Mase IS3501 User manual

IS3501 &
IS5501
#16501
USAGE AND MAINTANENCE
MANUAL

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WIRING DIAGRAM
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CONTENTS
FIGURES ............................................................... page 2
TAB."A" TABLE SUGGESTED OILS...................... page 2
WIRING DIAGRAM ................................................ page 4
1SAFETY REGULATIONS ....................................... page 6
2PRELIMINARY CHECKS ....................................... page 6
3GENERATOR USE ................................................ page 6
Starting
Generator Stop
4SAFETY DEVICES ................................................ page 6
Low oil pressure device
Warning
High temperature device
Alternator overload/over temperature device
5MAINTENANCE ..................................................... page 7
Engine maintenance
6INACTIVE PERIOD ................................................ page 7
7CONTROL PANEL ................................................. page 7
8PROTECTIONFUSE .............................................. page 8
9DIMENSION AND WEIGHT .................................... page 8
10 WIRING DIAGRAM DESCRIPTIONS ...................... page 8
11 MAINTENANCE CHART ......................................... page 8
12 TROUBLESHOOTING ........................................... page 8
13 TECHNICAL FEATURES ....................................... page 9
DANGER
WARNING
CAUTION
INFORMATION
Indicates that significant attention must be paid in order to prevent serious danger which
could lead to injury or death.
A condition which may occur during the lifetime of a product, system or plant that has
the potential for human injury, damage to property, damage to the environment, or economic loss.
Indicates that particular attention must be paid in order to prevent serious damage to the
product or other property.
General helpful information
Note: the information contained in this publication is correct at the time of printing. The manufacturer may make
regular improvements and upgrades to the product which are not reflected in the illustrations.
The drawings in this manual are provided as examples of generic installations. Even if your installation differs
considerably from the illustrations contained in this manual, the drawings should still provide you with general
guideline and principles of a proper installation.
5

MASEGENERATORS
This manual contains necessary information for proper
maintenence and use of the generator. It is essential for
your safety and the reliability of the generator, to carry out
proper installation and careful pre-delivery tests.
An error in installation or an oversight in testing may
compromise the efficiency of the generator and even
jeopardize your safety.
All information and illustrations in this handbook refer to
the latest produced model at the time of printing.
For any further information, please get in touch with your
nearest Mase dealer.
Mase reserves the right to introduce changes without
prior notice. No part or illustration contained in this
handbook can be reproduced without previous approval
by Mase
1. SAFETY REGULATIONS
- Carefully read all the instructions in this manual and in
the installation manual; they are very important for correct
installation and use of the unit.
- Do not allow unskilled or untrained people to use the
unit.
- Do not allow children or animals to get close to the
generator while it is operating.
- Do not handle the generator or the remote control panel
with wet hands; any misuse may cause electric shocks.
- Any testing of the unit is to be carried out only when the
engine is stopped. Possible checks on the generator
when it’s running must be performed only by skilled
personnel.
2. PRELIMINARY CHECKS
When starting the generator for the first time and after any
servicing, it is advisable to make sure that:
- The oil is at the right level through the dipstick ref. 1 Fig.
1 , as per table for suggested oils.
- The generator is well secured to the soundproofing box
with the proper bolts.
- The electric loads are disconnected so as to avoid
starting the generator under load.
- Every connection (fuel, exhaust, remote control, A.C.,
battery) has been properly carried out and there are no
bad connections.
- The sea cock is open, as per (ref. 2 fig. 2)
- If a non-return valve is used, the cooling circuit from the
valve up to the pump must be manually filled (ref. 1 fig. 2)
3. GENERATOR USE
Before starting the generator, make sure all preliminary
checks, as per section 1 , have been properly performed.
Starting
To start the engine, push the button << ON >> (fig. 3 ref.
4), all the pilot and warning lamps will glow for 5 sec. as
a self -check function. Afterwards the << panel on >> will
stay lighted (fig. 3 ref. 5). Start the engine by pushing the
<<Start >> button (fig. 3 ref.3), for 5 sec. max. Release
it only when the engine runs. During proper genset
operation, the led will (fig .3 ref. 6) glow. Once started, the
safety shut-downs on the generator are automaticily
activated (see item. 4).
Generator Stop
The generator can be stopped by pushing the <<OFF>>
button on the control panel (fig. 3 ref 2).
4. SAFETY DEVICES
The generator is equipped with a set of safety shut-downs
in case of any misuse or running problems:
- Low oil-pressure device:
shuts down the generator in case of insufficient oil
pressure. Its intervention is shown by the warning light
going on (fig. 3 Ref. 7). It is usually enough to top off the
oil before starting the generator again.
The low oil-pressure device does not necessarily show
the oil level; a check of the oil level is consequently
necessary at regular intervals.
-High temperature shut-down:
shuts down the generator in case of high engine
temperature. Its intervention is shown by the warning light
going on (fig.3 ref.8).Should this device illuminate, refer
to the troubleshooting charts in Section 11 & 12 of this
manual, eliminate the cause(s) of the shut-down, then
restart the generator.
-Alternator overload/over temperature shut-down:
shuts down the generator in case of thermo or electric
overload of the alternator.
Should this warning light illuminate, (fig. 3 ref. 9), wait
until the temperature of the alternator windings returns to
normal. However, it is recommended to refer to the
troubleshooting charts in Section 11 & 12 of this manual
and eliminate the cause(s) of the shut-down, then restart
the generator.
If one of the above safety devices intervenes refer to the
troubleshooting charts in Section 11 & 12 of this manual,
look for and eliminate the cause(s), then push the <<
STOP >> button to reset the panel.
WARNING
WARNING
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WARNING
INFORMATION
7. CONTROL PANEL (fig. 3)
1)HOURMETER
2) OFF BUTTON
3) START BUTTON
4)ONBUTTON
5) PANEL ON LED (GREEN)
6) GENERATOR OUTPUT LED (GREEN)
7) OIL PRESSURE LED (RED)
8) ENGINE TEMPERATURE LED (RED)
9) GENERATOR TEMPERATURE LED (RED)
If the unit stops because the circuit breaker trips, the
operating time indication disappears from the control panel
display and a code appears to indicate the cause of the
generator shut-down.
The table below lists the codes and their meanings.
ALARM CODES
CODE CAUSE OF CIRCUIT-BREAKER TRIP
E - 80 No power on generator
E - 81 Low oil pressure
E - 82 High motor temperature
E - 83 High alternator temperature
E - 85 Generator overload
E - 87 At 30sec. from start unit does not
reach 80% of nominal voltage
batt Low battery
Code E - 80 This code indicates the unit has stopped
because of no voltage. When this code appears, it
means:
- the control panel is unable to measure the alternator
voltage for cut-off of an electrical connection;
- the alternator is damaged.
Code E - 81 This code indicates the unit has
stopped because the motor lubrication system pressure
is insufficient.
Code E - 82 This code indicates the unit has
stopped because the engine has reached too high a
temperature.
Code E - 83 This code indicates the unit has
stopped because the alternator has reached too high a
temperature.
In case the two fuses (ref.1/2 Fig.4) have blown,
the generator will not start.
5. MAINTENANCE
Any servicing must be performed with the engine stopped,
and only by skilled and licensed staff.
Engine maintenance
The engine must be serviced at regular intervals as shown
in the table in Section 11 of this manual. For further and
more detailed information, please consult the Yanmar
handbook supplied by the engine manufacturer,
accompanying this generator.
Check oil level with the proper dipstick (fig. 5 ref. 1) and
make sure it is always in the minimum and maximum
range of the dipstick.
Engine oil capacity:
IS 3501 1.2 qt. IS 5501 1.7 qt.
Oil changing and filling can be carried out through the
valve on the side of the sump pump. (fig. 1 ref. 1).
We suggest to carry out the draining when the oil is still
warm enough to allow easy flow.
Beforeperformingmaintenanceon the water-air exchanger
(ref. 3 fig. 6), it is necessary to empty the water intake
circuit through the special valve.(ref. 3 fig. 2)
6. INACTIVE PERIOD
Should the unit go unused for a long time, it is necessary
perform the following maintenance.
- Replace sump oil.
- Replace oil filter.
- Replace fuel filter.
- Replace the zinc anodes (ref. 1 fig. 6)
- If the generator room temperature is near or below 32°C
drain the engine cooling circuit using the drain valve (ref.
3 fig. 2)
- Lubricate the water pump impeller.
CAUTION
INFORMATION
7

Code E - 85 This code indicates the unit has
stopped because the voltage has dropped to below 70%
of the nominal value for longer than 15 seconds.
Code E - 87 This code indicates the unit has
stopped because the generator voltage has not reached
80% of the nominal value 30 seconds after starting. This
could be caused by insufficient motor RPM or a broken
alternator.
batt This code indicates the battery is low.
When this code appears, the generator is not stopped.
When a circuit breaker has tripped and the generator
has stopped, the panel must be reset by pressing the
“OFF” button in order to restart the unit.
If the unit is started and the alternator does not produce
voltage, or the control panel does not read voltage, the
control panel switches off completely after one minute,
stopping the unit.
8. PROTECTION FUSE ( fig. 4 )
1)RELAYCIRCUITFUSE
2)BATTERY CHARGER FUSE
9. DIMENSIONS AND WEIGHT( fig. 7 )
IS 3501 IS 5501
L)Length 26-1/4" 28-7/8"
W) Width 18" 20-1/2"
H)Height 23-1/2" 24-5/8"
Weight 211lb 286lb
10. DESCRIPTION WIRING DIAGRAM (fig. 8 )
1ROTOR
2STATOR
3DIODE 3A
4VARISTOR
5PRINTED CIRCUIT RELAY
6POWER TERMINAL BOARD
7RELAY CIRCUIT TERMINAL BOARD
8CONTROLPANEL TERMINAL BOARD
9FUSE 1A
10 CAPACITOR
11 BATTERY CHARGER REGULATOR
12 FUSE 20A
13 STARTER
14 BATTERY
15 FUEL PUMP
16 FUEL SOLENOID
17 OIL PRESSURE SWITCH
18 OVERHEAD ENGINE THERMOSTAT
19 WATER TERMOSTAT
20 ALTERNATOR THERMOSTAT
11. MAINTENANCE CHART
12. TROUBLE SHOOTING
INFORMATION
WARNING
COMPLAINT
PROBABLE REASON
Defective starting buttons z
zz
z
Defective fuel solenoid z
zz
zz
zz
z
Defective battery Battery
cable section
z
zz
z
Defective starting motor z
zz
z
Piping fuel filter choked z
zz
zz
zz
z
12V circuit fuse z
zz
z
Avv./Ev.relay z
zz
z
Too much oil in crankcase zz
Safety device intervention z
zz
zz
Overload z
Defective governor linkage z
Worm valve guides z
Blocked valves z
zz
z
Worm cylinder and position rings z
Defective injector z
zz
zz
Defective injector pump z
zz
zzz z
Defective feeding pump z
zz
zz
BLACK SMOCKE START AND STOP UNSTABLE RUNNING DOES NOT START WHITE SMOCKE
C
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13. TECHNICAL FEATURES
BLA
IS3501
Engine
Model: Yanmar L70AE
Type: Diesel / 4-stroke
Cylinders: 1
Cylinder block material: Aluminium
Bore: 3.07"
Stroke: 2.44"
Displacement : 296cc
Power @ 3600rpm: 6.7hp
RPM: 3600
Compression ratio: 20:1
Combustion system: Direct injection
Engine head material: Aluminium
Speed governor: Centrifugal mech
Lubrication system: Forced
Oil sump capacity with filter: 1.2qt.
Engine stop system: Fuel solenoid
Fuel pump: Electric
Fuel pump discharge: 2.3'
Fuel consump. @ full load: .396gal/hr
Air combustion requirement: 16.9cfm
Starting battery: 45Ah - 12V
Starter: 0.8kW - 12V
Max. inclination: 30°
Water pump flow: 4.4gal/min
Generator Ratings (@77o F)
Type: Synch., 2-poles, self-excited
Cooling: Air/water (Intercooler w/a)
Voltage: 120 - 240V
Nominal current: 26.6 - 13.3A
Frequency: 60Hz
Max. power: 3.2kW
Continuous power: 2.9kW
Battery charging output: 10A - 12V
Power factor (cos ø): 1
Insulating class: H
Voltage stability: ±10%
Frequency stability: ±5%
IS5501
Engine
Model: Yanmar L100AE
Type: Diesel / 4-stroke
Cylinders: 1
Cylinder block material: Aluminium
Bore: 3.38"
Stroke: 2.75"
Displacement : 406cc
Power @ 3600rpm: 10.0hp
RPM: 3600
Compression ratio: 20:1
Combustion system: Direct injection
Engine head material: Aluminium
Speed governor: Centrifugal mech.
Lubrication system: Forced
Oil sump capacity with filter: 1.7qt.
Engine stop system: Fuel solenoid
Fuel pump: Electric
Fuel pump discharge: 2.3'
Fuel consump. @ full load: .660gal/hr
Air combustion requirement: 23cfm
Starting battery: 45Ah - 12V
Starter: 0.8kW - 12V
Max. inclination: 30°
Water pump flow: 4.4gal/min
Generator Ratings (@77o F)
Type: Synch., 2-poles, self-excited
Cooling: Air/water (Intercooler w/a)
Voltage: 120 - 240V
Nominal current: 47.5 - 23.7A
Frequency: 60Hz
Max. power: 5.7kW
Continuous power: 4.8kW
Battery charging output: 10A - 12V
Power factor (cos ø): 1
Insulating class: H
Voltage stability: ±10%
Frequency stability: ±5%
IS
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