Mase MPL 137 S User manual

MPL 137 S
MPL 143 S
Rev.0 A.A. 20 - 03 - 06
cod.42726
GRUPPO ELETTROGENO MANUALE DI USO E MANUTENZIONE I
Tipo modello
N° matricola
Codice
GENSET USE AND MAINTENANCE MANUAL GB
GROUPE ÉLECTROGÈNE MANUAL DE USO Y MANTENIMIENTO E
ELEKTROAGGREGATEBRAUCHSANWEISUNG UND
WARTUNGSVORSCHRIFTEN D

GB DEFINITIONSUSED................................................ 4
1 GENERALINFORMATIONS ............................ 6
1.1 Conformuse ................................................... 6
1.2 Residualrisks................................................. 6
1.3 Symbolsonthegeneratorgroup ..................... 7
1.4 Position of safety labels.................................. 8
1.5 Generaldangerinformation ........................... 10
1.5.1 Dangerofentanglement ................................ 10
1.5.2 Dangerofburns ............................................ 10
1.5.3 Dangerofharmtohearing............................. 11
1.5.4 Dangerofintoxication ................................... 11
1.5.5 Dangeroffireorexplosion ............................ 11
1.5.6 Dangeriffailingtousepersonalprotection
devices ......................................................... 11
1.5.7 Dangercausedbytheengine starting........... 12
1.5.8 Dangerofelectromagneticradiation.............. 12
1.5.9 Dangerofelectrocution ................................. 12
1.5.10Dangerresultingfrombadstorage ............... 12
1.6 Referencedocuments................................... 13
1.7 Referenceregulationsandlegislativeprovisions. 13
1.8 Marking ........................................................ 13
1.9 Identificationofthegeneratorunit ................. 13
2 GENERALCHARACTERISTICS .................... 14
2.1 Configurations............................................... 14
2.2 Compositionofgeneratorunit ....................... 14
2.3 Instrumentpanel........................................... 15
2.3.1 Differentialmagnetothermalpanelversion
(Optional)...................................................... 15
2.3.2 Socketspanelversion(Optional) .................. 15
2.4 Tableoftechnical characteristics.................. 16
2.6 Deratingforoperativeambientconditions ...... 17
3 INSTALLATION............................................. 18
3.1 Generalinstallationcriteria ........................... 18
3.2 Importantinformation .................................... 18
3.2.1 Inspectionofmaterials.................................. 18
3.2.2 Safetystandardsfordieselengines .............. 18
3.2.3 Foundations ................................................. 18
3.3 Exhaust plant ............................................... 18
3.3.1 Exhaustpipe ................................................ 18
3.3.2 Exhaust pipe design ..................................... 18
3.4 Ventilation .................................................... 18
3.5 Fuel system ................................................. 18
3.6 Electricalconnection .................................... 18
3.6.1 Power cables sizes ...................................... 18
3.6.2 Powercableconnection................................ 19
3.6.3 Groundconnection ....................................... 19
3.7 Outdoorinstallation....................................... 20
3.8 Insideinstallation.......................................... 21
4 USINGTHEGENERATOR ............................. 22
4.1 Preliminary checks....................................... 22
4.2 Refuelling...................................................... 22
4.3 Battery ......................................................... 22
4.4 Starting ........................................................ 22
4.5 Usingthegenerator ...................................... 23
4.6 Stopping....................................................... 23
4.7 Emergencystop ........................................... 23
5 PROTECTIONSANDWARNINGSIGNALS .. 23
5.1 Protectionagainstshort-circuitandoverload. 23
5.2 Socketpanel(Optional) ................................ 23
5.3 Protectionagainstdispersiontoground/earth
(optional) ...................................................... 23
5.4 Engineprotectionmodule ............................. 24
6 MAINTENANCE ............................................. 25
6.1 Preamble...................................................... 25
6.2 Ordinaryenginemaintenance ....................... 25
6.3 Engineoil change ......................................... 25
6.3.1 Changingoilfilter .......................................... 25
6.4 Changingfuelfilter ........................................ 25
6.4.1 Systembleeding........................................... 26
6.5 Airfiltercleaning/replacement....................... 26
6.5.1 Dustexhaustdevice ..................................... 26
6.6 Coolantcheck .............................................. 27
6.7 Battery check............................................... 27
6.8 Suctiongridandventcleaning ...................... 27
6.9 Scheduledmaintenancetable....................... 27
6.10 Periodofinactivity ........................................ 27
7 ANOMALIES,CAUSESANDREMEDIES ...... 28
7.1 Howto order the spare sparts....................... 28
8 TRANSPORT,STORAGE,LIFTING,HANDLING
ANDPACKAGING ....................................... 29
8.1 Transportandstorage................................... 29
8.2 Liftingandhandling....................................... 29
8.2.1 Liftingandhandlingwithcrane ...................... 29
8.2.2 Liftingandhandlingwith forklifttruck............. 29
8.3 Packaging .................................................... 30
9 GUARANTEEANDRESPONSIBILITY........... 31
9.1 Guarantee .................................................... 31
9.2 Limits of responsibility .................................. 31
10 DISPOSAL .................................................... 31
10.1 Disposalofthewastematerialsderivingfrom
maintenanceandscrapping .......................... 31
11 WIRINGDIAGRAMS ..................................... 32
11.1 Wiringdiagramstandardversion ................... 32
11.2 Wiringdiagramofsocketpanelversion......... 33
CONTENTS

GB
This manual has to be preserved for all through life of the
gen set to which ago reference
Thankyou for havingchosena productMASE.
Asaleadinggeneratormanufacturer,MaseGeneratorsoffersawiderangeofgeneratorswithanoutputfrom1KVA
portablegeneratorsto1600KVAunitsforspecialapplications.
Foundedin1970,theCesena-basedcompanyextendsoveraareaof16,000squaremeters,includinga9,000sq.mtr.
manufacturingfacility.
MaseGeneratorsbeganasacompanyproducing500Watt,lightandcompactportablegenerators.Thesegenerators
madetheMaseGeneratorsnamewellknownthroughouttheworld.MaseGeneratorsisaleaderinhigh
quality,reliableproducts,andinnovativeresearchperformedbyResearchandDevelopmentDepartment.
Thegeneratoryouhavepurchasedisthefruitofyearsofexperienceinthesectorandforthemodernconception,the
strongsizing, thematerials employees,the continuousupdatings,constitutes an effectiveanswer tothe operators’
demandsofthesector.
This Manualinstructions will furnish you usefulinformationand precious suggestions so you canfully exploit
allthepossibilities that thegenerators offersyou.
If any partofthemanualresultedincomprehensible, pleasecontactus.
Intorenew ourthankswe cordiallygreetyou.
MASE GENERATORS S.p.A. ViaTortona, 345
47023 Cesena (FC) Italy
Tel.[phone] Fax.[phone]
Technicaldata,informations,layouts of the texts and graphic preparations: edited by the Technical Office
MaseGenerators
THECOMPANYMASEGENERATORSSPARESERVESALLRIGHTSTOIMPLEMENTMODIFICATIONSTOTHISPRESENTMANUAL
WITHOUTADVANCENOTICEORNOTIFICATION,WHENNECESSARY,INACCORDANCEWITHITSPOLICYOFCONTINUALPRODUCT
IMPROVEMENT.THEMASEGENERATORSSPA,RESERVESALLTHERIGHTSONTHEMANUALPRESENT.ANYTOTALORPARTIAL
REPRODUCTIONISPERMITTEDWITHOUTWRITTENAUTHORIZATIONOFTHEMASEGENERATORSSPA.

GB DEFINITIONSUSED
The terms used are current technical terms, and where considered necessary the meaning is described
below
- Generator
Anassemblyofaninternalcombustionpistonengineandanalternatecurrent,synchronous,2-4pole,self-excited
generator,joinedtogether tocreateastationfor self-productionofelectricalenergy.
- Usersystem
Composed of the power supply circuits of the user equipment, including the relevant sectioning, handling,
breaking, transformation, protection, etc. devices which do not form part of the production, transmission and
distribution systems.
- Category 1 electrical system
A system where the rated voltage is greater than 50 V and smaller than 1000 V including alternate current.
- Load
Asetofnumericalvaluesofelectricalandmechanicalmagnitudeswhichcharacterisetherequirementsimposed
on a rotary machine by an electrical circuit or by a mechanical device at a certain instant.
- Thermal switch
Main cut-out and breaking device made up of a switch which opens automatically by thermal effect.
- Differentialswitch
Maincut-outandbreaking device made up of a switch which opensautomaticallybydifferential effect.
- Skilled person
Apersonwithtechnicalknow-howorsufficientexperiencetoallowhimtoavoidthedangersinherentinelectricity.
- MASE specialised personnel
Apersonabletoevaluatethejobassignedtohimandrecognisethepossibledangersonthebasisoftrainingat
theMASEtrainingcentres,withprofessionalexperienceandknowledgeoftheequipmentinquestionandofthe
possibledangersderivingintheeventofnegligentbehaviour.
- Supplier
A body (e.g. manufacturer, agent, installer) which supplies the equipment or services relating to the machine.
- Control
Control action by which an output variable of the controlled system (controlled variable) is affected by an input
variableof the controllingsystemin order toachievea certain goal.
- Manual control
Controlwherethechangeofavariablehandledisproducedbyapersonthroughmanualintervention.
- Automaticcontrol
Controlwherethechangeofavariablehandledisproducedbyacontrollingdevice(automaticcontroller)without
theinterventionofaperson.
- Danger
Sourceofpossibleharmordamagetohealth.
- Protection
Guardor protectiondeviceas safetymeasureto protectpersonsfrom apresentor potentialdanger.
- Casing
Partintended to assure protectionofthe equipment against specificoutsideinfluences and protection inevery
sense against contacts.

GB
- Connection in bad state
Thelivepartsarenotfullycoveredwithinsulationremovablebydestructiononly,theconnectionsarenotsecure
becauseof unstable tighteningof the partsanda developmentofoxide betweentheparts.
- Directcontact
Contact of persons or animals with live parts.
- Controlcircuit
Circuit used to control machine operation.
- Equipment
Generaltermwhichcomprisesmaterials,devices,equipment,accessoriesandsimilarusedinconjunctionwith
an electrical installation.
Indicatesthatparticularattentionmustbepaidinordertopreventseriousriskswhichcould
lead to death or possible harm to the health of personnel.
Aconditionwhichmayoccurduringthelifetimeofaproduct,systemorplantconsidered
atriskregarding damage to persons, property, the environmentoreconomicloss.
Indicatesthatparticularattentionmustbepaidinordertopreventseriousconsequences
whichcouldresult in damagetotangible goods, suchastheresources or theproduct.
Instructionsofparticularimportance.
Carefullyconsult this manual before using or carrying outanyoperationon the generator.
#Theroutinemaintenanceoperations,mustbecarriedoutbyqualifiedpersonnelwhohavetheappropriate
equipment and protections.

GB 1GENERALINFORMATIONS
1.1 CONFORM USE
Thegenerator is suitable forindependentproduction of electricalenergywithin the voltageandwattage limits
declaredby themanufacturer.
Any other use outside the already stated field of use is prohibited: the generator is intended for industrial use.
Thegenerator has beendesignedto operate independently(withoutoperator) if notforsporadic checks.
The limits of use are:
- operatingtemperature:-15°+40°
- relative humidity: 30% - 90%
- thegeneratorissuitableforoperationoutdo;itmaynotbeoperatedinclosedenvironmentssincethegenerator
producesexhaustgas.
Inside installation is subject to approval by maseor an installer authorised by mase.
Arbitrarymodificationsto the machine areprohibitedfor safety reasons.
Original spare parts must be used on pain of losing machine conformity.
All the operations that require dismantling of special parts may only be carried out by technicians authorised by
thelocal dealer orthemanufacturer.
Only masetechnicians or personnel trainedbymasehavethenecessary knowledge of the generatorandthe
special equipment as well as the experience to carry out any operation in the most economical and reliable way.
1.2 RESIDUAL RISKS
The generator has been designed taking into account the safety regulations set out in the EC directives and
standards;nonetheless, the following residual risksremain:
- injury caused by contact with hot parts during maintenance.
- injury caused by electrocution during maintenance on the electric panel.
- risks connected with long periods of exposure to the noise of the generator.
- risks due to contact with the generator lubricants during maintenance.
- risks due to the fire hazard the fuel represents.
Becauseofthe typical intrinsic danger of theGenerators,youare reminded that, although the generatorhas
beendesigned,constructed and tested in accordance withthesafety regulations, only proper and carefuluse
can guarantee full safety; to this end, the various precautions to be taken during use of the Generator are listed
below.

GB
Cod. 42352
EE
LL
STOP
E
S
D
IE
S
I
D
Cod. 42351
Cod. 41781
Cod. 42353
Cod. 41810
MACCHINA AD AVVIAMENTO
AUTOMATICO A DISTANZA
STARTING
AUTOMATIC REMOTE
FERNSTARTVORRICHTUNG
AUTOMATICA A DISTANCIA
MACHINE A DEMARRAGE
AUTOMATIQUE A DISTANCE
I
GB
D
E
F
Cod. 42347 Cod. 42397
Cod. 42118
Cod. 41777 Cod. 41776
Cod. 42467
Cod. 41776
Cod. 41775 Cod. 41776
1.3 SYMBOLS ON THE GENERATOR GROUP

GB
EE
LL
STOP
E
S
D
IE
S
I
D
1.4 POSITION OF SAFETY LABELS
• These labels warn the user of any danger which may cause serious injury.
Carefullyread the meaningand the precautionsdescribedin thismanual.
• Ifthelabel detachesorbecomesillegible,replaceitwitha newonewhich canberequestedfroman authorised
masedealer.
Danger Symbols Meaning
- Cautiontoavoidburns,donottouchduringoperation.
Theexhaustmanifoldandtheengine,payattentiontothelabelsonthegenerator.
- Leavethe engineto cooldown beforestoring itindoors.
- ReadandunderstandtheUseandMaintenanceManualbeforestartingthegenerator.
- TheMasegeneratorhasbeendesignedsoastoguaranteesafeandreliableoperation
providedthattheinstructionsarefollowed.Otherwise, personalinjuryordamageto
the equipment may result.
- The exhaust gases contain toxic carbon monoxide.
- Neveroperatethegeneratorinaclosedspace.
- Provideforadequateventilation.Ifinstalledindoors,scrupulouslyobservetheventilation
regulations.
- Thefuels are highlyflammableand incertainconditions also explosive.
- Fillupinawell-ventilatedareawiththeengineoff.
- Do not smoke or create sparks while filling up.
- Immediatelyclean off anyfuelleaks.
- Dangerof electric discharge: consultthemanual.
- Dangerof electric discharge: consultthemanual.
- Dangerofpossiblecorrosiveacidleaks.
- Dangerofexplosion.

GB
Danger Symbols Meaning
ProhibitionSymbols Meaning
- No smoking or use of open flames.
- Do not clean, lubricate, repair or adjust moving parts.
- Donot extinguish fireswithwater, use homologatedextinguishers.
- Dangerofentanglementandcutting:
Presence of rotating parts, pulleys, belts and fan.
- Dangerofburns:Hotsurfaces.
- Dangerof burns: Possibilityofpressurised hotwater
expulsion.
ObligationSymbols Meaning
- Obligationtoconnect the generator to earth.
- Obligation to wear eyes protection.
InformationSymbols Meaning
- Indicates the location of a point of the lifting hook of the generator.
- Indicates the location of the centre of gravity for the lifting with fork.

GB 1.5 GENERAL DANGER INFORMATIONS
• It is recommended to learn how to stop and operate all the controls.
• Donotallowunqualifiedpersonneltousethegenerator.
• Even though the generator is protected, do not stand near it.
• Donot removethelabels foranyreason andrequestreplacement ifnecessary.
• BeforestartingtheGeneratororbeforestartinganylubricationormaintenanceoperation,itisessentialthatthe
personnel responsible has read and understood all the WARNINGS, CAUTION and DANGER notices in this
manualandintheadditionaltechnicaldocumentationprovided.
• Beforeanyoperationonthegenerator,ensurethattheprimaryengineisnotrunningandthatnopartsaremoving,
andpostasignsayingDONOTSWITCHONorsimilaratthestartswitchorthecontrolsbeforecarryingoutthe
maintenanceorrepairworkonthegenerator.
• Nevertheless,themanufacturercannotforeseeallthepossiblecircumstanceswhichmayleadtopotentialrisks
intheeffectiveconditionsofuseoftheGenerator.
Anyoperationsand/orproceduresformaintenancenotexpresslyrecommendedorindicatedintheusermanuals
mustalwaysbenotifiedto andapprovedbythemanufacturer.
Intheeventthataprocedurenotspecificallyrecommendedneedstobeapplied,theuserisresponsibleforassuring
that such procedure is safe and does not cause harm to persons.
• Themanufacturer declinesall responsibilityfor damagetopersons orthings derivingfrom inobservanceofthe
safetyregulations.
• Carefullyexaminethe safetywarningplatesonthe generatorandrespecttherelevant instructions.
1.5.1 DANGER OF ENTANGLEMENT
• Donotremovetheoriginalprotectionsfromanyoftheexposedrotatingparts,hotsurfaces,airintakes,beltsand
liveparts.
• Donotcarryoutanymaintenanceoperation withthegeneratorrunning.
• Donotwearflappinggarments,suchasscarves,foulards,bracelets,etc.andallgarmentsmustbetiedwithelastic
at the edges.
• Donotclean or carry out maintenance on moving parts.
1.5.2 DANGER OF BURNS
• Donotpermit unskilled persons or withoutadequatetraining to use the generator.
• Do not permit children or animals to approach the generator when it is in operation.
• Nevertouchthe exhaust, the relevant protection or theenginebody when the generator is running orstillhot.
• Donot leanagainstor siton thegeneratorfor anyreason whatsoever.
• Identifythepositionofthefireextinguishersorotherprotectionandemergencydevicesandlearntheirfunctioning.
• Identify any sources of danger such as fuel, engine oil or acid solution leaks, condensate in the drip caps, high
voltage,highpressure.
• Do not cause short-circuits by placing keys or tools on the batteries or on the cable fittings.
• The battery fluid contains sulphuric acid which is extremely corrosive and harmful to the skin. Always wear
protectiveglovesandbeextremelycarefultoavoidspillagewhenpouringtheacid.Intheeventofcontact,wash
theaffectedpartthoroughlywithrunningwaterandconsultaphysician,inparticularwhentheeyesareinvolved.

GB
1.5.3 DANGER OF HARM TO HEARING
• Donotstandnearthegeneratorfor longperiodswithoutprotectiveearmuffssincehearing maybereduced.
Prolongedexposuretonoiseabove85dB(A)maycausehealthdisorders.Itisinanycaserecommended
to use appropriate protection systems (e.g. headsets, earplugs, etc. ).
1.5.4 DANGER OF INTOXICATION
• The exhaust gases contain toxic carbon monoxide.
• Neverusethegeneratorintunnelsor inany placewith poorventilation. Ifindooruseisinevitable,itis essential
toprovideforproperandefficientventilationinordertopreventintoxicationofpersonsoranimals.
• Check that the engine exhaust is free and that the pipes allow evacuation of the exhaust fumes.
• Checkthattheexhaustgasesaredischargedtotheoutsideinasafepositionawayfromdoors,windowsandair
intakes.
1.5.5 DANGER OF FIRE OR EXPLOSION
•Alwaysturnofftheenginebeforerefuelling.
•Donot smoke during refuelling.
• Refuelling must be carried out with extreme care, ensuring that fuel does not overflow from the engine tank
respectingthemaximumlevel.
•Inthe event of fuel spillage fromthetank,thoroughly dry and clean the partsinvolved.
• Check that there are no fuel leaks and that the pipes are undamaged.
• When refuelling has been completed, tightly close the fillercap.
•Keepflammableliquids,matchesandotherexplosiveand/orflammableproductsawayfromthegenerator,since
thetemperature nearthe exhaustishigh duringoperation.
•Neverleaveflammableliquidsorclothssoakedinflammableliquidsinproximityofelectricalequipment(including
lamps) or parts of the electrical system.
•Thebatteriesdevelophydrogen,ahighlyexplosivegas.Itisrecommendednottosmokenorcausesparksinthe
vicinity,inparticularduringcharging.
• Do not obstruct the cooling air inlets/outlets.
•Intheeventoffire,use ahomologated fireextinguisher andnever usewater.
1.5.6 DANGER IF FAILING TO USE PERSONAL PROTECTION DEVICES
• Thepersonsresponsibleforhandlingmustalwayswearprotectiveglovesandsafetyshoes.
• Wearsafetyshoesandoveralls.
• Ifthe generatorneedsto belifted from theground, theoperatorsmust wearaprotective helmet.
• Immediatelychangewetoveralls.
• Useprotectivegloves.

GB 1.5.7 DANGER CAUSED BY THE ENGINE STARTING
• Donot leavedisassembledparts, toolsor anything elsenot formingpartof thesystemon ornear the engine.
• Install the protections necessary for safety on the parts completing the system.
• Operate the generator on a flat surface as far as possible. For continuous operation, the maximum permitted engine
inclinationis20degrees.Greaterinclinationofthegeneratormightcausethefueltoleakoutorcauseproblemswithengine
oilpressure.
• Topreventtheriskoffireandforproperventilation,positionthegeneratoratleast1m.(3ft.)frombuildingsorotherequipment
duringoperation.
• Check the oil level by means of the dipstick.
• Check that all the electrical utilities are off so that the generator is not started on load.
• Checkperfectfunctioningofthedeviceswhichstopthegeneratorintheeventoffailureduetolowoillevel.
• Identifythe position oftheemergency stopbuttons,switches and otheremergency systems onthegenerator.
• Learnthespecialemergencyproceduresrelativetotheinstallationinquestion.
1.5.8 DANGEROFELECTROMAGNETIC RADIATION
• Donotallowaccesstopersonswearingapacemakerbecauseofpossibleelectromagneticinterferencewiththedevice.
1.5.9 DANGER OF ELECTROCUTION
• Whenusingthegeneratoralwaysbearinmindthatinwetorveryhumidplacesandinconfinedconductionspacesitis
obligatorytocomplywithArticles313and318ofPresidentialDecreeNo.54727/04/55,aswellasChap.11SectionIV
oftheCEI64-8regulation.
• Immediatelychangewetoveralls.
• Insulatealltheconnectorsanddetachedwires.
• Donotleavethepowerterminalboardofthegeneratoruncovered;checkthattheelectricalpowerandauxiliaryservice
connectionshavebeenmadeproperly.
• Donotpowerloadswithavoltagedifferentfromthatdeliveredbythegenerator.
• Do not spray water directly onto the electrical parts.
• Do not clean the internal electrical parts with compressed air, since short-circuits or other faults may occur.
Donottamperwiththeactiveprotections,thermalswitchesanddifferentialmagnetothermalswitches.
• Intheeventofmalfunctioning,donotremovethepaneltoattemptrepairingit.ContactMasespecialisedpersonnel.
• Do not access the generator with wet hands, since it is a potential source of electric shock if improperly used.
• Takethenecessaryprecautionstopreventthedangerofelectrocution;checkthattheearthingsystemhasbeeninstalled
andconstructedinaccordancewithregulations.
• Forthesafetyoftheusers,theearthconnectionofthegeneratormustalwaysbecarriedoutpayingparticularattention
tothecable cross-section used. For the connection of the earthcableusethe dedicated terminal on the generator.
The manufacturer is not responsible for any damage caused by miss-ground to the system.
1.5.10 DANGER RESULTING FROM BAD STORAGE
• Packedandunpackedgeneratorsmustbestored inacoolanddryplaceand neverexposedtobadweather.
• Avoidstackingpackedgeneratorstopreventthemfromfallingcausingdamageto personsand/or things.

GB
KVA
Hz
Cos.Ø
VV
AA
Degrees of protection IP
°C
m
Performance class
year of manifacture
Rated power factor
Rated voltage
declared frequency
Mass Kg
Class of insulation
Temp. max of use
Altitude max. of use
Rated current
Rated power 3F
Code Serial n°
1
2
5
4
67
89
11
12
13
15
16
3
14
10
1.6 REFERENCE DOCUMENTS
Theinstructionsforuseprovidedwitheachgeneratorare
madeupofacollectionofdocumentsofwhichthismanual
representstheGeneralPart.Thefollowingdocumentsare
normallyprovidedseparate.
aCEdeclarationofconformity.
bInstructionmanualforuseandmaintenanceof
thegenerators,(thismanual).
cEngineuseandmaintenancemanual.
dListofmase ServiceCentres.
eMaseWarranty certificate.
fWarrantycard.
1.7 REFERENCE REGULATIONS AND LEGISLATIVE PROVISIONS
The generator groups, built by mase, destined to the
countriesoftheEuropeanCommunity,areconformingto
theapplicableECdirectives,andtheyareprovidedofaEC
DeclarationofConformity.
98/37/ECandsubsequentamendments:
Essential machine requirements for safety and health
protection(“Machine”directive).
73/23/ECandsubsequentamendmentscontainedinthe
directive 93/68/EC : Guarantee of safety of electrical
material intended for use within certain voltage limits,
(“LowVoltage”Directives).
1.8 MARKING
The generator identification plate carries all the
identificationdatainaccordancewiththeprovisionsfor
ECmarkingforthosecaseswhererequired. Belowisa
facsimile of the identification plate fixed on the hull of
eachgenerator.
1.9 IDENTIFICATION OF THE GENERATOR UNIT
1 - Machinename
2 - Machinecode
3 - Serialnumber
4 - Ratedpower
5 - Declaredfrequency
6 - Ratedpowerfactor
7 - Ratedvoltage
8 - Ratedcurrent
9 - Degreeofprotection
10 - Class of isolation
11 - Temperaturemax.ofuse
12 - Altitude max. of use
13 - Performanceclass
14 - Yearofconstruction
15 - Manufacturer-Adress
16 - Weight
The machine code number, the serial number
and the year of construction must always be
indicatedwhencontactingthemanufacturerfor
information, order of spare parts, etc..

GB
F
AB
MIC E
G
L
H
D
G
NO I
2 GENERALCHARACTERISTICS
The generators have been designed for use in the
industrial field, using highly reliable 1500 rpm water-
cooled diesel engines. Particular attention has been
paidtothedegreeofprotectionagainstexternalagents,
engine protection and protection of the electrical parts
against overload or overheating, adopting automatic
systems able to stop the generator in the event of
malfunctioning.
Thegeneratorisparticularlyquietthankstoaninternally
insulatedsoundproofcasingandanadvancedsoundproof
system for combustion smoke exhaust.
Thealternatorsusedarethesynchronousself-energized
typewith electronic voltageadjustment.
2.1 CONFIGURATIONS
Theconfigurationof the generating set is onlyforfixed
installation.
2.2 COMPOSITION OF GENERATOR UNIT
Thegeneratorunitisessentiallycomposedofthefollowing
components.
A - Fixedframe
B - Openablecowlingengineside
C - Openablecowlingalternatorside
D - Instrumentpanelprotectioncage
E - Socketspanel(Optional)
F - Fuel tank
G - Support
H - Filler cap
I - Liftinghook
L - Airaspirationgrate
M - Airexpulsiongrate
N - Exhaust pipe with rain protection
O - Emergencybutton

GB
910 11 12
13
8
6
3
12
5
4
7
8
2.3 INSTRUMENT PANEL
Each generator is fitted with an instrument panel for
commandsandcontrolswiththefollowingcomponents:
1 - Ignitionkey
2 - Hourcounter
3 - Ammeter
4 - Voltmeter
5 - Engineprotectionmodule(seepar.5)
6 - Lowvoltagetermalprotection
7 - Fuellevel
8 - Generalmagnetothermalswitch
2.3.1 DIFFERENTIAL MEGNETOTHERMAL PANEL VERSION
(OPTIONAL)
8 - Differentialmagnetothermalswitch
2.3.2 SOCKETS PANEL VERSION (OPTIONAL)
9 - Three-phaseoutlet,EC63A400V-3P+N+GND
10 - Three-phaseoutlet, EC32A400V-3P+GND
11 - Single-phase outlet, EC 16A 230V - 2P+GND
12 - Single-phase outlet, EC 16A 230V - 2P+GND
13 - Differentialmagnetothermalswitchonsocketline

GB
2.6 DERATING FOR OPERATIVE AMBIENT CONDITIONS
Diesel engines
Important: the outputs of Diesel engines for stationary
applications refer to the following standard ambient
conditionsinagreementwithISO3046/1Standard
- ambienttemperature+25°C
- ambient pressure 1000 mbar (750 mm/Hg,
correspondingto0m.abovesealevel);
- relativehumidity30%.
Synchronousgenerators
The ambient conditions for reference for synchronous
generators and stationary applications, in agreement
withIEC 34 standards, arethe following:
-ambienttemperature40°C
-altitude1000metresabovesealevel(674mm/Hg).
Forinstallationandoperatingambientconditionsother
thanthoseindicatedforreference,appropriate“derating”
ofthepowersupplied by the unit must be performed.
Theimpactofeveryfactordescribedinthissectionmust
not be considered individually but in combination with
theotherfactors.
The derating of synchronous generators is less
demanding than for Diesel engines; inasmuch, the
deratingofthepowergeneratoringeneralcoincideswith
thederatingoftheDieselengine.
Particularderatingsmaybedeterminedonthebasisof
theeffectiveconditionsofuse.
Forinformation:thefollowingTableindicatesthederating
valuesforaspiratedandturbocompressedengines.
Table with derating estimates for aspirated and turbocompressed Diesel engines
(for more information about the type of intake, see “Table. Technical Features” Chap.2.4)
Thetwo coefficientsK1andK2 mustboth be multipliedto theratedpower ofthe generator toobtain thepowerat
ambientconditionsdifferenttostandardconditions.
Resultant power = Rated power x K1x K2
EXAMPLE: Machine Operation - power: 100 kVA a 35°C a 1000 m.s.l.
100 x 0.96 x 0.92 = 88.3 kVA
Altitude (m.a.s.l.) a 25°C
0
500
1000
1500
2000
2500
3000
Reduction factor (K1)
for naturally aspirated engine 1 0,950,890,830,760,740,68
Reduction factor (K1)
for turbo aspirated engine 1 0,960,920,880,830,790,75
Ambient temp. (°C) a 0 m.a.s.l.
25°
30°
35°
40°
45°
50°
Reduction factor (K2)
for naturally aspirated engine 1 0,980,960,950,930,91
Reduction factor (K2)
for turbo aspirated engine 1 0,980,960,940,920,90

GB 3INSTALLATION
3.1 GENERAL INSTALLATION CRITERIA
TheinstallationofoneormoreGeneratingSetsmustbe
designed by specialised engineers qualified for the
design of this type of plant. The installation must be
carried out by qualified organisations employing
specialised personnel and using suitable equipment.
Thesystems mustbe installedinworkmanlike manner
anduponcompletion the installer must issuetheclient
withaDeclarationofConformityofthesystemsinstalled
in accordance with the design specifications and the
specificstandards.
3.2 IMPORTANT INFORMATIONS
3.2.1 INSPECTION OF MATERIALS
On receiving the set, it is advisable to check that the
materialscorrespond to that listedonthe delivery note
accompanying the shipment. Some of the packages
maybeopenedatrandomtocheckthatnodamagehas
occurred during transit. If damage is noted, the carrier
must be informed immediately to enable the relevant
claims procedure to be started.
3.2.2 SAFETY STANDARDS FOR DIESEL ENGINES
The location and installation of the generating set
(foundations, fuel tank, air intake, gas exhaust) must
comply with the “Safety Standards” in force in the
countryofinstallation.
3.2.3 FOUNDATIONS
The foundations must be calculated and designed by
civil engineers, taking maximum care to avoid the
transmissionofvibrationsandnoisetootherpartsofthe
structure.
3.3 EXHAUST PLANT
3.3.1 EXHAUST PIPE
Theexhaustpipemustconveytheexhaustgastoazone
whereitwillnotcausedamageorharm,andawayfrom
doors,windowsand air intakes.
The outlet must be provided with a fixed protection to
preventtheingressofrainwater.
Sectionsofpipespassingthroughwallsmustbeinsulated
to prevent the transmission of heat to the walls
themselves.
3.3.2 EXHAUST PIPE DESIGN
Thebackpressureontheengineexhaustgreatlyinfluences
thepowerdeliveredbytheengineanditsthermalload.
Anyexcessivebackpressure(measuredontheoutletside
of the exhaust manifold for induction engines and on the
turbine outlet side for turbocharged engines) causes a
decrease in power, an increase in the temperature of the
exhaustgases,producessmoke,increasesfuelconsumption
and superheats the cooling water, with subsequent
deterioration in the lubricant and consequences for other
engineparts.
The pipelines should be as short as possible and with a
minimunnumberofbends.
3.4 VENTILATION
Ventilationoftheroominwhichthegeneratingsetisinstalled
isoffundamentalimportancefortheproperoperationofthe
set itself (SEE ALSO PAR. 3.8).
3.5 FUELSYSTEM
ThestandardGeneratingSetsnormallysuppliedbymase
arefittedwithacompletefuelsystemfromtheenginetothe
standardfueltankincorporated.
3.6 ELECTRICAL CONNECTION
Theelectricalconnection mustbecarriedoutexclusivelyby
a specialised technician according to EN 60 204.1 (IEC
204.01)regulations.
Thegeneratingsetsaresuppliedalreadyset-upforconnection
totheuser.
Thefunctionofthegeneratingsetistosubstitutethemains
electricity supply, and as such, must be considered as an
externalsourceofenergy.Intheexecutionoftheconnections
must be respected the suitable connections in the wiring
diagramfurnishedwiththegroup.
3.6.1 POWER CABLES SIZES
Thechoiceandsizeofcablestouseistheresponsibility
of the plant installer.
It should be emphasised that using smaller sections
thanthatrecommendedwouldcauseexcessivevoltage
dropsandleadtodangerousoverheatingofcables.

GB
21 5
3 4
6
3.6.2 POWER CABLE CONNECTION
The set of generator-utility-network connection cables
mustbeproperlyarrangedinasuitableductorunderground
passage(also see para3.7/3.8).
Forinstallation,usethefollowingprocedure:
1) Removethesmallpanel(ref.1).
2) Openthehatch (ref.2).
3) Fit the cables in the aperture (ref.3) inside the panel
(ref.1), through the casing (ref.4), as far as the power
terminalboard(ref.5).
4) Clampwith specificcableretainers (ref.6).
5) Connect the power cables to the respective terminals
indicated by the icons.
3.6.3 GROUND CONNECTION
Metal parts of the plant with which people can come into
physical contact and which, due to an insulation fault or
otherreasons, may becomelive,must be connectedtoa
groundsystem.
Toconnecttoground,usetheproceduregiveninpar.3.6.2,
then connect the ground cable to the respective terminal
indicated by the icon (ref.6).
Thesizingofthegroundwirestothegroundsystemandthe
relativecontactresistancemustcomplywithcurrentlaws
andstandards.
Do not tamper with the active protections, thermal
switchesanddifferentialmagnetothermalswitches.
• In the event of malfunctioning, do not remove the
paneltoattemptrepairingit.ContactMasespecialised
personnel.
• Takethenecessaryprecautionstopreventthedanger
ofelectrocution;checkthattheearthingsystemhas
been installed and constructed in accordance with
regulations.
• Forthesafetyoftheusers,theearthconnectionofthe
generatormustalwaysbecarriedoutpayingparticular
attention to the cable cross-section used. For the
connection of the earth cable use the dedicated
terminalonthe generator.
ThemanufacturerisNOTresponsibleforanydamage
causedbyfailuretoearththesystem.
Theearthingsystemmustbelocatedasfaraspossible
from railway/tram lines in order to prevent electro-
corrosionoftheinternalcomponentsoftheenginein
contactwithwater.

GB 3.7 OUTDOORINSTALLATION
Forunitsinoutdoorinstallations,itisadvisabletoensure
a position that provides maximum protection against
atmosphericagents,powder,etc.
Avoid direct exposure to sunlight that would otherwise
cause abnormal heating of the system.
It is advisable to protect the system with shed roof.
For temporary or short-term installations, the unit may
simply be placed on a flat surface.
Forpermanentorlong-terminstallations,itisadvisable
toprepareaconcretefoundation.
The area where the power set is installed must be
suitably fenced off in order to prevent access by
unauthorizedpersons.
No admittance and Hazard signs must be installed
as required by current legislation.
Key:
1 - Casing in painted sheet metal
2 - Onboardcontrolpanel
3 - Foundation
4 - Air expulsion
5 - Cableduct
6 - Air intake
7 - Gas exhaust pipe
8 - Metalprotectionenclosure
9 - Distribution panel not supplied as
standard (automatic start remote
controlswitches-Optional)
Outdoorinstallation

GB
3.8 INSIDE INSTALLATION
Correct indoor installation of the system must observe
thefollowinginstallationrequirements:
- Thesitemustbeadequatelydimensionedinorder
to allow correct operation of the group as well as
easy access for routine maintenance operations
andeventualrepairs.Thefigureshowstheminimum
recommendeddimensionsforclearancearoundthe
system and the height of the site.
- Accesstothesitemustallowtheintroductionofthe
complete system using standard transport and
handlingdevicesavailableinthepremises.
- Theremustbeaperturesofadequatedimensionsto
ensurecontinualandefficientrecirculationofair.
- Installation of exhaust piping to the exterior of
limited length and the fewest possible number of
curvesiscompulsory.
- Thesystemmaybearrangedwithsufficientpassage
space on at least three sides, provided that easy
access and observance of safety regulations are
maintained.
- The control panel (for automatic sets) must be
positionedsothattheinstrumentsareclearlyvisible
totheoperatorworkingnearthesystem(forexample,
see ref. 2 and 4 in the figure below).
Inside installation
Key:
1 - Casing in painted sheet metal
2 - Onboardcontrolpanel
3 - Foundation
4 - Distribution panel not supplied as
standard(automaticstartremotecontrol
switches-Optional)
5 - Cableduct
6 - Air intake
7 - Gas exhaust pipe
8 - Conveyerairexpulsion(Solutionn°1)
9 - Fan(Solutionn°2,seeairflowintab.
"Technicalcharacteristics"par.2.4)