Mase IS. 2.5 User manual

IS 2.5
Rev.2 11-02-02 M.C. cod. 41978
INSTALLATION MANUAL
masemase masemase
mase
GENERATORS

GENERATORS IS 2.5
- 2 -
12
Fig. 1
Fig. 2
Fig. 3
IS 2.5
A
BCDEF
510 334 396 127,5 260 122.5

- 3-
IS 2.5 GENERATORS
IMPORTANT
A- Tubes, internal diameter 45 mm
B- Tubes, internal diameter 15 mm
C- Clamps
CAUTION
The measurements shown in fig. 4 should
correspond exactly.
IMPORTANT.
A- Tuyauterie d'un diamètre interne de 45 mm.
B- TuyauterieencaoutchoucNèoprèned'undiamètre
interne de 15 mm.
C- Bagues de serrage.
ATTENTION
Il est très important de respecter les dimensions
indiquèes sur les figures 4
IMPORTANTE
A- Tubazione diam. 45 mm. interno.
B- Tubazione in neoprene diam. 15 mm interno.
C- Fascette di serraggio.
ATTENZIONE
E' molto importante rispettare le misure
riportate in fig. 4
BELANGRIJK
A - Slangen, inwendige diameter 45 mm.
B - Slangen, inwendige diameter 15 mm.
C - Slangenklemmen
LET OP
Maten zoals aangegeven in fig. 4 dienen
aangehouden te worden.
1Presa a mare
2Rubinetto genera acqua
3Rubinetto svuotamento impianto
4Filtro acqua
5Gruppo elettrogeno
6Marmitta
7Silenziatore
8Bocchettone scarico a mare
9Linea di galleggiamento
Sea intake Prise en mer
General tap-water Robinet gènèral de l’eau
Tap to drain system Robinet de vidage de l’installation
Water filter Filtrè à eau
Electric generator Groupe èletrogène
Mmuffler Pot
Silencer Silencieux
Sea drainage nozzle Goult dècharge en mer
Water line Ligne de flottaison
Huiddoorvoer
Huidafsluiter
Aftapkraan
Wierpot
Generator
Waterslot
Demper
Huiddoorvoer
Waterlijn
Fig. 4

GENERATORS IS 2.5
- 4 -
Fig. 5
1Presa a mare
2Rubinetto genera impianto
3Rubinetto svuotamento impianto
4Filtro acqua
5Vanvola antisifone
6Marmitta
7Silenziatore
8Bocchettone scarico a mare
9Linea di galleggiamento
10 Drenaggio
11 Miscelatore di scarico
12 Pompa acqua
13 Gruppo elettrogeno
Sea intake Prise en mer
General tap-systemr Robinet gènèral de l’eau
Tap to drain system Robinet de vidage de l’installation
Water filter Filtrè à eau
Anti-siphon valve Soupape antisiphon
Muffler Pot
Silencer Silencieux
Sea drainage nozzle Goult dècharge en mer
Water line Ligne de flottaison
Drainage Drainage
Drain mixer Mèlangeur de purge
Water pump Pompe à eau
Electric generator Goupe èletrogène
IMPORTANT
A- Tubes, internal diameter 45 mm
B- Tubes, internal diameter 15 mm
C- Clamps
CAUTION
The measurements shown in fig. 5 should
correspond exactly.
IMPORTANTE
A- Tubazione diam. 45 mm. interno.
B- Tubazione in neoprene diam. 15 mm interno.
C- Fascette di serraggio.
ATTENZIONE
E' molto importante rispettare le misure
riportate in fig. 5
IMPORTANT.
A- Tuyauterie d'un diamètre interne de 45 mm.
B- TuyauterieencaoutchoucNèoprèned'undiamètre
interne de 15 mm.
C- Bagues de serrage.
ATTENTION
Il est très important de respecter les dimensions
indiquèes sur les figures 5.
BELANGRIJK
A - Slangen, inwendige diameter 45 mm.
B - Slangen, inwendige diameter 15 mm.
C - Slangenklemmen
LET OP
Maten zoals aangegeven in fig. 5 dienen
aangehouden te worden.

- 5-
IS 2.5 GENERATORS
1
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Pompa acqua
Water pump
Pompe à l'eau
Waterpomp
1Ritorno gasolio •Diesel return • Retourn du gasoil
2Gasolio • Diesel • Gasoil Fig.10
Miscelatore di scarico
Drain mixer
Mèlangeur de purge
Waterinjectiebocht
VALVOLA ANTISIFONE
ANTI-SIPHON VALVE
SOUPAPE ANTISIPHON
BELUCHTER
Valvola antisifone
Anti-siphon valve
Soupape antisiphon
Beluchter
2
1

GENERATORS IS 2.5
- 6 -
Fig. 11
1
3
4
5
2
Fig. 14
Fig. 15
Fig. 12
9X 0,35 mm
1 MARRONE BROWN MARRON BRUIN
2 BIANCO WHITE BLANC WIT
3 BLUE BLUE BLUE BLAUW
4 GRIGIO GREY GRIS GRIJS
5 VERDE GREEN VERT GROEN
6 ROSA PINK ROSE ROZE
7 GIALLO YELLOW JAUNE GEEL
8 NERO BLACK NOIR ZWART
9 ROSSO RED ROUGE ROOD
CALZA EARTH CONDUCT. AFSCHERMINGS-
METALLICA BRAID MATALLIQUE KABE L
ALLACCIAMENTO CRUSCOTTO / C. PANEL CONNECTION
BRANCHEMENT / AANSLUITINGEN BEDIENINGSPANEEL
NUMERAZIONE
SCHEDA COMANDI
PRINTED CIRCUIT
NUMBERING
NUMERATION
CARTE COMMANDES
PRINTPLAAT
AANSULUITINGEN
COULER
COLOUR
COLORE
Fig. 13
KLEUR
1
2
3
1

- 7-
IS 2.5 GENERATORS
Fig. 17
Fig. 16
Fig.18
Fig. 19
Fig. 20
CARICO
LOAD
CHARGE
BELASTING
RETE
MAINS
RESEAU
WALAANSLUTING
CARICO
LOAD
CHARGE
BELASTING
CARICO
LOAD
CHARGE
BELASTING
115V
120V
230V
240V
230V
240V
115V
120V
115V
120V
115V
(120V)
115V
(120V)

- 13 -
IS 2.5 GENERATORS
INDEX GB
THE GUARANTEE OF THE PRODUCT BECOMES
VOID IF THE SPECIFICATIONS CONTAINED IN
THE FOLLOWING INSTALLATION MANUAL ARE
NOT RESPECTED
E
1.1 Characteristics of the installation space...........14
1.2 Fastening the unit to the ground ......................14
1.3 Ventilation........................................................14
2.1. Sea water feed system ....................................14
2.2 Typical installation with electric generator
above the water-line ........................................14
2.3. Typical installation with electric generator
below the water-line.........................................14
2.4. Components ....................................................15
2.5. Drainage system .............................................15
3.0 Fuel circuit .......................................................15
4.1. Battery connection...........................................16
4.2. Control panel connection .................................16
4.3. A.C. Connection ..............................................16
4.4. Generator - Mains Switching ...........................17
INSTALLATION1
2COOLING WATER CIRCUIT
3 FUEL CIRCUIT
ELECTRICAL CONNECTION4

GENERATORS IS 2.5
- 14 -
GB
1.0. INSTALLATION
1.1. Characteristics of the installation space
The generator must be installed in a sufficiently aired
space, supplying a little amount of air necessary for the
combustionof themotor.
The space must be separate and acoustically insulated
fromlivingareas.
The generator should be positioned so that normal
maintenanceoperations caneasilybe carriedout.
Propulsionmotorsarerecommendedforinstallationinthe
area as long as they comply with the above-mentioned
conditions.
1.2. Fastening the unit to the ground
Tofastentheunitsecurely,abaseshouldbeinstalledto
absorbvibrationsandsupporttheweight.
Drill holes in the base according to the instructions in
fig. 1.
1.3. Ventilation
Thegeneratorisequippedwithaninternalforcedcooling
systemthroughawater/airexchanger.
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 always free.
2.0. COOLINGWATERCIRCUIT
Inelectricgeneratorsdescribedinthismanual,themotor
is cooled by an open-circuit system in which sea water
circulates.
The capacity of the sea water circuit is 900 l/h (IS 2.5) .
Oninstallationaseawaterfeedcircuitshouldbefittedfor
cooling and a waste system to expel the mixture of flue
gasandwater.
2.1. Sea water feed system
Boats usually use one of two systems to collect water
(fig.3):
1- Direct infeedsystem
2- Systemwithbaffle
MASE recommend the direct infeed system ref. 1 fig. 3
sincethissystempreventswaterunderpressureentering
thesuctionductsandinsteadformsapressurewhichcan
easily be overcome by the water pump of the electric
generator.
IMPORTANT
Do not apply any type of protective hood to the
direct infeed system.
THE DIRECT INFEED SYSTEM SUPPLIED BY MASE
HAS BEEN MODIFIED TO PREVENT SOLID BODIES
ENTERING THE SYSTEM AND BLOCKING IT.
IFOTHERMATERIALSAVAILABLEONTHEMARKET
ARE USED, MORE CARE AND MORE FREQUENT
CLEANINGIS NECESSARY.
Thebafflesystemmightcause thefollowingproblems:
a- If it is installed with the slots facing the prow.
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,
evenasfarastheexhaustport,allowingwatertoenter
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
electricgeneratortooverheat.
2.2. Typical installation with electric generator
above the water-line (fig. 4)
2.3. Typical installation with electric generator
below the water line (fig. 5)

- 15 -
IS 2.5 GENERATORS
GB
2.4. Components
1- Direct sea intake 1/2"
IMPORTANT
If the unit is installed more than 1 metre above
the water-line, a check valve should be fitted after
the sea intake (fig. 6, ref. 1) to prevent the 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- Balltap(general)1/2"
3- Balltap(drainage)1/2"
Thisisusedtodrainthecoolingsystemoftheelectric
generator for general maintenance or when a long
period of inactivity is expected.
4- Waterfilter (canbe inspected)
Thismustprovideefficientprotectionfor thecooling
circuitfromtheentranceofmud,sandandseaweed.
IMPORTANT
The filter mesh should be very fine. Mesh 2 - 470
micron is recommended, other sizes do not give
good filter performance.
5- Anti-siphonvalve:thisvalvereturnsthecoolingcircuit
toatmosphericpressurewhenthemotorisswitched
off,topreventthesiphonphenomenon.
It must be installed when the generator is fitted
with the drainage mixer on or beneath the water
line, andshould bepositioned atleast50 cmabove
waterlevel.(seefig.8/9)
IMPORTANT
The drainage duct of the anti-siphon valve must
run beneath the valve itself in order to prevent
water accumulating in the duct, which should
always remain empty to allow air to pass through
when the unit is switched off. (see fig. 7)
N.B.: The drainage duct should be taken into the bilge because
duringnormaloperationsmallquantitiesofwatermightbeleaked
fromtheduct.
Theboxalreadyincludes2holestoconnecttheanti-siphonvalve
(fig. 9).
2.5. Drainagesystem
Thefluegas/waterdrainagesystemofthegeneratormust
be separate from that of the main motors
IMPORTANT
The length of the tube from the highest point of
the drain duct to the muffler should not exceed 2
metres. This is to prevent the water left in the
drainage duct returning to the motor after filling
the tank muffler, when the unit is turned off.
1- Tankmuffler(capacity3.5litres)
Thisdampensthenoiseofthedrainageandstopsthe
water flowing back towards the motor. The muffler
shouldbeinstallednolessthan1metreawayfromthe
generatorandpositionedataheightlessthanorequal
to that of the base plate of the generator.
2- Silencer
This further reduces noise. It should be installed no
morethan 1metre fromthe seadrainage nozzle.
3- Sea drainagenozzle; Itshould beinstalled so thatit
isalways abovethe waterline.
3.0. FUELCIRCUIT
The unit is fed by diesel fuel through the tubes marked
“DIESEL”and“DIESELRETURN”(fig.10,ref.1-2).This
latter is used for the return of the excess fuel. It is
necessarytoinstalla filterinconnectionstothefuel
tank,itisalsoadvisabletofitatapontothepowersupply
line downstream of the tank and a single-acting valve
(check valve only for a difference in height of 50 cm or
more)topreventthefuelsystememptyingforanyreason.
Useavalvewitha50millibaropening.
Thefuelpipesshouldbeinhydrocarbon-resistantrubber,
ofinner diameter6 mm.
IMPORTANT
The unit is fitted with automatic diesel oil
drainage. If manual drainge is necessary, press
the "ON" button and 30 second before set going
the unit.
IMPORTANT
The fuel filter must be a "cartridge-type" with a
filtering grade of 5 to 10 micron

GENERATORS IS 2.5
- 16 -
GB
4.0. ELECTRICALCONNECTIONS
4.1. Batteryconnection
To start off the unit an independent battery of 12V is
needed, capacity 18 - 30 Ah min.
It should be connected to the clamp of the generator as
shown in fig. 11 with cables of section 25 mm2up to
distancesof5metresandwithcablesofsection35mm2
for longer distances, and following the sequence of
operationsdescribedbelow:
- Firstconnect thepositivepole (+)ofthe batterytothe
terminalmarkedwiththesymbol(+)onthegenerator,
(thestarter).
- Thenconnectthenegativepole(-)ofthebatterytothe
terminalmarked withthesymbol(-)on thegenerator.
- Wipe the connections with special mineral grease to
protectagainstoxidationandcorrosion.
The generator includes an electronic device to
automaticallyrecharge the start-upbattery, giving10
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.
Inordertoreducegalvaniccurrentstoaminimum,the(-
) of the battery of the electric generator should not be
connected to the (-) ofthe other batterieson board.
4.2. Control panel connection
Thisconnectioncanbemadethroughtheterminalboards
(fig.12,ref.1)usingthecablesprovidedalreadyconnected
to the control panel. The terminals to be used are those
marked no. 1 to no. 9 for the control cables. The earths
braidshouldbeconnectedtothefastonterminal(fig.12,
ref.2)insulatingthemcarefullyandusingapre-insulated
female faston. 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).
Thecontrolpanelcontains5LEDsforoperationandalarm
(fig.14,ref.1),anhourcounter(fig.14,ref.2)andthestart
and stop buttons (fig. 14, ref. 3/4/5).
For fixing the control panel is necessary to perforate as
showninfig.14.
IMPORTANT
The control panel is indispensable for operating
the unit and must be installed; do not use devices
othet than the control panel supplied with the unit
since they might not be compatible with the
generator.
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
functionincorrectly.
4.3. A.C.Connection
Thisconnectioncanbedonethroughthepowerterminal
board(fig.15,ref. 1)placedinsidethederivationbox.
This range includes the possibility of use both at 115V
50Hz - 120V 60Hz and 230V 50Hz - 240V 60Hz.
For this reason it is possible to make two types of
connection (and use), according to the following
configurations.
1- Parallelconfiguration:inthisconfigurationthereisa
singleoutputat115(120)VbetweenpointsP1andF2,
connectingtheoutputsofthealternator(P1,F1,P2,F2)
as shown in the diagram in fig. 16.
2- Serial connection; in this configuration it is possible
touseavoltageof230(240)VbetweenpointsP1and
F2, as shown in the diagram in fig. 17.
Inserialconnection,powercanbepickedupbothat110
(120)VbetweenpointsF1-F2andP1-P2andat220(240)
V between points P1and F2at the same time, as shown
in the diagram in fig. 18.
Itisalsopossibletofeedtwoseparatelines asshownin
fig. 19 on the outputs P1- F1and P2- F2.

- 17 -
IS 2.5 GENERATORS
GB
N.B.Inthiscasethepowerwhichcanbetakenfromeachofthetwo
outputsishalftheratednominalpower.
- Ensurethatthesumoftheloadstobesupplieddoesnot
exceedthenominalpoweroftheelectric generator.
- A thermal switch is positioned on the alternator to
protectthealternatorfrom damagecausedbyshort-
circuitoroverload.
- Magnetothermicprotectivedevicesorsimilarshouldbe
placedbetweenthegeneratorandelectricalequipment,
accordingto the tablesshown below.
- Tomakeboth parallelandserial connections,usethe
special bridges provided in the accessories to the
electricgenerator onthe terminalboard fig.15ref. 1.
Single voltage distribution
N.B: In these cases just one magnetothermic device should be
installed,see fig. 16/17.
Double voltage distribution
N.B:Inthesecasestwomagnetothermicdevicesshouldbeinstalled,
see fig. 18/19, dimensioned on the current values (A) shown in
Table. 2.
IS 2.5
Hz 50
V
115/230
W1700
A
7.4
Hz 60
V
120/240
W1900
A
7.9
Hz 50 60 50 60
V115 120 230 240
W. 1700 1900 1700 1900
A14.8 15.8 7.4 7.9
TAB 1
IS 2.5
4.4. Generator - Mains switching
A switch should be placed on the line to switch the user
appliancesfromthegeneratortoanexternalpowerline.
Theswitchshouldbedimensionedaccordingtothesize
of the loads: a general diagram is shown in fig. 20.