FM 50H - FM 5.4H FM 80H
Contents
1. 32 GUARANTEEANDRESPONSIBILITY 33 Guarantee A 33 Limits of responsibility 33 DISPOSAL 33 Disposal of the waste materials deriving from maintenance and scrapping 33 34 O 5 0 5 4 7 5 8 0 H e GENERATOR O 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 aleading 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 manufacturing facility 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 andinnovative 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 in2. 13 Cod 45248 FM5 0H 5 4H 7 5H 8 0H GENERATORS 7 5 MECC ALTE Cod 45247 11 12 13 Pai mase FM5 0H 5 4H 7 5H 8 0H FM 80 H MECC ALTE e D 5 HH 7 7 y Li fH Vi 12 les 13 Cod 45236 Fig 13 FM5 0H 5 4H 7 5H 8 0H 50H MECC ALTE 11 13 Fig 14 Cod 45235 FM5 0H 5 4H 7 5H 8 0H 50 Nuova Saccardo 14 CHA ES 4 KM N JAJ AIV UA i YN A A A 13 Cod 45631 Fig 15 FM5 0H 5 4H 7 5H 8 0H 50 Nuova Saccardo E LUA 7 d 14 O y N m ANA O o 1 Ise eo en A
3. FS100E AKVA M Cod 45629 se GENERATORS FM5 0H 5 4H 7 5H 8 0H INDEX alen nione 2 WIRING 2 22 2 4 4 4 1 5 DEFINITIONS USED 2 13 1 GENERALINFORMATIONS 14 6 ti ee ue USO oti tette 14 61 12 Residualrisks ditte 14 62 13 Symbology definitions and manualinformations 15 14 Referencedocuments 16 7 15 Referenceregulationsandlegislative provisions 16 6 Marking und dtd Crede t teret 16 1 7 Identification ofthe generator unit 16 71 18 Position of safety labels 17 72 1 8 1 Meaning ofthe safety labels 18 19 Generaldangerinformation 20 8 1 9 1 Dangerofentanglement 20 19 2 DangerofDUtms uet tii 20 81 1 9 3 Dangerofharmto hearing 21 82 1 9 4 Dangerofintoxication 21 1 9 5 Danger offire orexplosion 21 9 1 9 6 Danger if failing to use personal protectiondevices 21 94 19 7 Danger caused by the engine starting 22 1 9 8 Dangerofelectromagneticradiation 22 1 9 9 Dangerofelectrocution 22 10 1 9 10 Danger r
4. GENERATORS GRUPPO ELETTROGENO MANUALE DI USO E MANUTENZIONE GENSET USE AND MAINTENANCE MANUAL GEBRAUCHSANWEISUNG UND WARTUNGSVORSCHRIFTEN FM 50H FM 5 4H FM 80H FM 7 5H REV 10 A A 19 05 2006 cod 41822 Tipo modello N matricola Codice FM5 0H 5 4H 7 5H 8 0H mase mase FM 5 0 H 5 4 H 7 5 H 8 0 H Fig 2 Fig 3 Fig 4 E S FM 5 0 H 5 4 H 7 5 H 8 0 H mase S A E sw Service d Grade ma MAX 40W ZW 20W40 P MIN 20 10 0 0 20 30 40 Ambient temperature C Fig 5 Fig 6 FM 50H 6 0 61007 mm Ka 0 02 to 0 03 In 4 e FM 5 4 H FM 7 5H FM 80H mase FM5 0H 5 4H 7 5H 8 0H GENERATORS FM 5 4 MECC ALTE NO Rao EA NENG gt 2 EE 5 EN e oe N M P H 4 Ae FH 14 i y LI N EN E M 3 Ab 11 12
5. Machine code Serial number Rated power Declared frequency Rated power factor Rated voltage Rated current Degree of protection 10 Class of isolation 11 Temperature max of use 12 Altitude max of use 13 Performance class 14 Year of construction 15 Manufacturer Adress 16 Weight JO Om E ON Rated power Declared frequency Rated power factor Rated voltage Rated current Degree of protection r Class of insulation Temp max of use Altitude of use Performance class Year of manufacture INFORMATION The machine code number the serial number and the year of construction mustalways be indicated when contacting the manufacturer for information order of spare parts etc ma e 5 0 H 5 4 7 5 H 8 0 H 1 8 Position of safety labels Cod 42350 Cod 42346 42118 46106 Fig 14 FM 5 0 H 5 4 H 7 5 H 8 0 H mase gt 1 8 1 Meaning of the safety labels These labels warn the user of any danger which may cause serious injury Carefully read the meaning and the precautions described in this manual Ifthe label detaches or becomes illegible replace it with a new one which can be requested from an authorised Mase dealer Danger Symbols Meaning gt z Caution
6. O 2GENERAL CHARACTERISTICS The generators ofthe FM series have been designed to assure professional users maximum efficiency and reliability for any type of work All the models have been developed for heavy duty using highly reliable 3000 rpm air cooled diesel engines and are fitted with low oil pressure protection The alternators are type 2 pole synchronous self energized self regulating and have a capacitor single phase versions or compound three phase versions for energizing All the generators are protected by a powder coated plate inside A differential magnetothermal switch is positioned on the instrument panel to safeguard the operators and protect the alternator from damage caused by short circuit or overload 2 1 Table of technical characteristics MAX POWER A C CONTINUOUS POWER A C POWER FACTOR MAX POWER A C CONTINUOUS POWER A C POWER FACTOR 40 5 1000mt 50 Hz CAPACITOR COMPOUND CONDENSATORE FOUR STROKE CYLINDER HEAD VALVES MANUFACTURER HONDA COOLING AIR NO OF CYLINDERS 1 FM 5 0 H 5 4 H 7 5 H 8 0 H mase O 2 2 Noiseemission The values listed are emission levels and not necessarily safe operating levels Although there is a correlation between emission and exposure levels this cannot be reliably used to establish whether or not further precautions are required Among the factors which affect the effective level of exposure of the workforce are the characteristics ofthe wo
7. NGK BR6HS DENSO W20EPR U The carbonaceous residues which with use deposit on the spark plug must periodically be removed Fig 2 Ref 4 using a small metal brush or specific detergent Adjust the distance of the spark plug electrodes resetting a value of 0 7 0 8 mm Fig 6 mase FM5 0H 5 4H 7 5H 8 0H GENERATORS O For proper functioning and a long life of the engine it is important to periodically clean and replace the air filter An inefficient filter may cause loss of engine power and excessive smoke at the exhaust To clean or replace the air filter carry out the following operations Remove the filter holder cover Fig 1 Ref undoing the butterfly retaining nut Extract the filter complete with the two elements the sponge element and the paper element The sponge element is simply washed with a domestic detergent or with a low flammable solvent Leave to dry well and soak the clean element in engine oil then wring it out to remove the excess oil since too much oil in the element causes excessive smoke at the exhaust The paper element is cleaned with a blast of dry air from the inside to the outside with a pressure not exceeding 2 bar Should it be very dirty or have holes replace it 5 5 Air filter cleaning replacement Clean the air filter every 50 hours of operation Reduce the intervals ifthe generator operates in particularly dusty environments On average replace the complete air filter
8. Fig 8 and 10 ref 2 trips interrupting current delivery Torestore the thermal switch contact after having identified and eliminated the cause ofthe trip and waited for abouta minute press the thermal switch button setting it to the original position ANO Thesumofabsorptionofallthe utilities connected to the generator mustnever exceed the continuous power value of the generator Don tuse adapters on the electric taking Do never touch pot to the pot or the protection so that to avoid scorching 4 3 Stopping The generator is stopped by turning the switch Fig 4 ref 1 from position I to position 0 STOP Before stopping it itis recommended to run itfor afew minutes without applied load so that the internal temperatures of the engine and alternator are gradually reduced 27 FM 5 0 H 5 4 H 7 5 H 8 0 H mase O 5 CARE AND MAINTENANCE 5 1 Preamble CAUTION Any maintenance operation on the generator must be carried out with the engine off and leaving it to cool down sufficiently and must only be carried out by authorised and suitably trained personnel Itis important to regularly inspect and carry out maintenance on the generator the frequency of maintenance should be decided on the basis of the number of hours of operation as shown in the table at point 5 7 5 2 Ordinary engine maintenance It is recommended to scrupulously follow the instructions in t
9. See Fig 11 Instrument panel Voltmeter 500V Differential switch 4P 25A Magnetothermal switch 3P FM 5 4 H 6A Magnetothermal switch 1P 16A Single phase outlet EC 230V 16 2P GND Single phase outlet EC 230V 16 2P GND Three phase outlet EC 400V 16A 3P N GND Alternator 10 Terminal board 11 Compound 12 Stator 13 Rotor 14 Diode bridge 15 Radio interference suppressor AON JO FM 7 5 H See Fig 11 Instrument panel Voltmeter 500V Differential switch 4P 25A Magnetothermal switch 3P FM 7 5 H 10 Magnetothermal switch 1P 16A Single phase outlet EC 230V 16 2P GND Single phase outlet EC 230V 16 2P GND Three phase outlet EC 400V 16A 3P N GND Alternator 10 Terminal board 11 Compound 12 Stator 13 Rotor 14 Diode bridge 15 Radio interference suppressor A Y O1 80 H See Fig 13 Instrument panel Voltmeter 300V Differential magnetothermal switch 1P N 25A Magnetothermal switch 1P 16A Thermal circuit breaker 15A OO E Gabi 6 Battery charger terminals 12V 15A 7 Single phase outlet EC 230V 32A 2P GND 8 Single phase outlet EC 230V 16A 2P GND 9 Alternator 10 Terminal board 11 Rectifier 12 Stator 13 Rotor 14 Excitation capacitor FM 50 See Fig 14 Instrument panel Voltmeter 300V Differential magnetothermal switch 1P N 16A Thermal circuit breaker 15A Battery charger terminals 12V 15A Single phase outlet EC 230V 16A 2P GND Si
10. V and smaller than 1000 V including alternate current Load Asetofnumerical values of electrical and mechanical magnitudes which characterise the requirements 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 current effect Skilled person A person with technical know how or sufficient experience to allow him to avoid the dangers inherentin 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 ofthe 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 is produced by a person through manual intervention Automatic control Control where the change of a variable handled is produced by a co
11. by technicians authorised by the local dealer or the 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 Residualrisks 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 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 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 FM5 0H 5 4H 7 5H 8 0H GENERATORS O 1 3 Symbology definitions and manual informations Those parts of the text not to be ignor
12. every three cleaning operations Never clean the air filter with highly flammable petrol or solvents This may cause fire or explosions CAUTION Never turn on the engine without the air filter since this would cause serious damage to the engine 5 6 Period of inactivity If the generator is not to be used for a long period of time the following operations must be carried out Remove the spark plug pour 3 5 cm of oil in the spark plug hole on the cylinder head and make a few starting attempts without running the generator in such a way that the engine turns a few times so that the oil can spread and lubricate the cylinder and the piston this prevents the formation of rust on the cylinder and the valve When the operation has been completed remount the spark plug Completely empty out the fuel tank Change the engine oil Clean the air filter 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 29 O 5 0 5 4 7 5 8 0 H se GENERATORS 5 7 Scheduled maintenance table OPERATION HOURS Oil sump level check 8 Air filter cleaning 50 Oil sump replacement 100 Spark plug electrode cleaning and adjustment 100 Valve play check 300 Fuel tank and screen cleaning 300 Change the oil for the first time after 20 hours of operation 5 8 Wiring diagram list FM 5 4 H
13. out or cause problems with engine oil pressure Topreventthe risk of fire and for proper ventilation position the generator at least 1m 3 ft from buildings or other equipment during operation Check the oil level by means of the dipstick Check that all the electrical utilities are off so that the generator is not started on load Check perfect functioning of the devices which stop the generator in the event of failure due to low oil level Identify the position of the emergency stop buttons switches and other emergency systems on the generator Learn the special emergency procedures relative to the installation in question 1 9 8 Danger of electromagnetic radiation Donotallow access to persons wearing a pacemaker because of possible electromagnetic interference with the device 1 9 9 Danger of electrocution When using the generator always bear in mind that in wet or very humid places and in confined conduction spaces itis obligatory to comply with Articles 313 and 318 of Presidential Decree No 547 27 04 55 as wellas Chap 11 Section IV of the CEI 64 8 regulation Immediately change wet overalls Insulate all the connectors and detached wires Do not leave the power terminal board of the generator uncovered check that the electrical power and auxiliary service connections have been made properly Do not power loads with a voltage different from that delivered by the generator Do not spray water directly onto the electri
14. D HANDLING 7 1 Transport and storage Packaging Supplied directly by Mase Generators The total weight of the packed generator is given in Paragraph 2 1 Table of technical characteristics It is strictly prohibited to pollute the environment with the packaging Transport During transport the generator with or without packaging must be protected against atmospheric agents it mustnotbe turned upside down and mustbe protected against knocks The generator mustbe transported without oil and fuel to prevent leaks during travel Storage The generator must be stored in horizontal position and away from atmospheric agents and humidity 7 2 Lifting and handling Always check that the capacity of the lifting means and its accessories is greater than the weight of the generator printed on the identification plate Usealifttruckto handlethe generator with capacity greater than the weight of the generator indicated in the table oftechnical characteristics Paragraph 2 1 ofthe Use and Maintenance Manual inserting the forks underthe base atthe lower part of the generator For lifting with a crane hook steel cables or robust chains onto the special points marked with the label lifting hook or an eye bolt for the smaller generators taking care notto crush or damage any part generator without jerking and place it on the ground gradually then move it carefully with a lift truck or transpallet to its working place For handling on lev
15. cal parts Do not clean the internal electrical parts with compressed air since short circuits or other faults may occur Do not tamper with the active protections thermal switches and differential magnetothermal switches Inthe event of malfunctioning do not remove the panel to attempt repairing it Contact Mase specialised personnel Do not access the generator with wet hands since it is a potential source of electric shock if improperly used Take the necessary precautions to prevent the danger of electrocution check that the earthing system has been installed and constructed in accordance with regulations For the safety of the users the earth connection of the generator must always be carried out paying particular attention to the cable cross section used For the connection of the earth cable use the dedicated terminal on the generator For the earth connection follow the indications in the table to select the cable cross section to use depending on the generator power The generator must be connected to earth using a copper cable with a minimum cross section of 6 mm The manufacturer is not responsible for any damage caused by failure to earth the system 1 9 10 Danger resulting from bad storage Packed and unpacked generators must be stored in a cool and dry place and never exposed to bad weather Avoid stacking packed generators to prevent them from falling causing damage to persons and or things mase FM5 0H 5 4H 7 5H 8 0H
16. d for the collection of metals Any other material not listed above must be taken to companies authorised for the collection of industrial waste 33
17. e working for the electricity company or who come into contact with the lines during the failure Moreover once the line has been restored the generator may explode burn or cause fires in the electrical system of the facility No smoking or use of open flames Do not clean lubricate repair or adjust moving parts Do not extinguish fires with water use homologated extinguishers 9 O GB 19 5 0 5 4 7 5 8 0 H ma e GENERATORS D General danger information It is recommended to learn how to stop and operate all the controls Do not allow unqualified personnel to use the generator Even though the generator is protected do not stand near it Do not remove the labels for any reason and request replacement if necessary Before starting the Generator or before starting any lubrication or maintenance operation itis essential that the personnel responsible has read and understood all the WARNINGS CAUTION and DANGER notices in this manual and in the additional technical documentation provided Before any operation on the generator ensure that the primary engine is not running and that no parts are moving and post a sign saying DO NOT SWITCH ON or similar at the start switch or the controls before carrying out the maintenance or repair work on the generator Nevertheless the manufacturer cannot foresee all the possible circumstances which may lead to poten
18. ed are highlighted in bold type preceded by a symbol as illustrated and defined below DANGER _ I ndicates that particular attention must be paid in order to prevent running serious risks which could lead to death or possible harm to the health of personnel 7 _WARNING A condition which may occur during the lifetime of a product system or plant considered at 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 B INFORMATION nstructions of particular importance IVA A Carefully consult this manual before using or carrying out any operation on the generator 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 inthe 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 a
19. el ground atranspalletis sufficient with a suitable capacity according to the table oftechnical characteristics Paragraph 2 1 of the Use and Maintenance Manual N B The centre of gravity of the generator corresponds to about the centre of its geometrical volume Atolley is available complete of wheels and handles for the moving It deals with a kit of components that you they can subsequently be climbed on also to the purchase of the generator group and you he she is normally used from who has the necessity to frequently move it CAUTION On terrestrial in inclination with the purpose to avoid the spontaneous march ofthe carto always use corks on both the wheels mase FM5 0H 5 4H 7 5H 8 0H GENERATORS 8 GUARANTEE AND RESPONSIBILITY gt 8 1 Guarantee The MASE generators and their components are guaranteed free of defects and are covered by the guarantee for a period of 2 year 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 laboratories or at authorised workshops Transport expen
20. esulting from bad storage 22 2 Generalcharacteristics 23 2 1 Tableoftechnical characteristics 23 22 Noiseemission cessent 24 23 25 24 25 INSTALLATION nnnm 25 3 1 Positioningthe generator 25 4 26 41 Starting oit eee e 26 4 2 Protections iore ERR aves 26 EC We e Ep E 27 5 CAREANDMAINTENANCE 28 Oil A Potete ot 28 52 Ordinaryenginemaintenance 28 53 28 54 Sparkplug 28 55 29 56 Periodofinactivity 29 5 7 Scheduledmaintenancetable 30 58 Wiring diagram list 30 ANOMALIES CAUSES AND REMEDIES 31 31 Rules for ordering spare parts 31 TRANSPORT STORAGE LIFTING AND HANDLING A 32 Transportand storage 32
21. he latest information available 15 O 5 0 H 5 4 H 7 5 H 8 0 H mase 1 4 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 CE declaration of conformity Instruction manual for use of the generators this manual Engine use and maintenance manual List of mase Service Centres Mase Warranty certificate Warranty card rh OD OO 1 5 Reference regulations and provisions legislative The generator groups built by mase destined to the countries of the European Community are conforming to the applicable EC directives and they are provided of aEC Declaration of Conformity 98 37 EC and subsequentamendments Essential machine requirements for safety and health protection Machine directive 73 23 EC and subsequent amendments contained in the directive 93 68 EC Guarantee of safety of electrical material intended for use within certain voltage limits Low Voltage Directives 1 6 Marking The generator identification plate carries all the identification data in accordance with the provisions for EC marking for those cases where required Belowis a facsimile of the identification plate fixed on the hull of each generator Fig A 1 7 Identification of the generator unit See Fig A Machine name
22. he manual provided by the engine manufacturer with each generator The periodical maintenance operations to be carried out on the engine are indicated in the table at point 5 7 Daily check the oil level with the graduated dipstick Fig 4 Ref 3 the oil level must always be between the MAX and MIN notches on the dipstick see Fig 6 When checking the engine oil level ensure that the generator is positioned horizontally 5 3 Engine oil change The engine is supplied with oil for petrol powered engines with viscosity SAE 10W 30 INFORMATION Always check correct viscosity of the engine oil in relation to the range of ambient temperatures in which the generator operates as indicated in the table in Fig 5 Top up and fill through the hole indicated in Fig 4 Ref 3 To change the engine oil first remove the cap on the lower part of the oil sump Fig 4 Ref 2 and drain the oil into a collection container It is recommended to drain the oil when it is still sufficiently warm to flow easily Close the drain plug and fill the sump with the quantity of oil necessary to bring it up to the maximum level Oil sump capacity 1 1 I Dispose of the used oil in an appropriate manner since it is a polluting product Take the used engine oil to special Collection Centres for disposal Carry out the first oil change after the first 20 hours of operation and subsequently every 50 hours 5 4 Spark plug maintenance Spark plug type
23. ing The sum of absorption ofall the utilities connected to the generator must never exceed the continuous power value of the generator 4 2 Protections The generators of the FM series are fitted with a series of protections which safeguard them from improper use and faults which may compromise integrity of the generator and operators Low oil pressure protection Intervenes switching off the unit when sump oil level gets down to the minimum Its intervention is not signaled by warning lights therefore in case machine stops it is always necessary to check oil level to make sure that it is not the cause of generator s stopping Add the necessary quantity of oil to start up the generator again mase FM5 0H 5 4H 7 5H 8 0H lt gt The generator units are equipped with differential magnetic thermal switch that intervenes to protect from short circuits overloads andleakage towards the earth and interrupts electric current supply should there be an overload on alternator a short circuit or an accidental contact of non insulated electric conductors Before restoring electric current supply by switching the differential magnetic thermal switch on the ON position it is necessary to remove the cause of the fault Protection against short circuit and overload DC output protection only for FM 50 H and FM 80 H In the event of an overload short circuit or polarity inversion of the DC outlet terminals the Thermal circuit breaker
24. ion of the fire extinguishers or other protection and emergency devices and learn their functioning Identify any sources of danger such as fuel engine oil or acid solution leaks condensate in the drip caps high voltage high pressure mase FM5 0H 5 4H 7 5H 8 0H O 1 9 3 Danger of harm to hearing Do not stand near the generator for long periods without protective earmuffs since hearing may be reduced Prolonged exposure to noise above 85 dB A may cause health disorders It is in any case recommended to use appropriate protection systems e g headsets earplugs etc 1 9 4 Danger of intoxication The exhaust gases contain toxic carbon monoxide Never use the generator in tunnels or in any place with poor ventilation If indoor use is inevitable it is essential to provide for proper and efficient ventilation in order to prevent intoxication of persons or animals Check that the engine exhaust is free and that the pipes allow evacuation of the exhaust fumes Check that the exhaust gases are discharged to the outside in a safe position away from doors windows and air intakes 1 9 5 Danger of fire or explosion Always turn offthe engine before refuelling Do not smoke during refuelling Refuelling must be carried out with extreme care ensuring that fuel does not overflow from the engine tank respecting the maximum level In the event of fuel spillage from the tank thoroughly dry and clean the parts in
25. let EC 230V 16A 2P T Differential magnetothermal switch 1P N 16A OORUN 5 4 H FM 7 5 H See Fig 9 Voltmeter 500V Three phase outlet EC 400V 16A Single phase outlet EC 230V 16A 2P T Single phase outlet EC 230V 16A 2P T Differential switch 4P 25A Magnetothermal switch 3P 6A 5 4 10A 7 5 Magnetothermal switch 1P 16A NOOR WDM FM 80 H See Fig 10 Voltmeter 300V Thermal circuit breaker 15A Battery charger terminals 12V 15A Single phase outlet EC 230V 32A 2P T Single phase outlet EC 230V 16A 2P T Differential magnetothermal switch 1P N 25A Magnetothermal switch 1P 16A NOOR WD 3INSTALLATION 3 1 Positioning the generator The generators series must be positioned horizontally i e placed on a flat surface or made to sit horizontally by placing shims under the support feet The engine functions properly ifitdoes not exceed maximum inclination of 20 both on the longitudinal and the transversal axis Should the engine be operated in conditions ata greater inclination there is a risk of insufficient lubrication or suction of engine oil from the air filter O 25 O FM 5 0 H 5 4 H 7 5 H 8 0 H mase 4 USING THE GENERATOR 4 1 Starting Before starting the generator check that all the utilities are off to prevent putting the still cold engine under stress The generator engine has been calibrated in idle to 3120 rpm equal to 52 5 Hz as the engine stabilises at about 3000 rpm e
26. nd 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 ofthe 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 The manual defines the purpose for which the generator was constructed and contains all the information necessary to guarantee safe and proper use Constant observance of the instructions contained in this manual guarantees the safety of the 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 ifthe 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 generator 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 of the 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 t
27. ngine runs irregularly Check the position of the starter lever It must have been re opened after starting Check the spark plug condition Carry out maintenance or replace it e Check the air filter Clean its elements or if necessary replace them There is high smoke emission from the exhaust Check the air filter Clean its elements or if necessary replace them Check that the oil level does not exceed the MAX notch Bring it down to the correct level The alternator voltage is too low Check that the engine rpm is 3120 without applied loads Consult a Service Centre Check the state of the air filter Clean or replace if necessary The generator does not deliver power to the outlets but the voltmeter indicates that voltage is present Check that the differential magnetothermal switch or a magnetothermal switch is in the ON position The generator does not deliver power to the outlets and the voltmeter does not indicate that voltage is present Likely alternator fault Consult a Service Centre 6 1 How To 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 GB 31 FM5 0H 5 4H 7 5H 8 0H ma e GENERATORS O 7 TRANSPORT STORAGE LIFTING AN
28. ngle phase outlet EC 230V 16A 2P GND Alternator 10 Connector 11 Rectifier 12 Stator 13 Rotor 14 Excitation capacitor FM 50 N S M CEE See Fig 15 Instrument panel Voltmeter 300V Differential magnetothermal switch 1P N 16A Thermal circuit breaker 15A Battery charger terminals 12V 15A Single phase outlet EC 230V 16A 2P GND Single phase outlet EC 230V 16A 2P GND Alternator 10 Connector 11 Rectifier 12 Stator 13 Rotor 14 Excitation capacitor JO Om P FM 50 N S M SCHUKO See Fig 16 Instrument panel Voltmeter 300V Differential magnetothermal switch 1P N 16A Thermal circuit breaker 15A Battery charger terminals 12V 15A Single phase outlet SCHUKO Single phase outlet SCHUKO Alternator 10 Connector 11 Rectifier 12 Stator 13 Rotor 14 Excitation capacitor mase FM5 0H 5 4H 7 5H 8 0H GENERATORS 6 ANOMALIES CAUSES AND REMEDIES gt On starting the generator does not run and the starter motor does not emit any signal Check that the thermal switch located on the start unit has not tripped The generator switches off during the operating period Check if there is fuel in the tank Fill up Check if the low oil level protection has been activated Check the level and if low add the oil necessary to bring it up to the correct level There are no warning lights always carry out a visual inspection The e
29. ntrolling device automatic controller without the intervention of a person Danger Source of possible harm or damage to health Protection Guard or 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 O 13 5 0 5 4 7 5 8 0 H mase GENERATORS 1 1 Conform use 1 GENERAL INFORMATIONS 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 non industrial use The generator has been designed to operate independently without operator if not for sporadic checks The limits of use are operating temperature 5 40 relative humidity 30 90 the generator is suitable for operation outdoors provided that it is protected against rain it may not be operated in closed environments since the generator produces exhaust gas Inside installation is subject to approval by Mase or 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 Allthe operations that require dismantling of special parts may only be carried out
30. qual to 50Hz with a load For this reason the accelerator lever Fig 3 ref 4 must never shift for any reason since the output voltage frequency and power values of the generator would be compromised To start proceed as follows Disconnect the outlets alternatively the magnetothermal differential general switch to prevent putting the still cold engine under stress Turn the engine stop switch to position I Fig 4 ref 1 Open the fuel cock by turning the lever shown in Fig 3 ref 2 If the engine is cold close the air start lever by turning it as shown in Fig 3 ref 1 before attempting to start f the engine is hot the start lever need not be turned Proceed by firmly pulling the self winding cord Fig 1 ref G to start engine rotation Repeat the operation if the engine has not started at the first attempt As soon as the engine has started gradually return the air start lever to the original position Before powering any utility leave the engine to run without applied load for at least five minutes so that it gradually reaches the operating temperature This will guarantee longer life of the engine and eliminate the risk of seizures The available power is as indicated on the adhesive label carrying the technical characteristics Fig A CAUTION To prevent damage to the self winding cord of the engine never release it abruptly after having pulled it out fully but guide it until complete rewind
31. rkplace other sources of noise such as the number of machines and other adjacent processes and the time an operator is exposed to the noise Moreover the permitted exposure levels may vary from country to country Nonetheless this information allows the machine user to better evaluate the danger and risk Guaranteed acoustic power Pu sa 9800000 eo in accordance with Directive 98 37 EC The measurements were made with the generator running and in accordance with Directive 98 37 EC and regarding the place of testing the measuring conditions and the instruments in accordance with ISO 3744 of 1995 Acoustic pressure level at the dB A operator station La in accordance with Directive 98 37 EC The measurements were made with the generator running and in accordance with Directive 98 37 EC GB 24 mase GENERATORS FM5 0H 5 4H 7 5H 8 0H See Fig 1 The generators are essentially composed of the following components Lifting hook Load bearing chassis Instrument panel and outlets Earth connection terminal Exhaust Air filter Pull start handgrip Engine Vibration damper Alternator Alternator protection casing Tank ZE PTTIOTMOOU gt 2 4 Instrument panel Each generator is fitted with an instrument panel for the controls with the following components FM 50 H See Fig 8 Voltmeter 300V Thermal circuit breaker 15A Battery charger terminals 12V 15A Single phase outlet EC 230V 16A 2P T Single phase out
32. ses 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 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 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 9 DISPOSAL 9 1 Disposal of the waste materials deriving from maintenance and scrapping The packaging used for transportis biodegradable and thus easy to dispose of by companies authorised for paper collection The engine oil and engine oil filters both after an oil change and when scrapping must be taken to companies authorised for this collection The electrical components must be taken to companies authorised for the collection of electronic material All the painted metal parts must be taken to companies authorise
33. structions will furnish you useful information and precious suggestions so you can fully exploit all the possibilities that the generators offers you If any part of the manual resulted incomprehensible please contact us In to renew our thanks we cordially greet you MASE GENERATORS SPA mase GENERATORS MASE GENERATORS S p A Tortona 345 47023 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 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 ma e 5 0 H 5 4 H 7 5 H 8 0 H GENERATORS DEFINITIONS USED The terms used are current technical terms and where considered necessary the meaning is described below Generator Anassembly ofan 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 Usersystem 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 is greater than 50
34. tial risks in the effective conditions of use of the Generator Any operations and or procedures for maintenance not expressly recommended or indicated in the user manuals must always be notified to and approved by the manufacturer Inthe event that a procedure not specifically recommended needs to be applied the user is responsible for assuring that such procedure is safe and does not cause harm to persons The manufacturer declines all responsibility for damage to persons or things deriving from inobservance of the safety regulations Carefully examine the safety warning plates on the generator and respect the relevant instructions 1 9 1 Danger of entanglement Donotremove the original protections from any of the exposed rotating parts hot surfaces air intakes belts and live parts Do not carry out any maintenance operation with the generator running Do notwear flapping garments such as scarves foulards bracelets etc and all garments must be tied with elastic at the edges Do not clean or carry out maintenance on moving parts 1 9 2 Danger of burns Do not permit unskilled persons or without adequate training to use the generator Do not permit children or animals to approach the generator when it is in operation Never touch the exhaust the relevant protection or the engine body when the generator is running or still hot Do nat lean against or sit on the generator for any reason whatsoever Identify the posit
35. to avoid burns do not touch during operation The exhaust manifold and the engine pay attention to the labels on the generator Leave the engine to cool down before storing it indoors Read and understand the Use and Maintenance Manual before starting the generator The Mase generator has been designed so as to guarantee safe and reliable operation provided thatthe instructions are followed Otherwise personal injury or damage to the equipment may result The exhaust gases contain toxic carbon monoxide Never operate the generator in a closed space Provide for adequate ventilation Ifinstalled indoors scrupulously observe the ventilation regulations The fuels are highly flammable and in certain conditions also explosive Fill up in a well ventilated area with the engine off Do not smoke or create sparks while filling up Immediately clean off any fuel leaks Danger of electric shock consult the manual Obligation Symbols Meaning om Obligation to connect the generator to earth ma e FM 5 0 H 5 4 H 7 5 H 8 0 H GENERATORS O Prohibition Symbols Meaning Theconnectionsto an emergency electric network must be carried out by specialised electricians in compliance with the relevant regulations in force Improper connections may cause current feedback from the generator to the electrical lines connected These current feedbacks may cause electroconduction to the peopl
36. volved Check that there are no fuel leaks and that the pipes are undamaged When refuelling has been completed tightly close the fillercap Keep flammable liquids matches and other explosive and or flammable products away from the generator since the temperature near the exhaust is high during operation Never leave flammable liquids or cloths soaked in flammable liquids in proximity of electrical equipment including lamps or parts of the electrical system Do not obstruct the cooling air inlets outlets Inthe event of fire use a homologated fire extinguisher and never use water 1 9 6 Danger if failing to use personal protection devices The persons responsible for handling must always wear protective gloves and safety shoes Wear safety shoes and overalls fthe generator needs to be lifted from the ground the operators must wear a protective helmet Immediately change wet overalls Useprotective gloves GB 21 5 0 5 4 7 5 8 0 H ma e GENERATORS O 1 9 7 Danger caused by the engine starting Do not leave disassembled parts tools or anything else not forming part of the system on or near the engine Install the protections necessary for safety on the parts completing the system Operate the generator on a flat surface as far as possible For continuous operation the maximum permitted engine inclination is 20 degrees Greater inclination of the generator might cause the fuel to leak
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