers Immediatelly discharge entire contents of gaseous portable Cod 43244 a fire extinguisher throught the WARNING Avoid serious or death from fire or electrical shock j This generator set must be installed UL i Moving parts maintened and repaired in conformance E LO Avoid injurty to hands and appendages with the manufacturer s instructions zi c do not operate this equipement whit COD 42477 bi the shield removed COD 42485 COD 42482 Cod 40179 Cod 41961 Cod 42900 Accidental starting can cause severe injuy or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Cod 42136 the negative lead last when reconnecting the battery COD 42472 Cod 42329 Cod 42868 Cod 41650 Cod 42264 Cod 41527 Cod 017224 Cod 42329 Cod 46286 1 5 SAFETY LABEL INFORMATIONS These labels warn the user of any danger which may cause serious injury
22. AA INJECTION SYSTEM DIRECT FUEL FEEDING PUMPS ELECTRIC MAX PREVALENCE FUEL PUMP 700 27 5 __ FULL LOAD CONSUMPTION 0 8 0 21 L h gal h COOLING AIR WATER LUBRIFICATION SYSTEM FORCED O OIL SUMP CAPACITY 0 85 0 22 COMBUSTION AIR VOLUME 0 34 12 ELECTRIC PLANT 12 negative poletoground VW STARTING ELECTRIC STARTNGMOTOR 12 08 vaw STARTING BATTERY _____ ____12 45 BATTERY CHARGER 12 10 V A STOPPING SYSTEM SOLENOID O ALTERNATOR TYPE SYNCHRONOUS SELF REGULATED Lm ____ _ _ _____ n OF POLES n OFPOLES MAX CURRENT BS A ISOLATION CLASS VOLTAGEREGULATOR X SELF EXCITED VOLTAGE STABILITY ENO FREQUENCY STABILITY AA S e COOLING AIR WATER E 1 Limited time running power LTP ISO 8528 1 It is the maximum power that under the environment conditions established by the norm ISO 3046 1 the generator group it is able to disburse fora maximum of 500 hours for year of which a maximum of 300 hours among the interval of maintenance prescribed by the builder It is accepted the operation to this power conditions the duration of the group An overload of the 10 is admitted only for regulation 2 Prime power PRP ISO 8528 1 Itis the available maximum power for a variable power cycle that the generator group is able to disburse for a boundless number of hours for year among the interval of maintenance prescribed by the bu
23. NGER Do not connect the generator to a public electrical system e g wharfs ports houses other boats etc The feedback circuit may cause serious injury or death of the personnel working on the power lines and or the personnel near the working area dh DANGER The generator may only be installed by qualified technicians Malfunctioning due to improper installation may cause injury or death A DANGER Do not modify the default electrical connections for other applications If necessary contact our distributors 3 7 5 EMERGENCY STOP The generator can be stopped by setting the switch ref 3 to the OFF position GB 28 RETE MAINS RESEAU CARICO LOAD CHARGE Y mase 4 USING THE GENERATOR 4 1 PRELIMINARY CHECKS Before beginning with any starting procedures it is extremely important to familiarise yourself with the generator and its controls Furthermore visually inspect the generator and the installation Any source of real or potential risk must be eliminated before proceeding Identify the position of the emergency stop buttons switches and other emergency systems on the generator Learn the specific emergency procedures pertaining to the installation in question Check the oil level by means of the dipstick ref 1 See table for recommended oils chap 6 5 Check that all the anch
24. SAFETY CLOTHING Do not expose your skin to high pressure fuel spray Be careful so as not to bring your skin in contact with high pressure fuel spray from broken fuel injection pipe to penetrate your skin to cause inflamed If exposing to the spray should occur obtain prompt medical treatment Beware of dirt from air blowing Wear protective equipment such as goggles to protect your eyes when blowing compressed air or steam Dust or flying debris can hurt eyes GB 14 ma e 1 6 REFERENCE DOCUMENTS The instructions for use provided with each generator are made up of a collection of documents of which this manual represents the General Part The following documents are normally provided separate IS 2 7 B 1 8 MARKING The generator identification plate carries all the identification data conforming to ISO 8528 and in accordance with the provisions for EC marking for those cases where required Below 15 a facsimile of the identification plate fixed on the hull of each generator a declaration of conformity b Instruction manual for use and maintenance of 1 9 IDENTIFICATION OF THE GENERATOR UNIT the generators this manual c Engine use and maintenance manual Machine name d List of mase Service Centres Machine code e mase Warranty certificate Serial number f Warranty card Rated power Declared frequency Rated power factor Rated voltage Rated current Degree of protection 10 Cla
25. accidents is necessary to know the potential risks and operate with caution Read and follow all the precautions and the instructions for the safety PRESERVE THESE INSTRUCTIONS The manual shows varied typologies of precautions and instructions for the safety Danger Warning Caution 1 3 SAFETY SIMBOLS Indicates that particular attention must be paid in order to prevent serious risks which could lead to death or possible harm to the health of personnel condition which may occur during the lifetime ofa product system or plant considered risk regarding damage to persons property the environment or economic loss CAUTION Indicates that particular attention must be paid in order to prevent serious consequences which could result in damage to tangible goods such as the resources or the product Other symbols on this manual Particularimportantinstructions OPTIONAL Indicates components and non inclusive parts with the base configuration Carefully consult this manual before using or carrying out any operation on the generator The routine maintenance operations must be carried out by qualified personnel who have the appropriate equipment and protections GB 9 IS 2 7 B ma e 1 4 SYMBOLS ON THE GENERATOR GROUP Cod 41763 Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools COD 42481 Cod 425
26. alve ref 6 IS 2 7 B OG OPTIONAL OPTIONAL Anti siphon valve Drain mixer gt Water pump 21 IS 2 7 mase y 3 5 3 TYPICAL INSTALLATION WITH GENERATOR ABOVE THE WATERLINE O GENERATOR M lt rs VY A 1000 qn ARS ou S Qa E E ji 1 Sea drainage nozzle Co C 2 Silencer 8 5 Muffler 4 Water filter 9 Sistem general choke 5 B 6 Sea intake 7 Drain system ckoke Dimension mm 8 Drain pipe Generator upside water line 3 5 4 TYPICAL INSTALLATION WiTH GENERATOR BELow THE WATERLINE
27. e contact us In to renew our thanks we cordially greet you mase GEMERATORS MASE GENERATORS S p A Via Tortona 345 47522 Cesena FC Italy Tel 39 0547 354311 Fax 39 0547 317555 Technical data informations layouts of the texts and graphic preparations edited by the Technical Office Mase Generators THE COMPANY MASE GENERATORS SPA RESERVES RIGHTS TOIMPLEMENT MODIFICATIONS TO THIS PRESENT MANUAL WITHOUT ADVANCE NOTICE OR NOTIFICATION WHEN NECESSARY INACCORDANCE WITH ITS POLICY OF CONTINUAL PRODUCT IMPROVEMENT THE MASE GENERATORS SPA RESERVES ALL THE RIGHTS ON THE MANUAL PRESENT ANY TOTAL OR PARTIAL REPRODUCTION IS PERMITTED WITHOUT WRITTEN AUTHORIZATION OF THE MASE GENERATORS SPA GB 3 IS 2 7 CONTENTS OD lido A 5 PRELIMINARY PRESCRIPTIONS 7 1 GENERAL INFORMATIONS 8 1 1 Conform use mireia 8 1 2 Residual risks 8 1 3 Safety symbols 9 1 4 Symbols on the generator group 10 1 5 Safety label informations 11 1 6 Reference documents 19 1 Reference regulations and legislative provisions 15 to AAA 15 1 9 Identification of the generator unit 15 2 GENERAL CHARACTERISTICS 16 2 1 Composition of generator unit 16
28. e engine and the alternator Pressing OFF on thi switch the module will completely turn off GB 30 IS 2 7 5 SAFETY SWITCHES AND WARNING SIGNALS The generators are equipped with a set of safety switches which protect it against improper use and problems which may jeopardise its integrity 5 1 PROTECTION AGAINST SHORT CIRCUITS AND OVERLOAD The generator is protected against short circuits and electrical overload A magnetothermal switch ref 1 cuts the power when a short circuit occurs or when the power delivered exceeds the rated value Before restoring the contact remove the cause of the cutout 5 2 PROTECTION AGAINST SHORT CIRCUITS OF LOW VOLTAGE ELECTRICAL SYSTEM In the event of a short circuit of the low voltage electrical system two fuses 3A 30A ref 2 break the circuit stopping the generator In this case the warning lights of the engine protection module will all be off and it will not be possible to reattempt starting INFORMATION If one of the above safety switches trip find and eliminate the cause and then press the STOP button to reset the control panel otherwise the signal would remain in memory inhibiting engine starting ALARM CHART FOR CBU Alarm name Description Emergency stop Means that the emergency pushbutton is pressed that the emergency Means that the emergency pushbutton is pressed is pressed Means that after engine is stopped the electro
29. e exhaust discharges on the lee side the side sheltered from the wind Alway be aware of others make sure your exhaust is directed away from other boats and buildings HAZARDOUS VOLTAGE ELECTRICAL SHOCK Hazardous voltage Moving motor Can cause severe injury or death Operate generator set only with all guards and electrical enclosures in place Grounding generator set Hazardous voltage can cause severe injury or death Electroconduction is possible whnever electricity is present Open main circuit breakers of all power source before servicing equipment Configure the installation to electrically ground the generator set and alectrical circuits when in use Never contact electrical leads or appliances when standing in water or on wet ground as the chance of electroconduction increases under such conditions Disabling generator set Hazardous voltage can cause severe injury or death To disable the generating set from load turn off the the automatic switch of the line or disconnect the output cables from the commutation switch and block the final part of cables Hazardous voltage to load during an ispection cold cause severe damages to people and to equipment Do not use the emergency button instead the automatic switch of the line Battery short circuit Explosion can cause severe injury or death Short circuits can cause severe damages to people and or equipment Disconnect the battery before doing installation operations o gene
30. entification plate Use a lift truck to handle the generator with capacity greater than the weight of the generator indicated in the table of technical characteristics par 2 3 of the Use and Maintenance Manual inserting the forks under the base at the lower part of the generator For handling on level ground atranspallet is sufficient with a suitable capacity according to the table of technical characteristics par 2 3 of the Use and Maintenance Manual INFORMATION The centre of gravity of the generator corresponds to about the centre of its geometrical volume GB 42 ma e GENERATORS a lay yn 345 350397 T1 d h RA LEA mie mase IS 2 7 B 8 GUARANTEE AND RESPONSIBILITY 8 1 GUARANTEE The mase generators and all their components are guaranteed free of defects and are covered by the guarantee for a period as required by current legislation from the date of installation Not covered by the guarantee are failed observance of the installation regulations damage caused by natural disasters accidents defects of the electrical system including the load to which the generator is connected negligence improper use or abuse by the operator and damage caused by repairs carried out by unqualified personnel Repairs that cannot be carried out at the place of installation can be carried out at mase
31. f metals Please note that the system and its components contain materials that if dispersed in the environment may cause significant ecological damage The following materials must be delivered to specific collection centres authorised for their disposal Starting battery Exhaustlubrication oils Mixtures of water and anti freeze Filters Auxiliary cleaning material e g rags smeared or soaked with fuel and or chemical cleaning products Any other material not listed above must be taken to companies authorised for the collection of industrial waste GB 43 IS 2 7 lt lt a g qevosg IVWNIN431 91 Tes Tuis aL AV 154 91 IWISONY3H1 vL YOLOANNOD S3I1046 OZ MAHOS NOILOANNOO EL HOLIMS TVINH3HL 6L GION3 IOS LNO LNO 1914 CL HOLIMS 1 0 84 IWISONY3H1 dNNd IANA Z4 JVLSONWMNSHLSNION3 OL HOLIMS 3Y4NSSIAA 10 6 YOLOWYALYVLS 8 agni 34AnH3H n t 330 Addons DM ddng sy d ANA LO vd 29 HOO OE FINGOW NOILOALOdd 3NION3 gend 9 S JSN4 9 YOLIANNOI SITOAZL v HOllOvdvO AM3LIVH Z O rand UA GB 44
32. fuel INFORMATION For engine safety reasons use only original spare parts S A E grade service 30 20 10 0 10 20 30 40 Ambient temperature GB 34 ma e 6 6 REPLACING CLEANING THE FUEL Pump FILTER lt lt This operation is carried out following the steps below Remove the pipe ref 1 Slide out the filter ref 2 Clean or replace it For reassembly repeat the operations in reverse order After replacing the filter the fuel system has to be bled by carrying out the operations described in paragraph 6 8 A WARNING Do not let the fuel come into contact with the skin Wear gloves and protective goggles during maintenance operations In the event of contact with fuel immediately and thoroughly wash the affected part with soap and water When the operation has been completed thoroughly clean off all traces of fuel and take the cloths used to special waste collection centres 6 7 REPLACING THE LINE FUEL FILTER Follow the instructions given in the manual of the type of fuel filter installed See also Chap 3 6 1 Fuel filter 6 8 BLEEDING THE FUEL SYSTEM The fuel system is developed to eliminate air bubbles penetrated inside the system automatically For automatic bleeding activate the fuel pump for few minutes before starting the engine To activate the fuel pump turn on the engine module and then press and keep pressed START ref 3 until pre heating glow
33. gine is off If the circuit is empty the water pump impeller may be damaged during starting For the same reason when starting the generator for the first time manually prime the intake pipe leading from the valve to the pump 1 2 direct seawater intake ref 1 1 2 ball cock main system ref 3 1 2 ball cock system bleeding ref 4 Serves to drain the cooling system of the generator for general maintenance or for long periods of inactivity Water filter inspectable ref 5 It protects effectively the cooling circuit against intake of mud sand and seaweed The filter mesh must be the fine type it is advisable to use the type with 2 470um micron pitch Different sizes would not allow good filter efficiency Antisiphon valve ref 6 this valve brings the cooling circuit to atmospheric pressure when the engine is off preventing the siphonage phenomenon It must be used when the base of the generator is under the water line and must be positioned at least 500mm 1 6ft above sea level The drain pipe of the antisiphon valve must be positioned under the valve thus preventing water from accumulating in the pipe which must always remain empty to allow air to pass through it when the generator is switched off It is advisable to run the drain pipe through the bilge as small amounts of water may flow from it during normal operation Two holes have been made in the casing to connect the antisiphon v
34. graph 6 18 For more detailed information consult the manual provided by the engine manufacturer which accompanies each generator 33 IS 2 7 ENGINE OIL CHANGE XK Use diesel engine oil Top up the engine oil through the hole ref 1 To change the oil in the engine oil sump take out the dipstick ref 1 Suct exhaust oil with a manual pump ref 2 It is advisable to drain the oil when it is still sufficiently warm so that it flows easily CAUTION Dispose of the used oil in an appropriate manner since it is a polluting product Take the used oil to special waste collection centres for disposal Wear gloves to protect the hands from contact with oil In case of accidental contact with engine oil thoroughly wash the affected part with soap and water Do nottop up with oil or refuel above the maximum level An excessive quantity of oil may cause damage to the engine Always check proper viscosity of the engine oil relation to the range of temperatures in which the generator operates as indicated in following chart 6 5 OIL FILTER 36 To replace the engine oil filter cartridge follow the procedure below Remove and extract the filter ref 3 Screw in the new filter after cleaning the rubber seal and seating surface and ensure itis in perfect condition CAUTION When the operation has been completed thoroughly clean all the parts of the generator soiled with oil and
35. he manufacturer Only mase technicians or personnel trained by mase have the necessary knowledge of the generator and the special equipment as well as the experience to carry out any operation in the most economical and reliable way 1 2 RESIDUAL RISKS The generator has been designed taking into account the safety regulations set out in the EC directives and standards nonetheless the following residual risks remain injury caused by contact with hot parts during maintenance injury caused by electrocution during maintenance on the electric panel risks connected with long periods of exposure to the noise of the generator with open cowling risks due to contact with the generator lubricants during maintenance risks due to the fire hazard the fuel represents Because of the typical intrinsic danger of the Generators you are reminded that although the generator has been designed constructed and tested in accordance with the safety regulations only proper and careful use can guarantee full safety to this end the various precautions to be taken during use of the Generator are listed below mase IS 2 7 B GENERATORS SAFETY INSTRUCTIONS The electromechanics equipments included the generating sets switch command electric equipments and acceso can cause damages to people and if they are installed used or mainteined with not qualified operations they can put in serious danger the life of people To avoid
36. ilder and under the environment conditions established by the norm ISO 3046 1 The middle power during a period of 24 hours doesn t have to exceed 80 of the PRP An overload of the 10 is admitted only for regulation GB 18 3 INSTALLATION A DANGER The generator may only be installed by qualified technicians Malfunctioning due to improper installation may cause injury or death 3 1 GENERATOR HOUSING CHARACTERISTICS The generator must be installed in a sufficiently ventilated room able to assure the amount of air required for engine combustion The room must be acoustically separated and isolated from the living quarters The generator must be positioned in such a way as to facilitate normal maintenance operations It is advisable to install the generator in the propulsion engine room provided that it meets the above conditions The air must be clean The air temperature in the place of installation must be between 5 C 23 F and 40 C 104 F The relative humidity must not exceed 50 at a maximum temperature of 40 C Relative humidity of 90 at 20 C 68 F and 100 at 25 C 77 F is permissible 3 2 LIFTING Follow the procedure below to lift the generator Place a homologated lifting strap of adequate capacity ref 2 around the exhaust manifold ref 1 Lift and handle with attention See also chap 7 2 3 3 ANCHORING THE GENERATOR To anchor the generator arrange a base to su
37. l monitor Output all included alarms optional Input voltage of onboard batteries from 12V up to 24V optional Input battery voltage of the genset Input Start Stop from remote panel Switch off button Scroll through display buttons Emergency pushbutton predisposition CAUTION The low oil pressure protection does not give an indication of the oil level The oil level must daily be checked in order to prevent damage to the engine Theengine correctly works ifit doesn texceed inclina tions max of 30 for up to 3 minutes and 25 without limits oftime in comparison to both longitudinal and transversal axles If the engine works to greater incli nations it risks an insufficient lubrication and or aspi ration of oil from the filter air If one of the above safety switches trip find and eliminate the cause and then press the STOP button to reset the control panel otherwise the signal still in memory inhibiting engine starting GB 32 9 4 i a i i 3 Jm i mase ON OFF SCROLL DOWN MENU SCROLL UP MENU SELECT CI ED Fuses 5 Protection module fuses On the printed circuit of the engine protection module there are five fuses to protect the module Remove the frontal panel unscrewing the 4 screws to enter in it 5A 5x20mm for relay ALARMS 5A 5x20mm for relay IP insulated poles 5A 5x20mm for relay RUNS 5A 5x20
38. laboratories or at authorised workshops Transport expenses will be borne by the Customer Under no circumstances does the Customer have the right to claim compensation for damages or side effects caused by use of the machine in a manner not conform to what is described in this manual 8 2 LIMITS OF RESPONSIBILITY MASE GENERATORS s p a is responsible for anything regarding the safety reliability and performance of the Generator on the condition that The generator is used by persons trained through the use and maintenance manual The installation is carried out according to mase instructions e The service procedures are carried out exclusively by mase specialised technical personnel The electrical system and the loads to which the generator is connected is in conformity with the applicable CEI regulations The generator is installed and used in accordance with the installations provided in this manual Use original spare parts specific to each model Use suitable fuel Diesel fuel conforming to standards ASTM A975 9 DISPOSAL 9 1 DISPOSAL OF THE WASTE MATERIALS DERIVING FROM MAINTENANCE AND SCRAPPING The packaging used for transport is biodegradable and thus easy to dispose of by companies authorised for paper collection he electrical components must be taken to companies authorised for the collection of electronic material All the painted metal parts must be taken to companies authorised for the collection o
39. ly wash the affected part with soap and water and consult a doctor CAUTION Ifthe battery is left completely flat for long periods of time itmay be irreparably damaged Before proceeding with recharging the batteries check the level of electrolyte and if necessary top up with distilled water This operation must be repeated when the charging cycle has been completed Cover the positive terminal with Vaseline to protect it against corrosion and the formation of oxide GB 38 6 16 LIST OF RECOMMEND SPARE PARTS Seawater pump impeller Seawater pump gasket Seawater pump belt Oil filter Fuel filter Zinc Fuses OPTIONAL A kit with recommended spare parts is available and may be ordered from the Mase Service Network or Technical Service 6 17 PERIODS oF INACTIVITY 6 Start up the generator at least once a month If the generator is not to be used for a long period of time carry out the following operations Change the engine oil Replace the oil filter cartridge see par 6 5 Replace the fuel filter cartridge see par 6 6 6 7 Remove the injector and pour 2 cc of engine oil into the cylinder and let the engine turn a few times by manually operating the drive shaft pulley Refit the injector Replace the zinc pads see par 6 11 Aspirate some antifreeze into the seawater intake pipe in order to protect the exchangers against low temperatures and lubrica
40. mm for relay GLOWS 5A 5x20mm for relay EV solenoid mase IS 2 7 B GENERATORS 6 MAINTENANCE C 6 3 ENGINE CHECK 6 1 PREAMBLE It is recommended to strictly follow the instructions Check the oil level by means of the cap dipstick ref 1 in the manual provided by the engine manufacturer The oil level must always be between the MAX and which accompanies each generator MIN notches engraved on the dipstick It is important to regularly check and carry out When checking the oil level ensure that the generator maintenance on the generator The operations to carry is positioned horizontally out must be decided based on the hours of operation In order to carry out maintenance the side doors and top door must be removed WARNING The generator is started from a remote control panel In order to prevent accidental starting set the emergency switch to the 0 OFF position Disconnect the negative pole from the starter battery Any maintenance operation on the generator must be carried out with the engine off after leaving it to cool down sufficiently Carefully read paragraph 1 5 General danger information in the manual Periodically check the electrical safety switches such as the emergency button the earthing system etc 6 2 ROUTINE ENGINE MAINTENANCE The periodic operations to be carried out on the engine are indicated in the table Service schedule in para
41. nerator and the information provided are nevertheless guaranteed To facilitate consultation it has been divided into sections identifying the main concepts for a quick look at the topics consult the index Ongoing improvement and development ofthe product may have led to modifications to the generator which are not included in this publication Whenever a problem concerning the generator or this publication arises consult with Mase Generators SPA for the latest information available 7 IS 2 7 1 GENERAL INFORMATIONS 1 1 CONFORM USE The generator is suitable for independent production of electrical energy within the voltage and wattage limits declared by the manufacturer Any other use outside the already stated field of use is prohibited the generator is intended for marine use The generator has been designed to operate independently without operator if not for sporadic checks The limits of use are Operating temperature 10 C 14 F 40 C 104 F relative humidity 30 90 the generator is suitable for marine operation Installations are subject to approval by mase or by an installer authorised by mase Arbitrary modifications to the machine are prohibited for safety reasons Original spare parts must be used on pain of losing machine conformity All the operations that require dismantling of special parts may only be carried out by technicians authorised by the local dealer or t
42. nic board detects active parameters Missing engine stop as the engine is still running a If generator is running means that all detected parameters are simultaneously Mechanical failure missing 11 High engine digital temperature Means that the digital sensor detects high temperature 14 Digital low oil pressure Means that the digital sensor detects low oil pressure 15 Means that there is not wiring connection to digital gauge for oil pressure with 15 Digital oil gauge failure engine turned off 16 High level battery Means that the battery voltage is too high 17 Low level battery Means that the battery voltage is too low Alarm code Simbol oOo a gt 24 Alternator high temperature Means that the high engine temperature contact is open GB 31 IS 2 7 Cc ENGINE PROTECTION MODULE CBU device Can Bus transmission unit controls and driving the genset Large display and the control push buttons allow an easy use and monitoring of the CBU unit Displayed information Voltage Vac Frequency Hz Hourmeter Battery voltage of the genset Voltage of onboard batteries Lowoil pressure alarm High engine temperature alarm High alternator temperature alarm Displayed stop alarms Storage and back up of alarms Maintenance first 50 hours Input Output signals Commands Checks Connector mod 485 for MODBUS protocol It allows monitoring and driving the genset by the boat main contro
43. of anticorrosion zine f J Check thermostat function J o Check correct airflow in the cooling system e Intake Exhaustsystem Check theaircleanerelement Tt Repaceairceanerelement Check exhaust system Clean exhaustwatermixingelbow __ o Electricalsystem Check and tighten electrical connections Clean battery cables _____ __ Check the electrolyte level in the battery Engine and mounting Check for leakage af water and oil o Check tightness of mounting bolts mew CI Check and adjust the injection fuelpump Remote control system etc Check remote control operation _ po Testrungeneratorset_ l d n presence of this symbol it is possible to effect technical support autonomously e n presence of this symbol it is obligatory to effect the technical support in an authorized retailer workshop GB 40 1 2 7 6 19 ANOMALIES CAUSES AND REMEDIES The starter motor turns but the main engine does not start Check that there is fuel in the tank Fill up Check if the stop solenoid is powered Consult Service Centre Check that the emergency button is in ON position Turn ON position Check that the DC thermal breakers are on Restore Bleed the air bubbles from the fuel circuit
44. oring points of the generator are properly tightened Check that all the electrical utilities are off to prevent starting the generator on load Check that the water and fuel pipes are properly connected Check that all the electrical connections have been properly made and that no connections are in a bad state Check that the seawater cock is open ref 2 check valve has been fitted on the seawater intake as recommended in the installation manual check that the section of the water circuit leading from the pump to the valve has been manually primed ref 3 4 2 FUELLING The fuelling operations must be carried out extremely carefully and the tank must not be filled over the maximum level Fuel is a toxic and flammable liquid and must therefore be kept in hermetically sealed containers and stored in inaccessible places Fuelling must always be carried out with the engine off and the selector in the OFF position Do not smoke and do not use naked flames during fuelling Fuel in well ventilated places Avoid contact of fuel with the skin and do not inhale the fumes IS 2 7 B GB 29 IS 2 7 B ma e STARTING THE GENERATOR WARNING J MESS gt GENERATORS CAUTION lox Before starting the generator check that all the doors Vv is closed
45. pport the weight and vibrations Drill holes in the base as shown in fig 3 3 4 VENTILATION The generator is equipped with an internal forced cooling system through a water air exchanger The amount of air required for combustion is aspirated through the intake located on the base ref 4 Therefore always check that this intake is free of any obstruction IS 2 7 B 512 20 500 19 2 3 gt a qm W 526 20 3 4 510 20 mm 329 13 380 15 478 18 5 6 470 18 1 2 le f fo oo o p 385 15 1 5 400 15 3 4 mm in GB 19 IS 2 7 COOLING WATER CIRCUIT The generator engine is cooled by an open circuit system in which seawater circulates At the time of installation a seawate
46. protection device as safety measure to protect persons from a present or potential danger Casing Part intended to assure protection of the equipment against specific outside influences and protection in every sense against contacts GB IS 2 7 B ma e GB connection in bad state The live parts are not fully covered with insulation removable by destruction only the connections are not secure because of unstable tightening of the parts and a development of oxide between the parts Direct contact Contact of persons or animals with live parts Control circuit Circuit used to control machine operation Equipment General term which comprises materials devices equipment accessories and similar used in conjunction with an electrical installation GB 6 ma e IS2 7 B PRELIMINARY PRESCRIPTIONS FIELD OF EMPLOYMENT THE GENERATOR 1 PROPER FOR TO PRODUCE IN WAY AUTONOMOUS ELECTRIC ENERGY IN THE LIMITS OF TENSION AND WATT DECLARED BY THE BUILDER LA Consult this manual carefully before proceeding to the use and to any operation on the genset FAILURE TO RESPECT THE SPECIFICATIONS CONTAINED IN THIS USE AND MAINTENANCE MANUAL WILL RESULT IN FORFEITURE OF THE GUARANTEE ON THE PRODUCT This manual was drawn up by the manufacturer and forms an integral part of the generator equipment definition used as indicated in Directive 98 37 EC the information contained in the manual is addressed to all the persons involved in
47. r and any device which may cause heat or sparks Periodically check the state of the terminal connections and the battery liquid level If necessary disconnect the cables working in reverse order from connection Do not invert the polarities of the connection cables as the generator and the battery may be seriously damaged Do not connect any other loads to the battery In order to minimise galvanic currents the of the generator battery must not be connected to the of the other batteries on board 3 7 2 CONTROL PANEL CONNECTION Connect the cable to connector ref 3 using the cable _ 156 6 142 _ provided already connected to the control panel Insert _ 140 5 512 _ the control panel cable through the hole ref 4 D 4 5 0 177 On control panel ref 6 there is a display and buttons ptum for starting stopping and menu navigation 7 e CAUTION v Control panel must be absolutely installed because it s essential for generator functioning Do not use 6 differentdevices other that the supplied one as they can not be compatible with generator Remove battery connection before installing control E az Control panel is supplied with a 10 meters length SS SS cable Do not modify this cable as it may cause tle improper functioning of the panel circuit 116 4 567 100 3 937 C
48. r feed circuit must be arranged for cooling and an exhaust system for the combustion gas and water mixture 3 5 1 SEAWATER FEED SYSTEM Two water intake systems are normally adopted on boats Direct intake system ref 1 System with baffle ref 2 mase recommends using the direct intake system ref 1 since it prevents intake of pressurised water into the intake ducts instead generating a vacuum easily overcome by the water pump head of the generator dh CAUTION Do not fit any type of protection cap on the direct intake system The system with baffle ref 2 on the other hand may cause the following problems a mounted with the slots facing the bow In this case during navigation and with the generator off pressure is created in the water intake duct which may cause the system to fill up until reaching the exhaust port thus making it possible for water to enter the cylinders b mounted with the slots facing the stern In this case during navigation a vacuum may be created in the water intake duct such as to inhibit the water pump to activate the cooling system or such as to limit the flow rate with consequent overheating of the generator GB 20 ma e 3 5 2 COMPONENTS CAUTION If the generator is installed at a height over 1m 3 3ft above the waterline a check valve ref 2 must be fitted after the seawater intake to prevent the water circuit from emptying out when the en
49. rator set maintenances Remove all jewels before doing maintenance on the maintenance Remove negative lead first when disconnecting battery Reconnect negative lead last when reconnecting battery Never connect negative battery lead to positive lead of starting solenoid GB 13 O IS 2 7 DangerSymbols Meaning di DANGER A CAUTION P Do not touch the electrolitic battery acid Sufficient ventilation of the battery area Keep the area around the battery well ventilated paying attention to keep sparks open flame and any other form of ignition away During engine running or charging battery hydrogen gas is produced from the battery and can be easily ignited Battery acid Sulfuric acid in batteries can cause severe injury or death Sulfuric acid in battery ccan cause permanent damage to eyes burn skin and hole in clothing Always wear splash proof safety googles when working near the battery If battery acid is splashed in the eyes or skin wash immediately the affected area with large quantity of clean water Seek immediate medical aid in case of eyes contact Do not intentionally make the battery spark by short circuiting to check its remaining charge It will cause fires Make sure to use a gravimeter to check the remaining charge of the battery If the battery electrolyte frozen recharge the battery after warming up to thaw it
50. rements imposed on a rotary machine by an electrical circuit or by a mechanical device at a certain instant Thermal switch Main cut out and breaking device made up of a switch which opens automatically by thermal effect Differential switch Main cut out and breaking device made up of a switch which opens automatically by differential effect Skilled person A person with technical know how or sufficient experience to allow him to avoid the dangers inherent in electricity MASE specialised personnel A person able to evaluate the job assigned to him and recognise the possible dangers on the basis of training at the MASE training centres with professional experience and knowledge of the equipment in question and of the possible dangers deriving in the event of negligent behaviour Supplier A body e g manufacturer agent installer which supplies the equipment or services relating to the machine Control Control action by which an output variable of the controlled system controlled variable is affected by an input variable of the controlling system in order to achieve a certain goal Manual control Control where the change of a variable handled 1 produced by a person through manual intervention Automatic control Control where the change of a variable handled is produced by a controlling device automatic controller without the intervention of a person Danger Source of possible harm or damage to health Protection Guard or
51. ss of isolation 11 Temperature max of use 12 Altitude max of use 13 Performance class 14 Year of construction 15 Manufacturer Adress 16 Weight g EPAcertificate Engine manufacturing 1 7 REFERENCE REGULATIONS AND LEGISLATIVE PROVISIONS The generator groups built by mase destined to the countries of the European Community are conforming tothe applicable EC directives and they are provided of a EC Declaration of Conformity EN 12601 Reciprocating internal combustion engine driven generating sets 98 37 EC and subsequent amendments Essential machine requirements for safety and health protection Machine directive Directive 2006 95 EC 73 23 EC and subsequent amendments contained in the directive 93 68 EC Guarantee of safety of electrical material intended foruse within certain voltage limits Low Voltage Directives EN 60204 1 Electrical equipment of machines declared frequency Rated power factor Rated voltage ated current egrees of protection IU 2 A o Tl mase err MASE GENERATORS SPA Via Tortona 345 47023 Cesena FC Italy mase masegenerators com www Masegenerators com lass of insulation 4 emp max of use Altitude max of use Performance class 46 year of manifacture INFORMATION The machine code number the serial number
52. systems The sulphur contained in diesel exhausts causes deterioration of the system leading to exhaust gas or water leaks For the safety of the boat occupants install a carbon monoxide detector When installing the generator or carrying out maintenance operations adopt the following precautions Do not install the exhaust gas outlet pipes in places where the gasses may be conveyed through the portholes vents or air conditioning system If the exhaust gas outlet is near the water level water may enter the exhaust gas outlet and block or limit the gas flow 24 OPTIONAL Muffler OPTIONAL Silencer Sea exhaust union OPTIONAL Water gas separator Sea exhaust union 3 6 FuEL CIRCUIT The generator is diesel powered by means of the unions marked DIESEL FUEL INLET rif 1 e DIESEL FUEL OUTLET rif 2 This one returns the exceded fuel to tank The fuel pipes must be in hydrocarbon resistant rubber with an inside diameter of 8mm 0 31in For differences in level of more than 500mm 19 6in fit a single acting check valve in order to prevent the fuel system from emptying out Use a valve with 50mbar opening 3 6 1 FueL FILTER CAUTION The generator is NOT supplied with a fuel filter fitted inside the casing Therefore when connecting the fuel tank fit a fuel filter It is also advisable to fit a cock on the feed line downstream of the tank
53. t against galvanic currents Periodically check the wear out of zinc anode and replace if necessary in order to prevent that galvanic currents corrodes exchanger irreparably It is recommended to check the zinc anode at least once a month when the generator is new in order to check how fast it wears and then operate accordingly We suggest to replace the zinc anode at least once a year anyway GB 36 mase 6 12 SEAWATER PUMP MAINTENANCE At least once a year check the integrity of the rubber seawater pump impeller Before opening the seawater pump to inspect the impeller drain the seawater from the cooling system as described in paragraph 6 10 To access the impeller remove the cover ref 5 and use pliers to extract the impeller ref 6 pulling it hard towards the outside To refit a new impeller repeat the operations described above working in reverse order 6 13 CHECKING REPLACING THE V BELT XK di WARNING A WARNING Do not open the doors or hold the hands close to the V belts and pulleys when the engine is running A V belt is used to transmit the rotation motion from the drive shaft pulley to the seawater pump pulley ref 1 A too tight belt accelerates wear while a too slack belt results in the pulleys running in idle and insufficient water circulation Adjust the belt tension as follows Loosen the two adjusting screws ref 2 and move the seawater pump towards the outside to increase
54. te the seawater pump impeller and the metal parts in the cooling system Disconnect the starter battery and store it in a dry place see par 6 15 Disconnect the sea exhaust pipe from the engine manifold Clean the seawater filter Close the seawater intake cock Drain the seawater from the exhaust Clean and lubricate the antisiphon valve siphon break if installed Clean the outside of the generator removing all dust and impurities Cover the generator with a nylon sheet and store it in horizontal position in a dry and ventilated place IS 2 7 B GB 39 IS 2 7 ma e y 6 18 PERIOD CHECKS AND MAINTENANCE Every 50 Every 200 Every 400 Perform service at intervals indicated Nod hrs or 1 hrs or 3 hrs or 6 g Month Month Month Before Every 500 Every 1000 hrs or Yearly hrs or Yearly Fuel system Replace the fuel fiterelement _ Check the fuel injection nozze Check the fuel injection timing J e Check the fuel injection pump e _ Lubrification system Checktheollevel d oe JJ JJ Repacetheol mJm Replace the oilfiterelement_ o Cooling system Inspect exhaust system components for cracks and corrosion exhaust line hose 0 fof clamps silencer and outlet flapper Check eae of siphon break ee _ Replace seawater pump impeller Check condition
55. tector installation Inspect your detector before each generator set use Test carbon monoxide detector function per the manufacter s instructions and keep it operational at all times Installing exhaust system Carbon monoxide can cause severe nausea fainting or death In addiction to routine exhaust system inspection install a carbon monoxide detector Use the following precautions when installing and operating generator set Donotinstall exhaustoutlet where exhaust can be drawn inthroughtportholes vents or air conditioners If the generator set exhaust discarge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust GB 12 IS 2 7 Danger Symbols Meaning WARNING e AWARNING Avoid serious or death from fire or electrical shock This generator set must be installed maintened and repaired in conformance with the manufacturer s instructions EXHAUST SYSTEM Carbon monoxide Group generator use Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless non irritating gas able to ifinhaled only also for brief time to provoke the death Be especially careful if operating the generator set when moored or anchored under calm conditions as gases may accumulate If operating the generator set dockside moor the ccraft so that th
56. these conditions fou USP LAT E __ ____ 12 5 Ls Kos el surdi 12 24 27 O IS 2 7 Short circuits High voltage may cause serious injury or death Short circuits may cause physical injury and or damage to the equipment Avoid contact with the electrical connectors through tools or jewellery Take off wrist watches rings or any other jewellery before working on the electrical circuits Feedback to utility Feedback voltage may cause serious injury or death Connect the generator to the electrical system of the structure boat only through an approved electrical system and after opening the main switch of the structure boat The feedback circuit may cause serious injury or death of the personnel working on the power lines and or personnel near the working area Make sure that the sum of the generator loads doesn t overcome the nominal power of the generator group Despite the group is provided with a thermal switch rif 1 it s recommend to interpose magnetothermal protections or similar between generator and electric users according to the following table 3 7 4 GENERATOR NETWORK SWITCHING A switch must be interposed on the utility line to allow switching the utilities from the generator to an external power supply line The switch must be dimensioned on the basis of the entity of the loads involved a broad diagram is shown in ref 2 di DA
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