Geko 4401 E -AA/HEBA User manual

Operation manual of
Geko®
Stromerzeuger-Systeme
Metallwarenfabrik Gemmingen GmbH & Co.
D - 75050 Gemmingen
Telefon : [phone] • Telefax : [phone]
www.metallwarenfabrik.com
4401 E-AA/HHBA • 4401 E -AA/HEBA
5401 ED -AA/HHBA • 5401 ED -AA/HEBA
6401 ED -AA/HHBA • 6401 ED -AA/HEBA
7401 ED -AA/HHBA • 7401 ED -AA/HEBA
7401 E-AA/HHBA • 7401 E -AA/HEBA
4402 E -AA/HHBA • 4402 E -AA/HEBA
5402 ED -AA/HHBA • 5402 ED -AA/HEBA
6402 ED -AA/HHBA • 6402 ED -AA/HEBA
7402 ED -AA/HHBA • 7402 ED -AA/HEBA

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Operating hours counter
Fuel cock
Sockets
Silent economic
fast start switch
Starting handle
Ignition key switch
Drain plug
Oil filler neck/Oil-level indicator
Filler neck of the fuel tank
Ground screw
Air filter
Silencer
Fuel level indicator
Choke

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Safety rules
*An electric plant is delivered in a condition corresponding to safety requirements. Do not remove any protection devices. Do not remove any enclosure of electrical equipment. Do not apply unorigi-
nal completing products.
* Waste gases are toxic! Do not use the electric plant in a closed unventilated building.
* Warning! Even if a withdrawing hose for the waste gases of the engine is used, they can get in the building. Therefore, when using in closed buildings, in addition to good ventilation, it is necessary
to follow working normative documents. The withdrawing hose should not be produced from inflammable materials and directed to such materials. Fire danger!
* Be careful working with fuel. Fire and explosion dangers. Do not add fuel to the working plant. Do not pour out fuel on the ground. Use funnel in order to put fuel in.
* Never place the electric plant near inflammable materials. Fire danger!
* Do not touch hot details. Danger of burn!
* Necessarily follow the requirements presented in item 4 «Electric connections and safety measures». Wrong connection represents a danger to life.
* Use protective headphones when staying near the electric plant for a long time.
1. Design and action principle of the electric plant
1.1 Generator type
The generator corresponds to the requirements of the VDE 0530 standard. It represents an electric motor with a rotating magnetic system, is short-circuit protective, has self-excitation, is contactless and brus-
hless, and has the block of excitation by alternating current, which consists of electrically strong breakdown-protective film capacitors. The generator has an F class insulation, IP54 protection degree, and
dust- and spray-protection design. The copper windings of the stator have impregnation for moisture and tropic protection. The N VDE 0875 noise level and satisfaction to DIN VDE 0879-1 requirements
are guaranteed.
1.2 Silent Economic
As a rule, the plant should not deliver power continuously. On the contrary, electric power is often necessary urgently by inquiry similarly to the circuits of power-supplying enterprises. By using the Geko-
Silent Economic mode, the rotation frequency of the engine decreases, and it increases sharply after the receipt of an inquiry for the supply of electric power. Thus, the consumption of fuel, emission of
waste gases, noise level, and wear of the engine are essentially reduced. A special electronic processor controls the operating mode of the plant by a measuring system and sensors and operates the engi-
ne. Thus, even when starting the cold engine, the control system is immediately turned on and does not require additional actions. When load is connected, the control system instantly brings the engine to
the rated rotation frequency and total power, which allows the connection of a consumer with high start current.
1.3 General configuration of the plant
The basic components of the electric plant are the engine, generator, distribution box, and bearing frame made of tubes. The generator is connected to the engine by a cone coupling and an additional
threaded pin. The complete „engine-generator“ set is mounted on shock absorbers. Power is taken through three and single-phase ac sockets.
1.4 Voltage regulation
Regulation of the voltage of the electric plant is strictly set by its design. Voltage is varied within the admissible limits by changing the rotation frequency of the engine. The latter is supplied with an automatic
device, which supports constant rotation frequency (within ±5% limits).
The idle run voltage of the generator is equal to 250 V as a maximum. At the maximum load, it should not fall below 207 V. Warning! Consumers sensitive to the increased and decreased voltage can be
damaged when connecting to the electric plant.
1.5 Standard complete set
The electric plant of the standard modification is equipped with a manual starting device (or an electric starter under an order) and CEE sockets or sockets with protective contacts. The complete „engine-
generator“ set is mounted on rubber shock absorbers. All plants have distribution boxes, which contain electric components, sockets, etc.

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2. Driving engine
It is a single-cylinder, four-cycle engine with air cooling and a
horizontal crankshaft. Ignition is blocked when the level of oil is
low. The automatic device stops the engine or prevents its start
when the level of oil is low. This device is also triggered when
the electric plant is placed on an inclined basis. „Super“ gasoli-
ne or „Normal“ ethyl-free gasoline is used as fuel. Start is car-
ried out by the cord starter. The Honda gasoline engine is
equipped with electronic ignition.
•Insignificant emission of
polluting substances:
corresponds to the stric-
test requirements to waste
gases in the world accep-
ted in California
(California Air Resources
Board) for 2006. •Automatic stop at low oil level
•OHV:
reduces the consumption of oil by 50%
reduces the consumption of fuel by 20%
•Efficient silencer:
considerably lower noise level
•Automatic air valve:
start without the
manual control of the
air valve. •Air filter with increased
sound-absorption coeffi-
cient. An LVH25 air heater
can be installed
•Electronic ignition
Specifications of the engine:
GX 270 Super Silent GX 390 Super Silent
Engine type single-cylinder, four-cycle, with the top arrangement
of valves
Displacement 270 cm3bzw. 390 cm3
Maximum torque 19,1Nm/2500 min-1 26,5 Nm/2500 min-1
Power 5,4 kW 7,5 kW
Cooling system air
Ignition system transistor with magneto

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3. Electric part
Warning! Access to electric components is allowed only to skilled specialists. Non-authorized works in the distribution box are strictly forbidden. After each maintenance or repair of the device, it is neces-
sary to inspect safety according to VDE0701. In particular, it is necessary to test the resistance of the potential-equalization wire (<0.3Ω), insulation resistance (> 2 MΩ), and appropriate operation of avai-
lable protective devices.
4. Electric connection and safety measures
The plant in the delivery condition is intended for the supply of one consumer (IT circuit). The neutral wire is connected neither to the case nor to a protective wire. The only consumer is connected exclusive-
ly through the sockets on the electric plant. If extension cords are used, the total resistance should be no more than 1.5Ω. Accordingly, the maximum length of an extension cord with a section of 1.6, 2.5,
and 4.0 mm2 is equal to 60, 100, and 165 m, respectively. If extension cords are connected to more than one socket, the corresponding length should be halved. Wires no worse than H07RN-F according
to DIN VDE57282-810 must be used for portable extension cords. If the electric plant is planned to apply with another-type circuit, it is necessary to adapt protective measures. These works, as well as
manipulations with the distribution box of the electric plant, can be executed only by skilled electricians. They are responsible for the efficiency of safety measures. In addition, it is necessary to follow local
instructions. If necessary, the authorization of a local power-supplying enterprise should be received.
4.2 Protection touch voltage (DIN VDE 0100, T551)
The safety measure called «Protective separation with equalization of potentials» is conveniently carried out. The phase and neutral wires should not be grounded and should not be connected to the protective
wire and potential-equalization wire (PE). The potential-equalization wire should be laid continuously (generator-wiring-consumer). For the removal of static charges, grounding the case is allowed. If the electric
plant should feed an existing circuit with a grounded neutral (TN circuit), protection measures for this circuit must operate or new effective protection measures should be developed. If the required short circuit
current of the generator is insufficient for the circuit breaker of an available consumer or the wire resistance is more than 1.5 MΩ, it is necessary to provide protection measures (e.g., a protective circuit brea-
ker) independent of the operation current and conductor length. If the electric plant with the protective circuit breaker is intended for application in TN circuits, it is necessary to keep the maximum allowable
grounding resistance corresponding to the chosen protection measure. The executive should be an electrician. Each protective action should be checked by the electrician when commissioning.
4.3 Thermal protection means
The electric plant is equipped with a device for the control of winding temperature. When winding temperature exceeds a preset value, ignition is disconnected and the engine stops. The repeated start of
the engine is possible only after cooling the winding. Before repeated start, it is necessary to remove causes of overheating (e.g., to clean the polluted cooling edges or ventilating casings, to be convinced
of the absence of overload caused by too powerful consumers, to not apply the electric plant at too high ambient temperature).
5. Kinds of installations
5.1 Installation at an open place
Whenever possible, the electric plant should be applied outside buildings. In this case, the best supply and removal of air are provided. An area where obstacles are absent in a radius of 5 m is ideal for
placing the electric plant. This area should be free of combustible or explosive materials such as fuel, etc. The plant should be placed horizontally on the ground; the maximum allowable inclination is equal
to 35°. It is necessary to protect the electric plant from the action of direct solar beams by a shed if it does not affect the quality of air circulation.
5.2 Stationary installation in closed buildings
When the electric plant is applied in closed buildings, various supervising documents must be taken into account:
* Building norms and rules of German States
* Instructions of the Ministries of German States
* DIN 18600 «Instructions on construction and operation of public buildings»
* Regional TÜV instructions
* Instructions on the application of building norms and rules of German States
* Rules of manipulation with combustible liquids
* Instructions of power-supplying enterprises
* Instructions on operation of garages
* VDE 0100 and VDE 0108 instructions «Electrical installations in public buildings»

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In closed buildings, it is necessary to provide the free supply (danger of the overheating damage of the plant) and removal (poisoning danger) of air. A building should be clean, dry, and protected from
dust. It must not be used to store inflammable materials. Great attention should be paid to the removal of waste gases, because they include toxic carbon oxide. Flexible hoses for the removal of waste
gases are not usually tight, and toxic carbon oxide can leak into the building. Therefore, it is necessary to charge a corresponding specialist with the design and realization of such devices.
6. Noise level
The device has a sound power threshold of 96 (740X: 98) dB (A). It corresponds to a sound pressure level of 70 (740X: 71) dB (A) at a distance of 10 m.
7. Supply of electric-power consumers
The power of the electric plant should be taken into account when choosing consumers. It is necessary to involve an expert in the choice of the standard size of the electric plant.
8. Check before start
8.1 Oil level in the engine
1. Remove the plug and cleanly wipe the oil level indicator.
2. Insert the oil level indicator into the filler neck, but do not
screw.
3. If the oil level is low, it is recommended to add oil up to
the edge of the filler neck.
It is necessary to use oil for four-cycle engines that corresponds
to classes SG and SF or higher. SAE 10W-30 oil is generally
recommended for all temperatures.
8.2 Fuel
Ethyl-free car gasoline is used.
Never use a mixture of oil with gasoline or polluted gasoline.
Do not admit the hit of dirt, dust, or water into the gasoline tank.
* Gasoline is a combustible liquid and is explosive in certain cases.
* Fuel the engine only under good ventilation conditions, and the engine should be stopped during this pro-
cess. Do not smoke and do not allow the occurrence of an open flame or sparks when fueling and at fuel
storage sites.
* Do not let the overflow of fuel into the tank. After refueling, make sure that the neck cap is reliably closed.
* Watch that fuel does not spill when refueling. Gasoline vapors or spilled fuel can ignite. If gasoline spills, before the start of
the engine, make sure that the area has completely dried up, and gasoline vapors have completely disappeared.
* Avoid the contact of gasoline to skin and inhalation of gasoline vapor. Hold fuel in places inaccessible to children.
Oil level

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9. Start of the engine
1. Set the fuel cock to the „ON“ position.
2. If necessary, close the air valve.
At hot start, the valve opens automatically.
Warning! Do not use the valve if the engine is hot or the tempera-
ture of air is high.
Fuel cock
Choke
CLOSE
OFF
OFF
ON

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OFF/Aus ON/Ein
OFF
ON
Ignition
lock
4401E-AA/HHBA
4402 E-AA/HHBA
5401 ED-AA/HHBA
5402 ED-AA/HHBA:
6401 ED-AA/HHBA
6402 ED-AA/HHBA
7401E-AA/HHBA
7401 ED-AA/HHBA
7402 ED-AA/HHBA:
3. Start of the engine
* Set the ignition key to the „ON“ position
* Slightly pull the starter handle up to the sensation of
resistance, and then sharply jerk.
Warning! When the cord retracts back, do not release the
handle. It should be moved accurately in order to pre-
vent the damage of the starting device.
Electric start (all types)
* For the start by the electric starter, turn the ignition key
to the „Start“ position.
* When the engine starts, release the key.
* The key should move independently to the „ON/Ein“
position and remain in this position during operation.
Warning! Never try to start the working engine by the
electric starter - the damage of a tooth gearing is possi-
ble! OFF/Aus ON/Ein Start

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10. During engine operation
When the engine is warmed up, the valve opens automatically (do not push it).
The low oil level warning system prevents the damages of the engine when the level of oil in a crankcase is too low. When the oil level falls below the minimum admissible level, the warning system automa-
tically turns off the engine [in this case, the ignition lock remains in the „ON“ position].
Warning! If the engine has stopped and does not start, check the oil level before looking for a fault.
11. Turning-off the engine
To turn off the engine:
1. Disconnect consumers of electric power, take plugs out.
2. Give the engine to work about 1 min without load.
3. Set the ignition key to the OFF/Aus position (Off).
4. Set the fuel cock to the OFF/Aus position (Off).
12. Custom-order equipment
12.1 Radio device FFS 100 for remote start and stop of the electric plant (option)
The device is made in the form of a compact module Geko-SMD. Due to the small sizes of the transmitter, a user can constantly carry it with him.
The device is intended only for electronic start and not applied in combination with UBC 400.
By using FFS 100, the electric plant can be started or stopped [key should be in the „ON/Ein“ position (On)] from a distance up to 100 m (depending on the conditions of radio wave propagation). The
Geko remote control radio device works in the 433-MHz noiseless band.
Frequency codes FFS 100 are set by DIP switches on the transmitter and receiver. In the delivery condition, switches are in the following positions: 1 = ON; 2 = OFF; 3 = ON; 4 = OFF; 5 = ON; 6 = OFF;
7 = ON. For work, the switches of both devices should be set identically. The positions of switches 8-10 on the receiver must never be changed (factory installation: 8 = ON; 9 = OFF; 10 = ON).
See also electrical connection scheme 100126.
Receiver
DIP switches
DIP switches

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Key for moving upwards
Display
Key for moving downwards
12.3 Universal built-in controller UBC 400 (option)
It provides the display of 20 current parameters of the electric plant, which were not displayed
earlier.
Due to the application of the microprocessor measuring system, UBC is made in the form of a
Geko compact module, and the controller UBC 400 can be mounted in most Geko electric
plants.
It is applied for both one- and three-phase electric plants.
•Voltage N - L1, N - L2, N - L3
•Voltage L1 - L2, L2 - L3, L3 - L1
•Current L1, L2, L3
•Total current
•Frequency
•Power per Phase in kVA L1, L2, L3
•Total power in kVA
•Running time
•Maintenance periodicity 100 + 300 Std.
•Real time and date
All data are transformed by a high-efficiency measuring amplifier to digital signals. The latter sig-
nals are processed by a microprocessor. The parameter is chosen by arrow keys.
Change of the parameters of maintenance periodicity, the calibrations of voltage and current,
and the reset of the operating hours counter can be made only by our authorized representative.
See also electrical connection schemes 100122 and 100123.
Indicator of air heater
work
Resistive heating element12.2 Air heater LVH 25 (option)
It can be applied to all engines Honda-Super Silent GX 270 and GX 390. It prevents the icing of the carburetor at low temperatures,
which allows the reliable exploitation of the electric plant under extreme conditions.
Inlet air is heated by an automatic electric resistive heater controlled by a gauge. The mode is initiated by a light-emitting diode on
the casing of the air filter.
The heater is turned on at +10°C, because the icing of the carburetor often begins already at temperature from 0°C to + 5°C.
See also electrical connection scheme 100127.

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B.12345h Generator operating time in hours
(from 0 to 99999 h)
L1N= 230V Voltage of phase L1 with respect to neutral N
( 0 - 300V AC )
L2N= 231V Voltage of phase L2 with respect to neutral N
( 0 - 300V AC )
L3N= 232V Voltage of phase L2 with respect to neutral N
( 0 - 300V AC )
L12=400V Linear voltage L1-L2 ( 0 - 500V AC )
L23=401V Linear voltage L2-L3 ( 0 - 500V AC )
L31=402V Linear voltage L3-L1 ( 0 - 500V AC )
I1= 10,0A Current of phase L1 ( 0- 32,0 A )
I2= 10,1A Current of phase L2 ( 0- 32,0 A )
I3= 10,2A Current of phase L3 ( 0- 32,0 A)
IG= 30,3A Total current of all phases L1, L2, L3
( 0- 99.9 A )
F=50,0Hz Frequency in Hz ( 0 - 99,9Hz )
1=2300VA Calculation with voltage L1 and current I1 gives the
total power of phase L1 in VA ( 0 - 9999 VA)
2=2333VA LCalculation with voltage L2 and current I2 gives the
total power of phase L2 in VA ( 0 - 9999 VA
3=2366VA Calculation with voltage L3 and current I3 gives the
total power of phase L3 in VA ( 0 - 9999 VA)
G 6999VA Total power of the generator in all phases (G) in VA
( 0 -9 999 VA)
1- 1000h Operating time remaining to the first maintenance;
i.e., after this time, the first maintenance must be car-
ried out
2- 500h Operating time remaining to the second maintenance;
i.e., after this time, the second maintenance must be
carried out
STATISTIK (Statistics) menu; here, the major parameters of the
system are stored and displayed
ON= 11 Number of starts of the plant
B.12345h Operating hours of the plant
W1 1600h Periodicity of the first maintenance (preset time
is displayed here)
W2 500h Periodicity of the second maintenance (preset
time is displayed here)
mL1 248V Maximum measured voltage of phase L1 of
the generator
mL2 248V Maximum measured voltage of phase L2 of
the generator
mL3 248V Maximum measured voltage of phase L3 of
the generator
mI1 31A Maximum measured current of phase L1 of the
generator
mI2 31A Maximum measured current of phase L2 of the
generator
mI3 31A Maximum measured current of phase L3 of the
generator
Uhrzeit (Date, time) menu
Current time 17 h 23 min
Indications automatically vary at the transition to winter/sum-
mer time. If it is necessary to change indications, it is possible
to select the necessary time counters by key „_“
The following menu item is selected by pressing key „up“
with pressed key „down“

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Hours
To change the displayed value, it is necessary, having pressed and keeping the key hidden by the UBC 400 sign, to quickly press key «_» (for increase) or key „_“ (for
decrease). These keys should be pressed until the necessary value
Minutes
To change the displayed value, it is necessary, having pressed and keeping the key hidden by the UBC 400 sign, to quickly press key «_» (for increase) or key „_“ (for
decrease). These keys should be pressed until the necessary value
Date - day
To change the displayed value, it is necessary, having pressed and keeping the key hidden by the UBC 400 sign, to quickly press key «_» (for increase) or key „_“ (for
decrease). These keys should be pressed until the necessary value
Date - month
To change the displayed value, it is necessary, having pressed and keeping the key hidden by the UBC 400 sign, to quickly press key «_» (for increase) or key „_“ (for
decrease). These keys should be pressed until the necessary value
Date - year
To change the displayed value, it is necessary, having pressed and keeping the key hidden by the UBC 400 sign, to quickly press key «_» (for increase) or key „_“ (for
decrease). These keys should be pressed until the necessary value
Uhrzeit Datums- Jahr: Jah 2004
Bei Änderung des angezeigten Wertes muss die mittlere unsichtbare Taste gedrückt gehalten und für + ( höherer Wert ) die Pfeil nach oben Taste, oder für - (niedriger
Wert ) die Pfeil nach unten Taste zusätzlich kurz gedrückt werden. Die Tasten solange betätigen bis der angezeigte Wert stimmt.
The following menu item is selected by pressing
key „up“ with pressed key „down“
12.4 Automatic emergency device BLC 100 (option)
12.4.1 Safety rules
Installation must be charged only to skilled electricians. Do not begin to work with the given equipment without carefully studying all documentation applied to it. The given safety rules and other instructions
of the manufacturer should be executed every time when working with this device. If you have no instructions on work with the equipment, appeal to a representative of the manufacturer. Ask immediate
dispatch of the necessary documentation to address of the responsible for the safety use of industrial electronics. These safety instructions must be also attached when selling, hiring, and/or transferring com-
ponents.
Warning! Products of industrial electronics must be commissioned only by specialists with sufficient knowledge in electrical engineering, generators, and motor equipment.
Necessarily study warnings of the dangerous factors included in the documentation.
Metallwarenfabrik is not responsible for damage arisen due to failure to comply with warnings contained in this Operation Manual.
If changes that are not indicated in this Manual are introduced into the device, guarantees are automatically cancelled. The below safety instructions should be necessarily studied and fulfilled before com-
missioning the electric plant in order to prevent injuries and/or material damage. These safety instructions should be carried out constantly.
12.4.1.1 Purpose application
An industrial electronic device BLC 100 Geko is intended only for application in electric plants. All electric plants should be certificated by their manufacturers for application in certain areas and checked
on both resistance to overloads and operational reliability. The manufacturer of a device has to provide the corresponding safety measures. Before commissioning, the device should pass comprehensive
tests for conformity to the technical and local requirements for it, as well as to the safety rules concerning the area of its application.
12.4.1.2 CE marking
The industrial electronic device BLC 100 is intended for application in the structure of equipment. For this reason, it is offered to manufacturers of equipment only as a completing product. Thus, the device is
not subject to CE marking.

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12.4.1.3 Possible dangers at unforeseen application and inadequate manipulation
High voltage and current!
Danger of death or heavy injury! When working with the device, it is necessary to exclude touches to current carrying parts. All sockets (of any kind) should be joined only when the device is turned off.
Surfaces may be hot. Danger of burn!
*Atouch to the hot details of the case, radiator, etc. can lead to burns.
* Sufficient cooling of built-in components must be ensured. Inadequate manipulation can lead to injuries including burn, squeezing, cut, and shock! Inadequate operation and installation of the certain
components of the drive can lead to injuries under unfavorable conditions.
* Follow general building rules and safety requirements when installing and operating.
* Apply appropriate assembly and transport appliances.
* Take appropriate measures preventing pinching and squeezing!
*If necessary, apply corresponding protective appliances (e.g., goggles, footwear, gloves).
* Do not stand under a suspended load.
*Immediately remove liquids spilled on a floor (danger of slipping).
Protection against an electrostatic discharge / Installation instructions
Take into account when installing electronic modules.Apply corresponding protection against electrostatic discharges.
Warning! Inadequate manipulation with these devices and failure to comply with warnings can lead to material damage, physical injuries, damage by current, or even death.
Dangerous displacements! Unforeseen displacements of the elements of engines lead to danger to life, the possibility of heavy physical injuries, or material damage!
Attention! If a BLC-equipped genset will be started with disconnected battery or reverse connected battery, a 2A-fuse inside the
controlbox will blow. This has to be replaced by authorized personnel.
Dangerous displacements can arise due to the erroneous adjustments of engines. Causes may be different:
* polluted or defective electrical wiring;
*erroneous adjustment of components;
*faulty gauges;
*faulty components;
*errors in the software;
*going beyond the operational restrictions.
These defects can be revealed both immediately after installation and a while after the beginning of operation. In order to prevent
accidents, injuries, and material damage due to unforeseen displacements of the details of the engine, corresponding protective
measures must be realized in devices or plants.
Possible additional measures for the prevention of the specified cases:
* do not present in the zone of movement of the elements of a device or a plant;
*apply sufficiently durable protective barriers and casings;
* before opening the device or access in a dangerous zone, make sure that the device is stopped, and exclude a non-authorized repeated start.
The presence of persons with heart stimulants, metal implants, and acoustic devices near electrical equipment is dangerous to health!
Persons with heart stimulants and metal implants must not be admitted to zones where:
* electric devices and components are mounted, working, or commissioned;
*the components of engines with constant magnets are stored, repaired, or mounted.
If access to the specified zones is necessary, these persons should preliminary consult with a physician.
2A-fuse (BLC only)

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12.4.2 Functions of BLC 100
The modern automatic device of emergency electrical supply BLC provides unique advantages and previously absent conveniences for a user:
*the entire device, including protection, is completely built in the electric plant;
* one- and three-phase construction;
*the generator is connected after warming the engine either by the signal of the sensor of the temperature of the cylinder head or with a delay of 30 s. Thus, load is connected already at the rated
speed of the engine;
*repeated switching on the common circuit is carried out with preservation of circuit voltage in the specified limits (> 190 V and < 250 V) within three seconds;
*up to three attempts of the automatic start;
* a built-in device of recharging an accumulator (500 mA/12 V).
The automatic emergency device BLC switches load to the Geko electric plant if circuit voltage disappears or strongly fluctuates. After the recovery of circuit voltage, load is again automatically switched to
the circuit and the electric plant stops.
* Connection of the electric plant at circuit voltage <175 V or > 260 V.
* Disconnection of the electric plant at circuit voltage > 190 V and < 250 V.
12.4.3 Connection of the electric plant with BLC 100
See electric schemes 100107, 100108, and 100132. The circuit is connected to a head on the face panel of the distribution box. Output voltage is taken through a CEE socket.
Warning! It is necessary to avoid the overload of the circuit contactor. The maximum current load (both one- and three-phase) is equal to 20 A.
Only a skilled electrician can carry out these works. It is necessary to take into account requirements of item 4 «Electric connection and safety measures».
12.4.4 Indication of BLC 100
Light-emitting diode „Netzbetrieb“ (Work from the circuit):
is on when a consumer is fed from the circuit (circuit contactor is closed).
However, it is necessary to keep the key and ATS switch in the EIN (ON)
position.
Light-emitting diode „Generatorbetrieb“ (Work from the generator):
is on when a consumer is fed from the generator (generator contactor is
closed).
Light-emitting diode „TS-Betrieb“ (ATS mode):
blinks while the ATS switch is closed.
Light-emitting diode «Batterie Ladung» (Accumulator charging):
is on when circuit voltage is supplied and the accumulator is recharged or
charged.
Light-emitting diode „Übertemperatur“ (Overheating):
is on when the engine is overheated.
Light-emitting diode «Pilot Lamp» (Control lamp):
is on when the generator works; i.e., voltage is generated.
Light-emitting diode „Störung“ (Malfunction):
is on when a general fault arises

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12.4.5 Operating modes of BLC 100
Warning! Turn on the unit, keeping both on-off switches in the „OFF“ position. After turning on,
wait the end of built-in control BLC (about 10 s). After the light-emitting diode „Netzbetrieb“
(Work from the circuit) has lighted up, a desired operating mode can be chosen by the on-off
switches.
Start of the electric plant in the presence of load
In this operating mode, the electric plant starts immediately with closed
contacts X1.6 and X1.7. After the electric plant is warmed up, load is
connected.
When the switch is turned to the AUS position, the generator is
immediately disconnected.
After 30 s, the engine stops. If contacts X1.6 and X1.7 are not closed,
the electric plant does not start. After the closure of contacts X1.6 and
X1.7, the electric plant starts immediately. After warming up, it accept
load. After the direct-mode switch is opened, the electric plant is imme-
diately disconnected. If contacts X1.6 and X1.7 are opened again, the
generator is disconnected after 5 s.
After 30 s, the engine is turned off
The control of the voltage of a circuit with automatic start
The ATS/Control mode of the circuit is turned on. Light-emitting diode „ATS-
Betrieb“ (ATS mode) blinks. The electric plant is turned on with a delay of 4
s after the disappearance of circuit voltage.
Start of the electric plant in the absence of load and with the control
of circuit voltage
In this mode, the electric plant starts immediately, in the absence of load
(hot-reserve mode). Circuit voltage is monitored, and when it disappears,
the generator contactor connects a consumer to the electric plant after 2 s.
After the direct-mode switch is opened, the electric plant is immediately tur-
ned off.
OFF.
Circuit voltage is not monitored, the electric plant does not start. Warning!
If both switches are in the „OFF“ position, all messages on faults are erased
12.5 Protective circuit breaker (option)
The protective circuit breaker is a switch with an electromagnetic breaker, which is automatically opened when leakage current exceeding rated breaker-triggering current flows on the ground or through the
case. The application of the protective circuit breaker is an additional safety measure against a direct touch. This device is intended to prevent the appearance of both dangerous voltage on open current-
carrying parts of electrical devices and fires. Warning! Before the connection of the electric plant, it is necessary to check its serviceability by the test button of the protective circuit breaker. If the circuit
breaker is not triggered, it is forbidden to use the electric plant. See electrical connection schemes 100118 and 100119.
12.6 Control of insulation resistance in agreement with GW 308 (option)
The control of insulation resistance in combination with the standard protective measure «protective separation» is an additional protective measure in an IT circuit. Since the first short circuit on the case or
defect of insulation is not destructive and consequently remains unnoticed, the insulation control device, which reveals such defects and disconnects consumers, is useful and recommended by GW 308. The
neutral wire (N) and potential-equalization wire (PE) should not be connected with each other. The potential-equalization wire should be connected without breaks between the electric plant and all consu-
mers. The plant can be used without grounding. Before each connection, it is necessary to check the serviceability of the insulation control device by pressing the test button. In this case, a red control lamp
must light up, and the main switch must be opened. The red control lamp „ISO-Fehler“ (Insulation fault) is constantly on before opening the main switch when the insulation of the generator, as well as the
insulation of the consumer, is defective. See electric connection schemes 100110 and 100111.
12.7. Measuring instrument for insulation resistance (A-Isometer) (option)
The insulation resistance control in combination with the standard protective measure «protective separation» is an additional protection measure in an IT circuit. Since the first short circuit on the case or
defect of insulation is not destructive and consequently remain unnoticed, the insulation control device, which reveals such defects and disconnects the circuit, is a useful device with a light indicator accor-
ding to VDE 0100-410. The neutral wire (N) and potential-equalization wire (PE) should not be connected with each other. The potential-equalization wire should be connected without breaks between the
electric plant and all consumers. The plant can be used without grounding. Before each connection, it is necessary to check the serviceability of the insulation control device by pressing the test button. In
this case, a red control lamp must light up. The red control lamp „ISO-Fehler“ (Insulation fault) is constantly on before breaking the supply circuit when the insulation of the generator, as well as the insulation
of the consumer or wiring, is defective. See electric connection schemes 100114 and 100116.

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12.8 Additional fuel tank 50l or 100l (optional)
The additional fuel tank enable extra long running times of the genset.
A mechanical engine driven pump deliver the fuel from the lower tank to the careburator
The standard 20l-tank remain usable thanks to a manual operable three-way-tap.

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13.Possible faults and ways of their elimination
No.Faults Origin Elimination
1The engine can not be started Not enough oil is filled or Check the oil level, if necessary
the gas-electric generating set is refill the engine oil or provide
situated on an inclined ground an even surface
2The gas-electric generating set Engine oil in the combustion Remove the spark plug and
can not be started chamber (because of intensive pull through the engine with a reversing starter 3-4 times.
tilting or falling of the aggregate) Clean the carburettor and the air filter.
Mechanical damages in the range Maintenance or replacement
of the reversing starter or through a new spare part
blower hood
3The gas-electric generating set Capacitor is defect Replace the capacitor
does not deliver enough voltage interturn short circuit in stator replace the stator by a new one
Overcurrent circuit breaker Actuate or replace the circuit
is actuated or defect breaker
Insufficient rotation speed run up to rated speed, idle
of the engine running 3180 1/min, max. 250 V
The air filter and/or the Clean the component or insert
carburettor is contaminated a new filter set
4No or not enough voltage Insufficient rotation speed of the The engine must be set to the
after loading engine or the speed controller rated speed of 3180 1/min,
is not serviceable max. 250 Volt in an authorized
workshop
Climatic influences reduce Do not load the gas-electric
the power of the gas-electric generating set generating set with the rated speed, see operating instructions of the engine
5Excessive voltage of the gas-electric Excessive speed of the engine generating set Adjust the rated speed of the engine, however max. 253 Volt
6Generator gets inadmissible warm Overloading of the gas-electric generating set Switch off some consumers

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No.Faults Origin Elimination
Power reduction because Only partial loading possible
of situating in the height
Excessive environment temp. The gas-electric generating sets
are designed for an environment
temperature up to 40°C
7The aggregate turns off but can The overtemperature breaker See No. 6
again be started after cooling of the gas-electric generating
set is actuated
It is forbidden to change the installations of the adjusting screws marked with red varnish. Otherwise, all guarantees are cancelled. If defects repeat, it is necessary to address to the manufacturer or an aut-
horized workshop (see the list of the authorized workshops in the Appendix). Mount only original components when replacing them.
14. Scheduled maintenance
Before the beginning of maintenance works, the engine should be stopped.
14.1 Electric components
The generator does not require maintenance. It is only necessary to periodically clean the case from dust to
avoid the worsening of cooling conditions.
14.2 Engine
The screw of regulating the quality of the mixture, rotation-frequency regulator, and throttle valve restrictor
are sealed with red varnish. It is forbidden to disturb adjustments, because the generator and consumers
can be damaged.
14.2.1 Check of the fuel tank and fuel guides
* Check the fuel tank and fuel guides on tightness and the absence of damages.
* Check the condition of the thread of the fuel-tank cover.
* Clean components from pollution.

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14.2.2 Replacement of oil in the engine and check of the oil
level
Oil is replaced only on the hot engine and according to the engi-
ne operation manual.
* Place the electric plant on a suitable raised basis and slight-
ly incline aside the sink hole.
* Unscrew the cap of the filler neck.
* Turn out the plug of the sink hole and pour oil out.
* After the removal of old oil, turn in the plug of the sink hole
and place the electric plant on the flat basis.
* Fill engine oil up to the top label of an oil dip stick.
* Tightly screw the cap of the oil-filler neck by hand.
Spilled engine oil should be immediately picked up.
Waste oil is subject to recycling according to rules currently in force.
Check of the oil level
* After opening the cap of the filler neck, insert the dip stick into the neck, but not screw (oil level should be
between the bottom and top labels). If necessary, add oil.
14.2.3 Check and replacement of the spark plug
If the electric plant worked before this procedure, its silencer is strongly heated. Danger of burn.
*Remove the ignition wire from the spark plug.
* Unscrew the spark plug by a spark-plug wrench.
*If necessary, clean electrodes by a brass brush. If the spark plug is damaged, replace it.
*Check the interelectrode gap, if necessary install the appropriate gap. A feeler should be introduced smoothly between electrodes.
*In order to provide entry on the thread, screw the spark plug by hand and then draw it up by the spark-plug wrench through a half-turn.
*The spark plug should be tightly screwed. The insufficiently screwed spark plug is strongly heated and can cause the damage of the engine.
*Put the ignition wire on the spark plug.
*Spark plugs BPR6ES (NGK), and W20EPR-U (Denso) are recommended.
14.2.4 Cleaning and replacement of the air filter
*Carefully take out a cartridge.
*Wash out a foam-rubber replaceable element in warm water with a household was-
hing-up liquid, then carefully rinse and dry. Immerse the element in clean engine oil,
and then wring it out. If excessive oil remains on the insert, the engine will smoke at
the first start.
*Clean the pressboard cartridge by knocking out on a flat surface.
*When pollution is heavy, replace the filtering element.
Replaceable element
of the air filter
Cover of the air filter
Oil level