Mase IS3501 User manual

IS3501
IS5501
#11501
INSTALLATION
MANUAL

Fig. 1
IS 3501
IS5501
THE WARRANTY MAY BE VOIDED IF THE
SPECIFICATIONS CONTAINED IN THE
FOLLOWING INSTALLATION MANUAL ARE NOT
FOLLOWED
E
1.1 Installation space requirements .........................3
1.2 Fastening the unit ..............................................3
1.3 Ventilation .......................................................... 3
2.1. Raw water feed system ..................................... 3
2.2 Typical installation with electric generator
above the water-line .......................................... 5
2.3. Typical installation with electric generator
below the water-line ........................................... 5
2.4. Components ...................................................... 7
2.5. Drainage system ............................................... 8
3.0 Fuel circuit ......................................................... 8
4.1. Battery connection ............................................. 9
4.2. Control panel connection ................................... 9
4.3. A.C. Connection .............................................. 10
4.4. Generator - Main Switching ............................. 10
INSTALLATION1
2COOLING WATER CIRCUIT
3
FUEL CIRCUIT
ELECTRICAL CONNECTION
44
44
4
2

1.0. INSTALLATION
1.1. Installation space requirements
The generator must be installed in a space sufficient to
supply the necessary air for combustion of the engine.
The air needed for combustion is taken in through the
opening on the base so care must be taken to ensure that
this opening is not obstructed.
The space must be separate and acoustically insulated
from living areas.
The generator should be positioned so normal
maintenance operations can easily be carried out.
1.2. Fastening the unit
To fasten the unit securely, a base should be installed to
absorb vibrations and support the weight.
Drill holes in the base according to the instructions in
fig. 1.
1.3. Ventilation
The generator is equipped with an internal forced cooling
system through a water/air exchanger.
The air needed for combustion is taken in through the
opening on the base (fig. 2) so care must be taken to
ensure that this opening is not obstructed.
2.0. COOLING WATER CIRCUIT
The IS3501 and IS5501 motor is cooled by an open-
circuit system in which sea water circulates.
The capacity of the sea water circuit is 238 gal./h (IS
3501) and 317 gal./h (IS 5501).
During installation, a raw water feed circuit and a wet
exhaust manifold should be fitted to expel the mixture of
gas and water.
2.1. Raw water feed system
Boats usually use one of two systems to collect water
(fig. 3):
1- Direct infeed system
2- System with baffle
MASE recommends the direct infeed system ref. 1 fig. 3
since this system prevents water entering under pressure.
Fig. 2
12
Fig. 3
3

IMPORTANT
Do not apply any type of external sea strainer over
the raw water pick-up.
THE DIRECT INFEED SYSTEM SUPPLIED BY MASE
HAS BEEN MODIFIED TO PREVENT SOLID OBJECTS
FROM ENTERING AND BLOCKING THE SYSTEM.
IF A NON-MASE COMPONENT IS USED, MORE CARE
AND MORE FREQUENT CLEANING IS NECESSARY.
The baffle system might cause the following problems:
a- If it is installed with the slots facing the bow:
In this case, during navigation and with the electric
generator off, pressure is accumulated in the water
infeed duct which might cause the system to fill up,
even as far as the exhaust port, allowing water to
enter the cylinders.
b- If it is installed with the slots facing the stern:
In this case a depression might accumulate in the
water infeed duct during navigation, preventing the
water pump from starting up the cooling plant, or
limiting the capacity and subsequently causing the
electric generator to overheat.
4

2.2. Typical installation with electric generator
above the water-line (fig. 4)
1Raw water intake
2Intake valve
3Valve to drain system
4Water filter
5Electric generator
6Muffler
7Silencer
8Exhaust through-hull
9Water line
IMPORTANT
A- Hose - internal diameter 45 mm (1.77")
B- Hose - internal diameter 15 mm (.59")
C- Clamps
CAUTION
The measurements shown in fig. 4-5 should
correspond exactly.
2.3. Typical installation with electric generator
below the water line (fig. 5)
1Raw water intake
2Intake valve
3Valve to drain system
4Water filter
5Anti-siphon valve
6Muffler
7Silencer
8Exhaust through-hull
9Water line
10 Anti-siphon drain
11 Drain mixer Exhaust manifold
12 Water pump
13 Electric generator
Fig. 5
5
Fig. 4
MAX. 40"
MAX. 40"
MAX. 40"
MIN. 12"
MIN. 8"
MAX. 40"
MAX. 80"
MAX. 40"
MAX. 40"
MIN. 20"
MIN. 8" MIN. 12"
MAX. 80"

1
Fig. 6
Fig. 7
Fig. 8
Anti-siphon valve
Exhaust manifold Water pump
Fig. 9
ANTI-SIPHON
VALVE
6

1Diesel return
2Diesel
Fig. 10
2
2.4. Components
1- Raw water intake 1/2"
IMPORTANT
If the unit is installed more than 40" above the water-
line, a check valve should be fitted after the sea
intake (fig. 6, ref. 1) to prevent the raw water circuit
emptying when the motor is off. If this empties, the
rotor of the water pump might be damaged during
start up; for the same reason, when the unit is first
started up, the suction tube from the valve to the
pump should be filled manually.
2- Ball tap (general) 1/2"
3- Ball tap (drainage) 1/2"
This is used to drain the cooling system of the electric
generator for general maintenance or when a long
period of inactivity is expected.
4- Water filter (can be inspected)
This must provide efficient protection for the cooling
circuit from the entrance of mud, sand and seaweed.
IMPORTANT
The filter mesh should be very fine. Mesh 2 - 470
micron is recommended, other sizes do not give
good filter performance.
5- Anti-siphon valve: this valve returns the cooling
circuit to atmospheric pressure when the motor is
switched off to prevent the siphoning when the
generator is installed at or below the waterline. It
should be positioned at least 20" above water
level.(see fig. 8/9)
IMPORTANT
The drainage hose of the anti-siphon valve must
run beneath the valve itself in order to prevent
water accumulating in the hose, which should
always remain empty to allow air to pass through
when the unit is switched off. (see fig. 7)
Note: The drainage hose should be routed into the bilge
because during normal operation small quantities of water
may leak from the hose.
The box already includes 2 holes to connect the anti-siphon
valve (fig. 9).
1
7

2.5. Drainage system
The exhaust system of the generator must be separate
from that of the main engine(s)
IMPORTANT
The length of the hose from the highest point of
the drain duct to the muffler should not exceed
80". This is to prevent the water left in the
drainage hose returning to the motor after filling
the water lock muffler, when the unit is turned off.
1- Water lock muffler (capacity .9 gal)
This dampens the noise of the drainage and stops
the water flowing back towards the motor. The
muffler should be installed no less than 40" from the
generator and positioned below or equal to the base
plate of the generator.
2- Silencer
This further reduces noise. It should be installed no
more than 40" from the exhaust through-hull.
3- Exhaust through-hull should be installed so that it is
always above the water line.
.
3.0. FUEL CIRCUIT
The unit is fed by diesel fuel through the tubes marked
“DIESEL” and “DIESEL RETURN” (fig. 10, ref. 1-2). The
latter is used for the return of the excess fuel. It is
necessary to install a filter in the feed line connected
to the fuel tank, it is also advisable to fit a tap onto the
power supply line downstream of the tank and a single-
acting valve (check valve only for a difference in height
of 20" or more) to prevent the fuel system emptying for
any reason. Use a valve with a 50 millibar opening.
The fuel lines should be diesel fuel-resistant rubber, of
inner diameter 6 mm.
IMPORTANT
The genset has an automatic diesel fuel drainage
system. If manual priming is necessary, press the
"ON" button for 30 seconds before starting.
IMPORTANT
The fuel filter must be a "cartridge-type" with a
filtering grade of 5 to 10 micron
3
1
2
Fig.12
Fig.11
IS3501
IS 5501
9X 0.35 mm
1 BROWN
2 WHITE
3 BLUE
4 GREY
5 GREEN
6 PINK
7 YELLOW
8 BLACK
9 RED
GROUND
CONTROL PANEL CONNECTION
PRINTED CIRCUIT
NUMBER COLOR
Fig. 13
8

1
1
3
4
5
2
Fig.14
Fig.15
Fig.17
Fig.16
4.0. ELECTRICAL CONNECTIONS
4.1. Battery connection
To start the genset, an independent 12V battery, 18 - 30
capacity Ah min is needed.
It should be connected to the generator as shown in fig.
11 with cables up to 16'. For longer distances, follow the
sequence of operations described below:
- First connect the positive pole (+) of the battery to the
terminal marked with the symbol (+) on the generator,
(the starter).
- Then connect the negative pole (-) of the battery to the
terminal marked with the symbol (-) on the generator.
- Apply non-conductive grease to the connections to
protect against oxidation and corrosion.
- The generator has a built-in 10A charging circuit to
automatically recharge the start-up battery, giving
10 A, at a voltage of 12 V, when fully charged.
IMPORTANT
Install the battery in a well-ventilated area, away
from the generator and from any device which might
produce heat or sparks.
Periodically check the state of the connections of
the terminals and the water level of the battery. If the
cables need to be disconnected, follow the
instructions for connection in reverse order.
Do not invert the poles of the connecting cables
since serious damage might be caused to the
generator and the battery.
Do not connect other loads to the battery.
In order to minimize galvanic currents, the (-) of the
battery of the electric generator should not be connected
to the (-) of the other batteries on board.
4.2. Control panel connection
This connection can be made with the terminal strips (fig.
12, ref. 1) using the cables already connected to the
control panel. The terminals to be used are those marked
1 to 9 for the control cables. The ground should be
connected to the push-on terminal (fig. 12, ref. 3) insulating
them carefully and using a pre-insulated female push-on
connection. In making the connections it is important to
follow the diagram and the colours codes as indicate (fig.
13). Fasten the cable with the provided plastic support on
the bail (fig. 12, ref. 3).
The control panel contains 5 LEDs for operation and
alarm (fig. 14, ref. 1), an hour counter (fig. 14, ref. 2) and
the start and stop buttons (fig. 14, ref. 3/4/5).
For fixing the control panel is necessary to perforate as
shown in fig.14.
9
5-1/32"
4-3/4"
3-3/8"

IMPORTANT
The control panel is necessary for operating the unit
and must be installed; use of a non-Mase control
panel could present compatibity problems.
Make the connections with the battery disconnected.
CAUTION
The control panel is provided with a connecting
cable 10 metres long. This cable should not be
modified since it might cause the panel circuit to
function incorrectly.
4.3. A.C. Connection
This connection can be done through the power terminal
board (fig. 15, ref. 1) on the circuit panel.
This range includes the possibility of use both at 120V
60Hz and 240V 60Hz.
For this reason it is possible to make two types of
connection (and use), according to the following
configurations.
1- Parallel configuration: in this configuration there is a
single output at 110 (120) V between points P1and
F2, connecting the outputs of the alternator (P1, F1,
P2, F2) as shown in the diagram in fig. 16.
2- Serial connection; in this configuration it is possible
to use a voltage of 220 (240) V between points P1and
F2, as shown in the diagram in fig. 17.
In serial connection, power can be picked up both at 110
(120) V between points F1- F2and P1- P2and at 220 (240)
V between points P1and F2at the same time, as shown
in the diagram in fig. 18.
It is also possible to feed two separate lines as shown in
fig. 19 on the outputs P1- F1and P2- F2.
Note: In this case the power which can be taken
from each of the two outputs is half the rated
nominal power.
IS5501
IS 3501
- Ensure that the sum of the loads to be supplied does
not exceed the nominal power of the electric generator.
- A circuit breaker should be placed between the
generator and electrical equipment, according to the
tables shown below.
- To make both parallel and serial connections, use the
special bridges provided in the accessories to the
electric generator on the terminal board fig. 15 ref. 1.
Single voltage distribution
Note: In these cases just one circuit breaker
should be installed, see fig. 16/17.
Double voltage distribution
Note: In these cases two circuit breakers should be installed, see
fig. 18/19, sizedon the current values (A) shown in Table. 2.
4.4. Generator - Main switching
A switch should be placed in-line to switch power source
from generators to shore. The switch should be sized
according to the size of the loads: a general diagram is
shown in fig. 20.
IS 3501 IS5501
Hz 60 60
V120/240 120/240
W2900 4800
A12.1 20
Hz 60 60
V120 240
W. 2900 2900
A24.2 12.1
Hz 60 60
V120 240
W. 4800 4800
A40 20
10

Fig.18
Fig.19
LOAD
LOAD
MAIN
LOAD
Fig.20
IS 3501 IS5501
Hz 60 60
V120/240 120/240
W2900 4800
A12.1 20
IS5501
IS 3501
Hz 60 60
V120 240
W. 2900 2900
Hz 60 60
V120 240
W. 4800 4800
A40 20
A24.2 12.1
11