Gesan G 10000 V User manual

INSTRUCTION
MANUAL
MODELS:
G 3000 H
G 5000 H
G 7000 H
G 12000 H
G 5 TF H
G 7 TF H
G 12 TF H
G 3000 V
G 5000 V
G 7000 V
G 10000 V
G 12000 V
G 5 TF V
G 7 TF V
G 10 TF V
G 12 TF V

Generators sets GESAN
Petrol
Thank you for buying a GESAN generator set.
This manual has been written to assist you in maintaining and operating your generator set
correctly. Please read it carefully before putting the machine into operation so as to become
familiar with the precautions to be taken during use and be able to perform maintenance in ideal
conditions.
Please keep this manual at hand for consultation at all times and ensure it is included with the
machine should it be re-sold.
GRUPOS ELECTROGENOS GESAN, S.A. is constantly striving to improve its products, and
regularly introduces changes to the equipment it supplies. For this reason the characteristics
and information contained in this manual may be modified without prior notice and without
incurring any obligation.
If any problems or queries arise, please contact your distributor.

Generators sets GESAN
Petrol
INDEX:
• SAFETY PRECAUTIONS
• GENERAL DESCRIPTION
• CONTROL CARDS
• LABELS
• BEFORE OF OPERATION
• OPERATION
• HANDLING AND STORAGE
• MAINTENANCE
• WIRING DIAGRAMS
• TROUBLESHOOTING

Generators sets GESAN
Petrol
SAFETY INSTRUCTIONS
Please read carefully the following warnings for your own safety and the safety of others :
1. Make sure that the control panel is well lit if you run your generator set in poor lighting
conditions.
2. Make sure that you know how to stop the generator set in case of emergency and
familiarize yourself with its controls and power outlets.
Do not permit operation by someone unfamiliar with the generator set.
Do not let children operate the generator set without the help of an adult.
Children and pets must be kept at a safe distance from the engine, in order to avoid burns or
injury.
3. Carry out all necessary checks before starting the generator set in order to avoid accidents
or damage to the equipment.
4. Earth the generator set as well as the load properly.
5. Do not operate the generator set when it is raining or where there is snow. YOU MAY BE
ELECTROCUTED.
Do not get the generator set wet, or operate it with wet hands.
6. Do not connect the generator set to the mains. Connection should be carried out by a
qualified electrician in accordance with applicable standards and regulations.
A poorly made connection may cause current returns which could lead to the electrocution of
anybody working on the mains.
7.- The engine exhaust emits sufficient heat to set some substances on fire:
Ensure that the generator set operates at a safe distance from buildings and other equipment
(at least one metre).
Keep all inflammable substances away from the generator set.
Do not touch the engine or the exhaust pipe while the generator set is running. They can
cause serious burns.
Wait until the engine has cooled down before carrying out maintenance or storing it.
8. The fuel used is highly inflammable and volatile :
Ensure that the engine is not running when filling the fuel tank and that the premises are
sufficiently ventilated.
Do not get near flames or sparks while filling the fuel tank.
DO NOT SMOKE near the generator set.
Keep the generator set on a firm, level surface, otherwise fuel may spill and catch light.
Do not over-fill the fuel tank. After filling, ensure the fuel cap is properly closed.
Do not spill fuel when filling the tank. Fuel vapour or spilled fuel may catch light. If fuel is
spilled, ensure the area is dry before starting the engine.

Generators sets GESAN
Petrol
9. Exhaust fumes from the engine are poisonous:
Do not operate the generator set in a closed environment.
If operating the set in an enclosed space, provide adequate ventilation and direct the exhaust
fumes out of the area.
10. If the generator set operates in a place where damp and dust are unavoidable, it must be
dried and cleaned regularly.
11. At the slightest abnormality, stop and disconnect the set. Locate and correct the fault
before starting up again.
12. Regularly inspect all electrical cables. If damaged cables or hazardous connections are
found, stop the unit immediately and replace or correct the faulty cables before starting up
again.
13. Handle batteries with care. Batteries give off explosive gases; keep sparks, flames and
cigarettes well away. Provide adequate ventilation when charging or using batteries in enclosed
space.
Batteries contain sulphuric acid (electrolyte). Contact with the skin or eyes can cause severe
burning. Wear protective clothing and a protective mask.
- If electrolyte comes into contact with skin, wash with water.
- If electrolyte comes into contact with eyes, wash eyes with water for at least 15
minutes and seek medical assistance immediately.
Electrolyte is poisonous. If you swallow it, drink large amounts of water or milk, and follow with
milk of magnesia or vegetable oil and seek medical assistance.
Use only distilled water in batteries. Tap water will shorten battery life. If the battery is filled
above the maximum level the electrolyte will overflow causing corrosion of the engine or
adjacent parts. Clean away electrolyte which has been spilled.
14. Used oil can cause skin cancer in cases of prolonged and frequent contact. Although this
is unlikely, washing your hands after contact with used motor oil is recommended.
KEEP OUT OF THE REACH OF CHIDREN.
Please refer also to the engine and alternator user’s manual.
For further information or enquiries please contact :
GRUPOS ELECTROGENOS GESAN S.A.
Polígono Malpica- Alfindén, c/ Encina, nº 8
50171 La Puebla de Alfindén (Zaragoza)
SPAIN
Phone [phone] Fax [phone]

Generators sets GESAN
Petrol
GENERAL DESCRIPTION
STATIONARY
MOBILE

Generators sets GESAN
Petrol
TEST+SERV.-2
TEST
AUTO
OFF/RESET
SERV.-1/START
M
A
N
SERV.-2/START
A
U
T
O
Vac
SERV.-1
Vac Hz
SERV.-2
CONTROL CARD GECO
GECO is an AUTOMATIC CONTROLLER designed to start, control and monitor generator sets
in mains failure situations, and can be used with both 12 and 24 VDC batteries.
OPERATION
GECO can be switched to any one of six different operational modes:
AUTOMATIC
If mains is O.K. the mains light will be illuminated and the mains contactor will be
connected.
The mains contactor and load supplied lights will also be on.
If the mains fails and generator parameters are O.K., the generator lights
will come on.
Three seconds later the mains contactor will open and the generator contactor will close.
The lights will illuminate.
Up to three 20 second starting attempts are possible, with a 10 second pause between each
attempt. If after three attempts the generator has not started, the “Fail to Start” light
will illuminate and the hooter will sound (2 min.).
The start-up signal will cut out when the controller recieves the engine running signal, either by
detecting generator frequency >20Hz or by receiving positive battery current through terminal 4.
When mains returns, after a 60 second delay, the load will be transferred back to mains and the
generator will idle for 2 minutes then shut down.

Generators sets GESAN
Petrol
TEST+SERV.-2
SERV.-1
SERV.-1
TEST
SERV.-1
SERV.-1/START SERV.-2/START OFF/RESET
SERV.-2
OVERRIDE MAINS (AUTOMATIC MODE): Light off. Current is supplied by
generator.
OVERRIDE GENERATOR (AUTOMATIC MODE): Light on. Generator will not
start on mains failure.
TEST
Works as TEST WITH LOAD, but the load is not transferred to the generator. If the mains
should fail while in this mode, the load will automatically be transferred to the generator. The
test finishes when the controller is switched to any other mode.
TEST WITH LOAD
Works as AUTOMATIC by simulating a mains failure and transferring the load to the generator.
When the controller is switched to any other position, and if mains is O.K., the load will be
returned to mains.
MANUAL
OFF/RESET
Shuts down the generator and cancels all alarm signals (mains contactor closed). The
lamp lights up.
SERV 1 / START
The load is supplied by the mains (mains contactor closed) and the lamp lights up.
The generator starts and runs manually. Alarm signals work automatically.
SERV 2/ START
Generator starts and runs manually (generator contactor closed). The lamp lights
up.
Alarm signals work automatically.
STOP
Emergency stop. If not switched to OFF the mains contactor closes and the lamp
lights up.
The hooter sounds and the lamp lights up.
ALARM SIGNALS:
FAIL TO START/EMERGENCY STOP/GENERATOR FAIL failure/running
The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.
LOW OIL PRESSUREoil pressure
The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.

Generators sets GESAN
Petrol
BAT
HIGH WATER TEMPERATURE / WATER /
The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.
OVERLOAD
The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.
LOW FUEL LEVEL
The lamp lights up and the hooter sounds. Resets automatically when the fuel tank is refilled.
BATTERY CHARGER:
GECO features a 2 Amp automatic battery charger which is fed by an external transformer.
If battery voltage is O.K. the light will be on.
While the battery is being charged the light will be on continuously and when
the
floating voltage is reached the light will flash.
POTENTIOMETERS
Factory adjusted values
Potentiometer 1: Adjusts generator voltage monitor. 200-250 V.
Potentiometer 2: Adjusts generator frequency. 48-54 Hz.
Potentiometer 3: Adjusts min. mains voltage monitor. 200V.
Potentiometer 4: Adjusts battery charge voltage. 13.8(12VDC)/27.6(24VDC)
These potentiometers are adjusted at the factory to normal operating values.
SPECIFICATIONS
Mains failure-start delay: 3 sec.
Shutdown signal duration: 20 sec
Start-up impulse duration: 20 sec.
Generator alarm signal delay: 1 min
Pause between impulse duration: 10 sec
Running failure alarm signal delay: 3 sec
Generator contactor connection delay: 3 sec.
Max. battery charge current: 2 amp
Monitoring activation delay: 10 sec.
Max. hooter duration: 2 min.
Mains restored-transfer back delay: 1 min.
Number of start-up attempts: 3
Idling duration: 2 min.
Relay contacts rating: 8 amp

Generators sets GESAN
Petrol
Flow chart for o
p
eration of an emer
g
enc
y
automatic
g
enerator set

Generators sets GESAN
Petrol
LABELS
On your generator you will find the following labels:
LABEL 2
LABEL 3
(EARTH)
LABEL 4
(ELECTRICAL HAZARD)
LABEL 5
For your safety and the safety of the others, please replace immediately all these labels in case
of loss or damage.
LABEL 1
(UNDEFINED HAZARD)

Generators sets GESAN
Petrol
BEFORE OPERATION
(Please note that this section is valid for models DS170L, DS240L, DS240R and DS400L)
In order to carry out the maintenance checks stated below, please ensure that the unit is on a
flat and stable surface.
• RECOMMENDED OIL
Always choose the correct viscosity suited to the ambient temperature in which the unit will be
run.
From (4ºC) 40ºF……………………………………………………………….……………….…SAE 30
Between –18ºC (0ºF) and +4ºC (40ªF)……………………………………SAE 5W-30, SAE10W-30)
Below 4ºC (40ºF)……………………………………………………………..Synthetic 5W-20, 5W-30
If the temperature is above 4ºC (40ºF), multigrade oils (10W-30 etc) increase oil consumption
and can harm the engine. If using these types of oils, check the oil level ona more regular
basis.
If using oils SAE30 below 4ºC (40ºF), start up will be more difficult and can harm the engine due
to lack of lubrication.
WARNING!!!
Chosing the right oil is an important factor as it can affect the enigne’s life span and
performance.
Running the engine with too little oil can lead to serious damage.
Do not use non detergent or vegetable oils.
• CHECKING THE OIL LEVEL
a) Remove dipstick and wipe it clean.
b) Replace dipstick (See photo 1)
c) Remove the dipstick once again and check the oil level (The dipstick should be firmly
screwed to the tube whilst the engine is running)
d) If the oil level is too low, refill to the point marked on the dipstick and check once more. (See
photo 3)

Generators sets GESAN
Petrol
Photo 1 Photo 2 Photo 3
• RECOMMENDED FUEL
Use motor fuel.
WARNING!!!
*Do not mix oil with fuel which has already been used
*Do not let dirt or water enter the tank.
*Do not use fuel which contains alcohol.
NOTE: THE WARRANTY DOES NOT COVER ENGINE DAMAGE CAUSED BY THE USE OF
POOR QUALITY FUEL.
WARNING !!!
Fill the fuel tank where there is sufficient ventilation and with the engine is switched off.
Do not smoke or allow sparks or flames in the area where the engine is refuelled or where fuel
is stored.
Do not overfill the fuel tank and make sure that after pouring fuel, the fuel cap has been
screwed on properly.
Be careful not to spill fuel when refilling. Fuel vapour or spilled fuel may catch fire. In case of a
fuel spillage, make sure that the area is dry before starting the engine.
KEEP FUEL OUT OF THE REACH OF CHILDREN

Generators sets GESAN
Petrol
OPERATION
Once the engine is running, your GESAN generator set is ready to provide you with the energy
you require.
However, for your own safety and for the correct running of your generator set, please follow the
instructions set out below.
WARNING !!!
* Do not connect the generator set to the mains.
* Do not start the generator without checking that there is nothing connected to the output
sockets.
* Do not change the cable connections.
* Do not change the engine speed: The frequency and the voltage directly depend on the
rotation speed of the engine. This adjustment IS CARRIED OUT AT THE FACTORY.
MANIPULATING THE ACCELERATOR ON THE ENGINE ENTAILS THE LOSS OF THE
WARRANTY.
* Do not connect equipment using a voltage different from that supplied by the generator set.
* It is not advisable to use this generator set for equipment such as television sets, hi-fi
systems, computers, etc.
*If an electric welder is to be connected, please consult our engineers. Current peaks MAY
BURN OUT THE ALTERNATOR.
* Avoid overloads. The generator set is fitted with a circuit breaker. If the circuit breaker is set
off, ensure that the load is reduced before restarting the unit.
For problem-free operation remember that:
- The sum of the power ratings of the equipment connected to the generator set has to be
compatible with the characteristics shown at the end of this manual.
- Some apparatus (electric motors, air compressors, etc.) absorb power higher than their
nominal power rating when starting. Please consult your distributor in each case.
- Do not exceed the maximum current (Amps) values indicated for each output socket.

Generators sets GESAN
Petrol
COMMISSIONING
INSTALLATION
a) Place the machine on a firm, flat surface.
b) If the machine is to work outdoors, protect it against rain. Make sure the machine is running
in an environment where there is minimal damp and dust. Check that the exhaust is not
pointing at people.
c) If the machine is to run in an enclosed space, install a pipe of sufficient diameter to
evacuate exhaust fumes outside, where they will not endanger people. Make sure that the
machine is ventilated sufficiently for the engine to run.
d) Allow enough space for supervision, servicing and maintenance. We recommend that at
least 1 metre is left free around the machine.
CONNECTIONS
Open the control panel and connect the apparatus to be used to the terminals, then lift the
circuit breaker.
The terminals can also be connected to an external distribution box, to which the apparatus is
then connected.
DURING OPERATION
Make sure that the maximum power consumption is within the values shown in this manual, in
order to avoid alternator breakdown.
Check the fuel level from time to time to prevent the fuel circuit from emptying.
STARTING UP

Generators sets GESAN
Petrol
AUTOMATIC STARTING WITH GECO
These generator sets feature a set mounted terminal box and a control panel which may be
mounted on the set or separately if required. These generator sets may run both manually or
automatically.
1) Check that the switch on the control card is in the OFF position.
2) Following the wiring diagram supplied, wire up the terminal box to the control panel,
connecting both power cables and control cables.
3) Check that the circuit breaker inside the control panel is disconnected.
4) Check oil and radiator water levels. Fill if necessary.
5) Check fuel level.
6) Connect up the battery, first the positive terminal, then the negative terminal.
7) Connect the mains and check that the voltage indicator light is on.
8) Connect the circuit breaker or trip (lever up).
9) Turn the switch on the control card to the desired position:
STOPPING THE ENGINE
MANUALLY
Press button STOP of control card.
AUTOMATICALLY
If the bridge between terminals 1 and 2 is opened, first the generator contactor disconnects and
the engine stops one minute later.

Generators sets GESAN
Petrol
MANUAL START-UP
WARNING!!!
Check that nothing is connected to the generator set outputs
a) Open the fuel tap (1). Check the postion of idle cutoff where necessary.
b) For enines fitted with choke, pull the lever out.
c) Turn the engine knob to ON
d) Pull the starter grip smoothly out until a certain resistance is felt and then pull out hard.
e) For engines with choke, push the lever in.
(For automatic start or start up via signal, the choke is automatic)
ELECTRIC START:
WARNING!!!
a) Check that nothing is connected to the generator set outputs.
b)Turn the key to the contact position and start the engine by turning the key further to the right.
Once the welding set has started, release the key.
c) Open the fuel tap and check the idle cutoff where necessary.
d) For enines fitted with choke, pull the lever out.
e) Turn the engine knob to ON.
f)Turn the key to the contact point.
g) For engines fitted with choke push the lever in.

Generators sets GESAN
Petrol
NOTE: Do not use the electric starter for during more than 5 seconds at a time. If the engine
does not start up , release the key and wait ten seconds before trying again.
STOPPING THE ENGINE
MANUAL START UP
a) Disconnect all apparatus connected to the generator output.
b) Use the choke, where fitted.
c) Turn the engine knob to OFF.
d) Close the fuel tap.
ELECTRIC START
Stop the unit using the key, turning it to the left.

Generators sets GESAN
Petrol
HANDLING AND STORAGE
HANDLING
Depending on the chassis or baseframe, the generator set can be transported in different ways.
Generator sets with tubular chassis, should be transported using two slings tied to the chassis
as shown on the diagram in fig. 1 It is important that the slings are secured firmly to the chassis
and that they do not give.
For skid baseframes with a seat form should be loaded using the hook provided on the pole on
the upper part as shown in diagram fig.2.
jjjjkj
TRANSPORT
WARNING !!!
Before carrying the generator ensure that the battery is disconnected. Drain the fuel tank before
carrying the generator set.