Gesan DPR 100 User manual

MT 1
RENTAL SERIES
ELECTRICAL GENERATOR
1 WELCOME 2
2 BASIC SAFETY RULES 3
3 INSTALLATION OF THE ELECTRICAL GENERATOR 4
3.1 SOUND INSULATION 6
3.2 CONTROL UNITS 7
3.2.1 GPM-2 Analog Control Module 8
3.2.2 DEEP SEA Digital Control Module 9
3.2.3 INTELIGEN Digital Control Module 10
3.3 TRAILER 11
4 INSTALLATION OF THE ELECTRICAL GENERATOR 12
4.1 UNLOADING AND TRANSPORT 12 - 13
4.2 INSTALLATION OF PORTABLE UNITS 14
4.2.1 Placement 14
4.2.2 Fuel 14
4.2.3 Prior to Starting Generator 14
4.2.4 Electrical Connection 14
4.3 STORAGE 15
5 STARTING AND STOPPING THE UNIT 15
6 OPERATION MANUAL 16
6.1 ELECTRICAL PANEL COMPONENTS 16 - 17
6.2 GPM-2 ANALOG CONTROL MODULE 18 - 22
6.3 DEEP SEA 5210 DIGITAL CONTROL MODULE 23 - 30
6.4 DEEP SEA 5310 DIGITAL CONTROL MODULE 31 - 40
6.5 INTELIGEN DIGITAL CONTROL MODULE 41 - 44
7 MAINTENANCE OF ELECTRICAL GENERATOR 45
7.1 PRIOR TO MAINTENANCE 45
7.2 DURING MAINTENANCE 45
7.3 MAINTENANCE CHART 46
8 TROUBLESHOOTING 47
9 PROTECTION FROM THE ENVIRONMENT 47
10 WARRANTY 48
11 NOISE LEVEL 49
12 DECLARATION OF CONFORMITY 49
13 APPENDIX 1: FIGURES 49 - 50 - 51
14 APPENDIX 2: IMAGE INDEX 52

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1.- 1 WELCOME
Thank you for purchasing a GESAN electrical generator.
The purpose of this manual is to familiarize the user on how to use and work
with the electrical generator, its components and maintenance.
W e recommend carefully reading the manual prior to working with the
equipment in order to ensure proper use .
S ave this manual for future reference and if you ever decide to sell the
electrical generator, be sure to include the manual along with the unit.
T he following is a general description of the unit and the necessary information
for installation, operation and preventive maintenance.
Additionally, you should have received a specific user manual for the engine
and alternator, electrical setup and a set of keys.
Should you have any problem with the equipment provided, please contact
the distributor directly.
G RUPOS ELECTRÓGENOS GESAN, S.A., as a part of its dedication
to cons tant product improvement, will revise its manuals and incorporate the
improvements made to supplied units. Thus the information contained in this
document is subject to change without prior notice and without obligation to
update.

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2.- BASIC SAFETY RULES
Safety precautions and recommendations for handling the electrical generator supplied by GESAN.
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Do not allow the unit to be used by non-authorized personnel or by minors without adult supervision.
Use the necessary Individual protection equipment.
Ground the machine.
Make sure there is sufficient lighting on the control panel.
Do not install the open-skid electrical generator outdoors: risk of electrocution and inoperability.
The connection should be made by a qualified electrician in accordance with current norms and regulations. An
improper connection can cause electrical feedback with electrocution hazards for anyone working with the mains
power supply.
The supply line between the electrical generator and the consumers should be protected by means of a circuit
breaker for protection against earth leakage (ELCB).
Do not operate the unit with the doors open. Risk of electrocution, burns or entrapment.
The exhaust system produces enough heat to ignite certain materials.
Do not inhale exhaust gases produced by the unit.
Do not touch the engine nor the exhaust while the electrical generator is operating as this could produce severe
burns.
Ensure proper ventilation in the area where the generator is installed in order to guarantee sufficient flow of coolant
air.
D o not refuel while the engine is running or in poorly ventilated areas.
K now how to stop the unit in case of emergency.
The fuel used is flammable and volatile.
Do not overfill the tank and make sure it is closed properly after filling. Use extreme precaution if fuel is spilled: the
vapors and the fuel itself are flammable. Clean the area completely before starting up the unit.
Do not smoke or bring any flames or sparks in the vicinity of the electrical generator: risk of explosion.
I f you notice abnormal behavior by the electrical generator, stop the unit and locate, examine and resolve the
potential failure of the unit prior to restarting.
Keep the unit at least one meter away from buildings or other units.
Be cautious when switching or installing batteries as they contain acids which are highly hazardous. Avoid spills and
use protection to avoid contact with the skin and eyes. In case of contact, rinse thoroughly with water and contact a
doctor immediately.
In case of ingestion of battery acid, drink large amounts of water and milk and contact a doctor immediately.
Use only distilled water in the battery: tap water reduces its life cycle.
If a battery is filled above the maximum level, the electrolytes will spill out; if this happens, clean the area quickly to
avoid corrosion of the parts it has come in contact with.
Frequently clean the unit to avoid obstructions or the entry of foreign elements into the unit (dust, moisture, etc.).
Regularly inspect the unit’s electrical cords.
Prolonged contact with the used oil can cause skin cancer. Wash your hands after working with the generator.
Avoid oil spills on both the inside and outside of the generator. In case of an oil spill on the inside of the unit, clean it
properly as it could potentially become a flammable material.

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3.- INSTALLATION OF THE ELECTRICAL GENERATOR
G eneral overview of the electrical generator and its different configurations manufactured by GRUPOS
ELECTRÓGENOS GESAN, S.A.
Image 1- ELECTRICAL GENERATOR WITH CANOPY AND OPTIONAL TRAILER FOR UNITS WITHOUT DRIP PAN.
Note: this image corresponds to the detailed view of Image 2

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Image 2 - DETAILED VIEW OF IMAGE 1
1) Coolant tank hatch
2) Side access door
3) Fuel tank cap
4) Smoke exhaust
5) Engine
6) Antivibration feet
7) Base frame
8) Capot
9) Electrical panel door
10) Ventilation grill
11) Lifting frame and eyebolt
12) Electrical control panel
13) Alternator
14) Electrical power panel
15) Battery
16) Fuel tank
17) Retention bath
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Image 3 - INTERIOR OF A SOUNDPROOFED ELECTRICAL GENERATOR
3.1.- SOUND INSULATION
The supplied unit is soundproofed and includes sound-insulating canopy. See details on part 11

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3.2 .- CONTROL UNITS
The unit provided may be controlled by different modules depending on the type of function it has been designed
to perform.
The following is a generic control panel, which contains all of the electrical and mechanical options available.
Image 4 - GENERIC CONTROL PANEL
A
A
A
V
Hz
AMMETER FREQUENCY METER
HOUR METER
VOLTMETER
LOCK
AUTO FUEL
REFILL SWITCH
LOCK
OIL PRESSURE
GAUGE
(OPTIONAL)
BATTERY
VOLTMETER
(OPTIONAL)
ENGINE TEMP.
GAUGE
FUEL GAUGE
EARTH LEAKAGE
CIRCUIT
BREAKER
AUTOMATIC
CONTROL UNIT
EMERGENCY
STOP

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3.2.1.- GPM-2 analog control module
If you purchased a generator unit with a GPM-2 control module, the electrical panel will look like the following
diagram:
Image 5 - CONTROL PANEL FOR THE GPM-2 CONTROL MODULE
A
A
A
V
AMMETER FREQUENCY METER
HOUR METER
VOLTMETER
LOCK
TEMP AND FUEL
GAUGE BUTTON
LOCK
OIL PRESSURE
GAUGE
(OPTIONAL)
BATTERY
VOLTMETER
(OPTIONAL)
ENGINE TEMP.
GAUGE
FUEL GAUGE
EARTH LEAKAGE
CIRCUIT
BREAKER
VOLTMETER
SWITCH
Hz
EMERGENCY
STOP

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3.2.2.- DEEP SEA digital control module
If you purchased a generator unit with a DEEP SEA control module (models 5210 and 5310), the electrical
panel will look like the following diagram:
Image 6 - CONTROL PANEL FOR THE DEEP SEA CONTROL MODULE
Note: The button on the control module performs the same function as the diagnostic button (while in
OFF/AUTO mode).
DIAGNOSTIC
BUTTON
EARTH LEAKAGE
CIRCUIT
BREAKER
LOCK
ENGINE BLOCK
HEATER LIGHT
(YELLOW)
ELDON
XXXXXX
AMMETER
BATTERY
VOLTMETER
EMERGENCY
STOP

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3.2.3.- INTELIGEN Digital Control Module
I f you purchased a generator unit with an INTELIGEN control module, the electrical panel will look like the
following diagram:
Image 7 - CONTROL PANEL FOR THE INTELIGEN CONTROL MODULE
AMMETER VOLTMETER FREQUENCY METER
LOCK
HOUR METER
GREEN FUEL
BUTTON
ON: GREEN
LIGHT
AUTO FUEL
REFILL SWITCH
(OPTIONAL)
LOAD
AMMETER
FUEL
GAUGE
EARTH LEAKAGE
CIRCUIT BREAKER
A
A
A
V
Hz
EMERGENCY
STOP
LOCK
ENGINE BLOCK
HEATER PILOT
(YELLOW)
SLAVE/MASTER
SWITCH
(OPTIONAL)

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Image 8 - TRAILER
3.3 .- TRAILER
The generator can be supplied with a trailer for transporting the unit.
• Site Trailer: for private-use areas only. Includes DIN hitch ring, safety brake and jockey wheel.
* Note: Ask about the possibility of using trailer with drip pan.

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4.- INSTALLATION OF THE ELECTRICAL GENERATOR
4.1 .- UNLOADING AND TRANSPORT
The unloading and transport of the unit should only be done by qualified personnel, observing certain minimum
safety conditions.
• The ground must be capable of supporting the full weight of the Generator and the forklift.
• Make sure that the battery is disconnected.
• Make sure that the fuel tank is empty.
• Place the open arms of the forklift below the chassis at an equal distance with respect to the lifting frame.
• With a hoist, raise the unit using the lifting frame eyebolt.
The image below shows a generator unit that which includes a frame with a single lifting point.
Image 9 - LIFTING FRAME

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If your unit includes a trailer, one of the following may apply:
• Trailer 1 - Site trailer: Connected with a DIN hitch ring and safety chains to the rear of the towing vehicle. Use of
this trailer is not authorized on public roads. Use the safety brake whenever necessary.
• Trailer 2 - Road trailer: Keep in mind the legal considerations detailed in point 3.3.
Always perform the following precautionary steps:
• M ake sure the hitch ring and coupling connecting the towing vehicle to the trailer have the adequate towing capacity
supporting a weight equal to or greater than the gross trailer weight .
• M ake sure there is no wear or damage to the hitch system or coupling; never tow the generator if there is excessive
wear or if any piece is damaged.
• Make sure the coupling is properly fastened to the towing vehicle.
• Check the condition of the trailer’s tires.
• Connect the safety cable to the bumper or rear part of the towing vehicle; never attach it to the generator unit or
to the hitch ring itself.
• Check to make sure the brake systems on both the trailer and towing vehicle are in perfect condition.
• Make sure the trailer’s turn signal indicators and brake lights are correctly installed and functioning properly.
• After each transport, apply a light coat of grease to both the towing vehicle’s coupling and the trailer’s hitch ring.
before towing again.
• Install safety chains on units with site trailer.

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4.2 .- INSTALLATION OF PORTABLE UNITS
4.2.1.- Placement
T his type of unit must be installed in well ventilated areas in order to ensure sufficient flow of coolant air and
preventing combustion smoke from sitting in the engine’s exhaust.
The unit must be placed in a location that can safely bear the full weight of the generator unit and guarantee its
stability both horizontally and vertically.
It should always remain at a distance that allows access to the interior of the electrical generator (at least 1 meter
away from any building or wall).
Avoid installing in areas with moisture or locations where water could get into the interior of the unit.
* Note: Exhaust can be supplied with optional spark arrester in the exhaust tube for Ex zones.
4.2.2.- Fuel
A s diesel fuel is used, keep in mind the safety instructions previously mentioned in point 2 - BASIC SAFETY
RULES.
Before operating, check the fuel level to ensure that the tank has the amount needed by the generator unit for an
entire work day.
There is a optional of quick conectors for external fuel tank. We can connect them with conductors through canopy
fuel point for replenishing the generator base tank.
You should consider this series of points:
1) In order to connect or disconnect, you should move backwards the female lock fitting.
2) Make sure that the external tank aspiration circuit does not contain air.
3) In the external tank, the aspiration connector should be male and the return connector female, both are 3/8
BSP connectors.
4) Return should be correctly connected.
5) Connectors have to be watertight; they lock when they are disconnected.
6) T he distance between tank and genset has to be as shorter as possible. If you observe engine anomalous
behaviour (lack of power for aspiration problems), you should have to reduce distance or increase the hose diameter.
4.2.3.- Prior to starting generator
Before starting up the generator, inspect the consumer power supply conductors to make sure they are in perfect
condition and that the consumers are disconnected; the unit should always be started up at no load.
Make sure that there is nothing obstructing the ventilation ducts and that there are no foreign objects inside the unit.
Make sure the fluid levels of the electrical generator are adequate for the service the unit will be providing and that
there are no leaks or spillage.
4.2.4.- Electrical connection
The connecting of cables that supply consumers must be performed by qualified personnel; these conductors should
be connected to terminals U V W and N or L1 L2 L3 and N or to the socket panels .
T he four-pole circuit breakers have copper bus bars to facilitate the connection with conductors and prevent
deterioration produced by repeated connecting.
Depending on the options selected, sockets may or may not have individual protection, which is distinguished from
the general unit protection by the use of an individual circuit breaker for each socket.
Portable units are defined as those moved to different work sites at least twice yearly.

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5.- STARTING AND STOPPING THE UNIT
4.3.- STORAGE
If you think your generator will be inactive for a long period of time, follow these instructions:
1) Press STOP on the control module.
2) Press the emergency stop button to avoid future involuntary startups when connecting.
3) Empty the fuel tank. Make sure the internal protection valve is in the correct position.
4) Leave the battery disconnected.
5) Avoid storing the unit in areas with high dust accumulation or excessive moisture.
6) Do not use pressurized water when cleaning the unit.
7) Check your engine manual for care instructions; the manual has been provided along with this booklet.
8) F or alternator care instructions, please check your alternator’s manual, which has been provided along with
the document you are now reading.
To start up the electrical generator, follow the steps listed below:
1) Check the levels of oil, coolant and fuel.
2) Close the battery isolator.
3) Release the emergency shutoff switch if it has been pressed.
4) Check the electrical generator’s automatic switch (levers should be in the lowered position).
5) T o perform the startup of your electrical generator, please refer to point 6 - OPERATION MANUAL, taking
into account the control panel model of your unit.
6) Once the unit has been started, connect the electrical generator’s automatic switch.
7) Make sure the earth leakage circuit breaker (ELCB) is functioning properly by pressing the TEST button.
8) Turn on the electromagnetic circuit breaker once again and use the electrical generator normally.
To stop the unit:
1) Disconnect the loads.
2) Turn off the electromagnetic circuit breaker.
3) Leave the engine running at no load for 2 minutes to cool down the generator unit.
4) Stop the engine completely by switching the control module switch to the OFF position.

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6.- OPERATION MANUAL
The generator you purchased has been designed for manual service and thus starting and stopping the unit will be
done manually.
The following is a description of the different elements, according to the electrical generator chosen.
6.1.- ELECTRICAL PANEL COMPONENTS
AAMMETER:
Measures the Intensity (A), by means of a switch, of the different phases of the electrical generator.
Hz FREQUENCY METER:
Indicates the Frequency of the electrical generator (Hz).
VVOLTMETER WITH ATS:
Indicates the Voltage (V), by means of a switch, of the different phases of the electrical generator.
HOUR METER:
ndicates number of hours worked by the electrical generator.
The two digits in red on the right indicate hundredths of hours. Hours are indicated in white from the third
digit on.
HORAS

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EARTH LEAKAGE CIRCUIT BREAKER (ELCB):
Protection against earth leakage of one phase, setting off the electrical generator’s primary protection switch.
Configured to be activated when voltage is exceeded by 3 mA, with a time delay of 0s.
Includes a TEST button for checking the state of the ELCB.
It is the installer’s responsibility to adjust and seal the ELCB according to the current regulations.
GAUGES INDICATING ENGINE PARAMETERS:
Oil pressure.
Intensity of battery voltage.
Engine temperature.
Fuel level.
DIAGNOSTIC BUTTON:
A llows engine parameters to be checked when electrical generator is stopped (electronically controlled
engines). Also gives a readout of the generator’s different alarms.
EMERGENCY STOP BUTTON:
Pressing this button brings the electrical generator to an immediate stop. To cancel, turn to the left, when the
end of the emergency situation has been confirmed.
On soundproofed units the emergency stop button is installed apart from the electrical panel (built into the
canopy).

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6.2.- GPM-2 ANALOG CONTROL MODULE
Image 10 - GPM-2 CONTROL MODULE
1
2
3
4
5
6
7
15
8
9
10
11
1213141617

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NUMBER SYMBOL DESCRIPTION IDENTIFICATION
1
Unit startup failure /
alternator failure.
Flashing red light: three failed startup
attempts .
Continuous red light: voltage failure
or low frequency.
2
Battery charge alternator
failure.
Flashing red light: battery charge
alternator failure .
Continuous red light (unit stopped):
indicates contact.
3
Low oil level.
Flashing red light: low oil level.
Continuous red light (unit stopped):
indicates contact.
4
Low level / high coolant
temperature.
Flashing red light: high temperature.
Continuous red light: low coolant level .
5
Overload. Flashing red light: unit overload.
6
Low fuel level.
Red: low fuel level.
(Continuous/flashing red light:
stopped/warning) .
7Emergency stop / overspeed
.
Flashing red light: emergency stop.
Continuous red light: engine
overspeed.
8
Remote startup mode. Green LED.
9Unit heating.
Yellow LED.
10
Stop signal. F
lashing red light: imminent stoppage.
Continuous red light: stop command.
11
Maintenance signal.
F lashing blue: see maintenance
section.
12
Maintenance reset button . Button.
13
Unit startup button. Button.
14
Manual mode. MAN
15
Key position for stopping
unit.
STOP
16
Automatic mode. AUTO
17
Programmable alarm.
Flashing or continuous red light;
user-defined.
AUTO
TEST
STOP
Fuel
T
he GPM-2 control module has three positions: STOP, automatic (AUTO) and manual
(
MAN). Key selectable (numbers 14 through 16 of the descriptive chart for the control
module).