Mase MPL 66 S User manual

MPL 66 S
MPL 76 S
Rev.4 A.A. 08 - 11 - 06
cod.42636
I
Tipo modello
N° matricola
Codice
GENSET USE AND MAINTENANCE MANUAL GB
E
D

MPL 66- 76 S
- 2GB
GB
DEFINITIONS USED ................................................ 4
1 GENERAL INFORMATIONS ............................ 6
1.1 Conform use ................................................... 6
1.2 Residual risks ................................................. 6
1.3 Symbols on the generator group ..................... 7
1.4 Position of safety labels.................................. 8
1.5 General danger information ........................... 10
1.5.1 Danger of entanglement ................................ 10
1.5.2 Danger of burns ............................................ 10
1.5.3 Danger of harm to hearing ............................. 11
1.5.4 Danger of intoxication ................................... 11
1.5.5 Danger of fire or explosion ............................ 11
1.5.6 Danger if failing to use personal protection
devices ......................................................... 11
1.5.7 Danger caused by the engine starting ........... 12
1.5.8 Danger of electromagnetic radiation .............. 12
1.5.9 Danger of electrocution ................................. 12
1.5.10 Danger resulting from bad storage ............... 12
1.6 Reference documents ................................... 13
1.7 Referenceregulationsandlegislativeprovisions . 13
1.8 Marking ........................................................ 13
1.9 Identification of the generator unit ................. 13
2 GENERALCHARACTERISTICS .................... 14
2.1 Configurations ............................................... 14
2.2 Composition of generator unit ....................... 14
2.3 Instrument panel ........................................... 15
2.3.1 Differential magnetothermal panel version
(Optional) ...................................................... 15
2.3.2 Sockets panel version (Optional) .................. 15
2.4 Table of technical characteristics .................. 16
2.5 Noise emission ............................................. 17
2.6 Derating for operative ambient conditions ...... 17
3 INSTALLATION ............................................. 18
3.1 General installation criteria ........................... 18
3.2 Important information .................................... 18
3.2.1 Inspection of materials .................................. 18
3.2.2 Safety standards for diesel engines .............. 18
3.2.3 Foundations ................................................. 18
3.3 Exhaust plant ............................................... 18
3.3.1 Exhaust pipe ................................................ 18
3.3.2 Exhaust pipe design ..................................... 18
3.4 Ventilation .................................................... 18
3.5 Fuel system ................................................. 18
3.6 Electrical connection .................................... 18
3.6.1 Power cables sizes ...................................... 18
3.6.2 Power cable connection................................ 19
3.6.3 Ground connection ....................................... 19
3.7 Outdoor installation ....................................... 20
3.8 Inside installation .......................................... 21
4 USING THE GENERATOR ............................. 22
4.1 Preliminary checks ....................................... 22
4.2 Refuelling ...................................................... 22
4.3 Battery ......................................................... 22
4.4 Starting ........................................................ 22
4.5 Using the generator ...................................... 23
4.6 Stopping ....................................................... 23
4.7 Emergency stop ........................................... 23
5 PROTECTIONS AND WARNING SIGNALS .. 23
5.1 Protection against short-circuit and overload . 23
5.2 Socket panel (Optional) ................................ 23
5.3 Protection against dispersion to ground/earth
(optional) ...................................................... 23
5.4 Engine protection module ............................. 24
6 MAINTENANCE ............................................. 25
6.1 Preamble ...................................................... 25
6.2 Ordinary engine maintenance ....................... 25
6.3 Engine oil change ......................................... 25
6.3.1 Changing oil filter .......................................... 25
6.4 Changing fuel filter ........................................ 25
6.4.1 System bleeding........................................... 26
6.5 Air filter cleaning/replacement ....................... 26
6.5.1 Dust exhaust device ..................................... 26
6.6 Coolant check .............................................. 27
6.7 Battery check ............................................... 27
6.8 Suction grid and vent cleaning ...................... 27
6.9 Scheduled maintenance table ....................... 27
6.10 Period of inactivity ........................................ 27
7 ANOMALIES, CAUSES AND REMEDIES ...... 28
7.1 How to order the spare sparts ....................... 28
8 TRANSPORT, STORAGE, LIFTING,HANDLING
AND PACKAGING ....................................... 29
8.1 Transport and storage ................................... 29
8.2 Lifting and handling ....................................... 29
8.2.1 Lifting and handling with crane ...................... 29
8.2.2 Lifting and handling with forklift truck............. 29
8.3 Version with slow-drawn trailer ...................... 30
8.4 Packaging .................................................... 30
9 GUARANTEE AND RESPONSIBILITY ........... 31
9.1 Guarantee .................................................... 31
9.2 Limits of responsibility .................................. 31
10 DISPOSAL .................................................... 31
10.1 Disposal of the waste materials deriving from
maintenance and scrapping .......................... 31
11 WIRING DIAGRAMS ..................................... 32
11.1 Wiring diagram standard version ................... 32
CONTENTS

MPL 66 - 76 S
- 3GB
GB
This manual has to be preserved for all through life of the
gen set to which ago reference
Thank you for having chosen a product MASE.
As a leading generator manufacturer, Mase Generators offers a wide range of generators with an output from 1 KVA
portable generators to 1600 KVA units for special applications.
Founded in 1970, the Cesena-based company extends over a area of 16,000 square meters, including a 9,000 sq. mtr.
manufacturingfacility.
Mase Generators began as a company producing 500 Watt, light and compact portable generators. These generators
made the Mase Generators name well known throughout the world. Mase Generators is a leader in high
quality,reliable products, and innovativeresearchperformed by Research andDevelopmentDepartment.
The generator you have purchased is the fruit of years of experience in the sector and for the modern conception, the
strong sizing, the materials employees, the continuous updatings, constitutes an effective answer to the operators’
demands of the sector.
This Manual instructions will furnish you useful information and precious suggestions so you can fully exploit
all the possibilities that the generators offers you.
If any part of the manual resulted incomprehensible, please contact us.
In to renew our thanks we cordially greet you.
MASE GENERATORS S.p.A. Via Tortona, 345
47023 Cesena (FC) Italy
Tel.[phone] Fax.[phone]
Technical data, informations, layouts of the texts and graphic preparations: edited by the Technical Office
Mase Generators
THE COMPANY MASE GENERATORS SPA RESERVES ALL RIGHTS TO IMPLEMENT MODIFICATIONS TO THIS PRESENT MANUAL
WITHOUT ADVANCE NOTICE OR NOTIFICATION, WHEN NECESSARY, IN ACCORDANCE WITH ITS POLICY OF CONTINUAL PRODUCT
IMPROVEMENT. THE MASE GENERATORS SPA, RESERVES ALL THE RIGHTS ON THE MANUAL PRESENT. ANY TOTAL OR PARTIAL
REPRODUCTIONISPERMITTED WITHOUT WRITTEN AUTHORIZATION OF THE MASE GENERATORSSPA.

MPL 66- 76 S
- 4GB
GB DEFINITIONS USED
The terms used are current technical terms, and where considered necessary the meaning is described
below
- Generator
An assembly of an internal combustion piston engine and an alternate current, synchronous, 2-4 pole, self-excited
generator, joined together to create a station for self-production of electrical energy.
- User system
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
A set of numerical values of electrical and mechanical magnitudes which characterise the requirements imposed
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.
- Differential switch
Main cut-out and breaking device made up of a switch which opens automatically by differential effect.
- Skilled person
A person with technical know-how or sufficient experience to allow him to avoid the dangers inherent in electricity.
- MASE specialised personnel
A person able to evaluate the job assigned to him and recognise the possible dangers on the basis of training at
the MASE training centres, with professional experience and knowledge of the equipment in question and of the
possible dangers deriving in the event of negligent behaviour.
- 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
variable of the controlling system in order to achieve a certain goal.
- Manual control
Control where the change of a variable handled is produced by a person through manual intervention.
- Automatic control
Control where the change of a variable handled is produced by a controlling device (automatic controller) without
the intervention of a person.
- Danger
Source of possible harm or damage to health.
- Protection
Guard or protection device as safety measure to protect persons from a present or potential danger.
- Casing
Part intended to assure protection of the equipment against specific outside influences and protection in every
sense against contacts.

MPL 66 - 76 S
- 5GB
GB
- Connection in bad state
The live parts are not fully covered with insulation removable by destruction only, the connections are not secure
because of unstable tightening of the parts and a development of oxide between the parts.
- Direct contact
Contact of persons or animals with live parts.
- Control circuit
Circuit used to control machine operation.
- Equipment
General term which comprises materials, devices, equipment, accessories and similar used in conjunction with
an electrical installation.
Indicates that particular attention must be paid in order to prevent serious risks which could
lead to death or possible harm to the health of personnel.
A condition which may occur during the lifetime of a product, system or plant considered
at risk regarding damage to persons, property, the environment or economic loss.
Indicates that particular attention must be paid in order to prevent serious consequences
which could result in damage to tangible goods, such as the resources or the product.
Instructions of particular importance.
Carefully consult this manual before using or carrying out any operation on the generator.
#The routine maintenance operations, must be carried out by qualified personnel who have the appropriate
equipment and protections.

MPL 66 S - MPL 76 S
- 6GB
GB 1 GENERAL INFORMATIONS
1.1 CONFORM USE
The generator is suitable for independent production of electrical energy within the voltage and wattage limits
declared by the manufacturer.
Any other use outside the already stated field of use is prohibited: the generator is intended for industrial use.
The generator has been designed to operate independently (without operator) if not for sporadic checks.
The limits of use are:
- operating temperature: -15° +40°
- relative humidity: 30% - 90%
- the generator is suitable for operation outdo; it may not be operated in closed environments since the generator
produces exhaust gas.
Inside installation is subject to approval by maseor an installer authorised by mase.
Arbitrary modifications to the machine are prohibited for 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
the local dealer or the manufacturer.
Only masetechnicians or personnel trained by masehave the necessary knowledge of the generator and the
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 risks remain:
- 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.
Because of the typical intrinsic danger of the Generators, you are reminded that, although the generator has
been designed, constructed and tested in accordance with the safety regulations, only proper and careful use
can guarantee full safety; to this end, the various precautions to be taken during use of the Generator are listed
below.

MPL 66 S - MPL 76 S
- 7GB
GB
Cod. 42352
EE
LL
STOP
E
S
D
I
E
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. 41776 Cod. 41777
Cod. 42467 Cod. 41776 Cod. 41776
Cod. 41775
1.3 SYMBOLS ON THE GENERATOR GROUP
* Equipped with “automatic start” option -
replaces Code 42397

MPL 66 S - MPL 76 S
- 8GB
GB
EE
LL
STOP
E
S
D
I
E
S
I
D
1.4 POSITION OF SAFETY LABELS
• These labels warn the user of any danger which may cause serious injury.
Carefully read the meaning and the precautions described in this manual.
• If the label detaches or becomes illegible, replace it with a new one which can be requested from an authorised
masedealer.
Danger Symbols Meaning
- Caution to avoid burns, do not touch during operation.
The exhaust manifold and the engine, pay attention to the labels on the generator.
- Leave the engine to cool down before storing it indoors.
- Read and understand the Use and Maintenance Manual before starting the generator.
- The Mase generator has been designed so as to guarantee safe and reliable operation
provided that the instructions are followed. Otherwise, personal injury or damage to
the equipment may result.
- The exhaust gases contain toxic carbon monoxide.
- Never operate the generator in a closed space.
- Provide for adequate ventilation. If installed indoors, scrupulously observe the ventilation
regulations.
- The fuels are highly flammable and in certain conditions also explosive.
- Fill up in a well-ventilated area with the engine off.
- Do not smoke or create sparks while filling up.
- Immediately clean off any fuel leaks.
- Danger of electric discharge: consult the manual.
- Danger of electric discharge: consult the manual.
- Danger of possible corrosive acid leaks.
- Danger of explosion.

MPL 66 S - MPL 76 S
- 9
GB
GB
Danger Symbols Meaning
ProhibitionSymbols Meaning
- No smoking or use of open flames.
- Do not clean, lubricate, repair or adjust moving parts.
- Donotextinguish fires with water,usehomologated extinguishers.
- Dangerofentanglementandcutting:
- Presence of rotating parts, pulleys, belts and fan.
ObligationSymbols Meaning
- Obligationtoconnectthegeneratortoearth.
- 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.

MPL 66 S - MPL 76 S
- 10GB
GB
1.5 GENERAL DANGER INFORMATIONS
• It is recommended to learn how to stop and operate all the controls.
• Do not allow unqualified personnel to use the generator.
• Even though the generator is protected, do not stand near it.
• Do not remove the labels for any reason and request replacement if necessary.
• Before starting the Generator or before starting any lubrication or maintenance operation, it is essential that the
personnel responsible has read and understood all the WARNINGS, CAUTION and DANGER notices in this
manual and in the additional technical documentation provided.
• Before any operation on the generator, ensure that the primary engine is not running and that no parts are moving,
and post a sign saying DO NOT SWITCH ON or similar at the start switch or the controls before carrying out the
maintenance or repair work on the generator.
• Nevertheless, the manufacturer cannot foresee all the possible circumstances which may lead to potential risks
in the effective conditions of use of the Generator.
Any operations and/or procedures for maintenance not expressly recommended or indicated in the user manuals
must always be notified to and approved by the manufacturer.
In the event that a procedure not specifically recommended needs to be applied, the user is responsible for assuring
that such procedure is safe and does not cause harm to persons.
• The manufacturer declines all responsibility for damage to persons or things deriving from inobservance of the
safety regulations.
• Carefully examine the safety warning plates on the generator and respect the relevant instructions.
1.5.1 DANGER OF ENTANGLEMENT
• Do not remove the original protections from any of the exposed rotating parts, hot surfaces, air intakes, belts and
live parts.
• Do not carry out any maintenance operation with the generator running.
• Do not wear flapping garments, such as scarves, foulards, bracelets, etc. and all garments must be tied with elastic
at the edges.
• Do not clean or carry out maintenance on moving parts.
1.5.2 DANGER OF BURNS
• Do not permit unskilled persons or without adequate training to use the generator.
• Do not permit children or animals to approach the generator when it is in operation.
• Never touch the exhaust, the relevant protection or the engine body when the generator is running or still hot.
• Do not lean against or sit on the generator for any reason whatsoever.
• Identify the position of the fire extinguishers or other protection and emergency devices and learn their functioning.
• Identify any sources of danger such as fuel, engine oil or acid solution leaks, condensate in the drip caps, high
voltage, high pressure.
• 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
protective gloves and be extremely careful to avoid spillage when pouring the acid. In the event of contact, wash
the affected part thoroughly with running water and consult a physician, in particular when the eyes are involved.

MPL 66 S - MPL 76 S
- 11GB
GB
1.5.3 DANGER OF HARM TO HEARING
• Do not stand near the generator for long periods without protective earmuffs since hearing may be reduced.
Prolonged exposure to noise above 85 dB(A) may cause health disorders. It is in any case recommended
to use appropriate protection systems (e.g. headsets, earplugs, etc. ).
1.5.4 DANGER OF INTOXICATION
• The exhaust gases contain toxic carbon monoxide.
• Never use the generator in tunnels or in any place with poor ventilation. If indoor use is inevitable, it is essential
to provide for proper and efficient ventilation in order to prevent intoxication of persons or animals.
• Check that the engine exhaust is free and that the pipes allow evacuation of the exhaust fumes.
• Check that the exhaust gases are discharged to the outside in a safe position away from doors, windows and air
intakes.
1.5.5 DANGER OF FIRE OR EXPLOSION
• Always turn off the engine before refuelling.
• Do not smoke during refuelling.
• Refuelling must be carried out with extreme care, ensuring that fuel does not overflow from the engine tank
respecting the maximum level.
• In the event of fuel spillage from the tank, thoroughly dry and clean the parts involved.
• Check that there are no fuel leaks and that the pipes are undamaged.
• When refuelling has been completed, tightly close the fillercap.
• Keep flammable liquids, matches and other explosive and/or flammable products away from the generator, since
the temperature near the exhaust is high during operation.
• Never leave flammable liquids or cloths soaked in flammable liquids in proximity of electrical equipment (including
lamps) or parts of the electrical system.
• The batteries develop hydrogen, a highly explosive gas. It is recommended not to smoke nor cause sparks in the
vicinity, in particular during charging.
• Do not obstruct the cooling air inlets/outlets.
• In the event of fire, use a homologated fire extinguisher and never use water.
1.5.6 DANGER IF FAILING TO USE PERSONAL PROTECTION DEVICES
• The persons responsible for handling must always wear protective gloves and safety shoes.
• Wear safety shoes and overalls.
• If the generator needs to be lifted from the ground, the operators must wear a protective helmet.
• Immediately change wet overalls.
• Use protective gloves.

MPL 66 S - MPL 76 S
- 12GB
GB
1.5.7 DANGER CAUSED BY THE ENGINE STARTING
• Do not leave disassembled parts, tools or anything else not forming part of the system on or near 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
inclinationis 20degrees. Greaterinclinationof thegenerator mightcausethe fuelto leakoutor causeproblems withengine
oil pressure.
• To preventtheriskof fireandforproper ventilation,positionthe generatoratleast1m. (3ft.) frombuildingsor otherequipment
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.
• Check perfect functioning of the devices which stop the generator in the event of failure due to low oil level.
• Identify the position of the emergency stop buttons, switches and other emergency systems on the generator.
• Learn the special emergency procedures relative to the installation in question.
1.5.8 DANGER OF ELECTROMAGNETIC RADIATION
• Do not allow access to persons wearing a pacemaker because of possible electromagnetic interference with the device.
1.5.9 DANGER OF ELECTROCUTION
• When using the generator always bear in mind that in wet or very humid places and in confined conduction spaces it is
obligatory to comply with Articles 313 and 318 of Presidential Decree No. 547 27/04/55, as well as Chap. 11 Section IV
of the CEI 64-8 regulation.
• Immediatelychange wet overalls.
• Insulate all the connectors and detached wires.
• Do not leave the power terminal board of the generator uncovered; check that the electrical power and auxiliary service
connections have been made properly.
• Do not power loads with a voltage different from that delivered by the generator.
• 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.
Do not tamper with the active protections, thermal switches and differential magnetothermal switches.
• In the event of malfunctioning, do not remove the panel to attempt repairing it. Contact Mase specialised personnel.
• Do not access the generator with wet hands, since it is a potential source of electric shock if improperly used.
• Takethe necessary precautions toprevent the danger ofelectrocution;check that theearthingsystem has beeninstalled
and constructed in accordance with regulations.
• For the safety of the users, the earth connection of the generator must always be carried out paying particular attention
to the cable cross-section used. For the connection of the earth cable use the 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
• Packed and unpacked generators must be stored in a cool and dry place and never exposed to bad weather.
• Avoid stacking packed generators to prevent them from falling causing damage to persons and/or things.

MPL 66 S - MPL 76 S
- 13GB
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
6
7
8
9
11
12
13
15
16
3
14
10
1.6 REFERENCE DOCUMENTS
The instructions for use provided with each generator are
made up of a collection of documents of which this manual
representstheGeneralPart.Thefollowingdocumentsare
normally provided separate.
aCEdeclaration of conformity.
bInstruction manual for use and maintenance of
the generators,(this manual).
cEngine use and maintenance manual.
dList of mase Service Centres.
eMaseWarranty certificate.
fWarranty card.
1.7 REFERENCE REGULATIONS AND LEGISLATIVE PROVISIONS
The generator groups, built by mase, destined to the
countries of the European Community, are conforming to
theapplicableECdirectives, and they are provided of a EC
Declaration of Conformity.
98/37/EC and subsequent amendments:
Essential machine requirements for safety and health
protection (“Machine” directive).
73/23/EC and subsequent amendments contained in the
directive 93/68/EC : Guarantee of safety of electrical
material intended for use within certain voltage limits,
(“Low Voltage” Directives).
1.8 MARKING
The generator identification plate carries all the
identification data in accordance with the provisions for
EC marking for those cases where required. Below is a
facsimile of the identification plate fixed on the hull of
each generator.
1.9 IDENTIFICATION OF THE GENERATOR UNIT
1 - Machine name
2 - Machine code
3 - Serial number
4 - Rated power
5 - Declared frequency
6 - Rated power factor
7 - Rated voltage
8 - Rated current
9 - Degree of protection
10 - Class of isolation
11 - Temperature max. of use
12 - Altitude max. of use
13 - Performance class
14 - Year of construction
15 - Manufacturer - Adress
16 - Weight
The machine code number, the serial number
and the year of construction must always be
indicated when contacting the manufacturer for
information, order of spare parts, etc..

- 14
MPL 66 S - MPL 76 S
GB
GB
G
AB
MIC E
F
L
H
MPL 66 S
D
G
NU
Carrello optional
POS Q
R
T
U
2 GENERAL CHARACTERISTICS
The generators have been designed for use in the
industrial field, using highly reliable 1500 rpm water-
cooled diesel engines. Particular attention has been
paid to the degree of protection against external agents,
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.
The generator is particularly quiet thanks to an internally
insulatedsoundproofcasingand an advanced soundproof
system for combustion smoke exhaust.
The alternators used are the synchronous self-energized
type with electronic voltage adjustment.
2.1 CONFIGURATIONS
One of the characteristics is that it can be supplied in
different configurations:
1) For use as fixed installation;
2) With slow trailer with fixed drawbar (optional);
It is possible to change from a configuration to the other.
2.2 COMPOSITION OF GENERATOR UNIT
Thegeneratorunitisessentiallycomposedofthefollowing
components.
A - Fixed frame
B - Openable cowling engine side
C - Openable cowling alternator side
D - Instrument panel protection cage
E - Sockets panel (Optional)
F - Fuel tank
G - Support
H - Filler cap
I - Lifting hook
L - Air aspiration grate
M - Air expulsion grate
N - Exhaust pipe with rain protection
O - Fixed hook
P - Drawing hook
Q - Wheel
R - Mudguard
S - Steering wheel
T - Crank for rise setting
U - Emergency button

- 15
MPL 66 S - MPL 76 S
GB
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
commands and controls with the following components:
1 - Ignition key
2 - Hour counter
3 - Ammeter
4 - Voltmeter
5 - Engine protection module (see par.5)
6 - Low voltage termal protection
7 - Fuel level
8 - General magnetothermal switch
2.3.1 DIFFERENTIAL MEGNETOTHERMAL PANEL VERSION
(OPTIONAL)
8 - Differential magnetothermal switch
2.3.2 SOCKETS PANEL VERSION (OPTIONAL)
9 - Three-phase outlet, EC 63A 400V - 3P+N+GND
10 - Three-phase outlet, EC 32A 400V - 3P+GND
11 - Single-phase outlet, EC 16A 230V - 2P+GND
12 - Single-phase outlet, EC 16A 230V - 2P+GND
13 - Differential magnetothermal switch on socket line

- 16
MPL 66 S - MPL 76 S
GB
GB
MAX POWER (LTP)
1
66 76 kVA
CONTINUOUS POWER (PRP)
2
60 73 kVA
POWER FACTOR (Cos Φ)
THREEPHASE VOLTAGE
V
Hz
GRADE OF PROTECTION
MAX TEMP. OF USE °C
MIN TEMP. OF USE °C
MAX ALTITUDE OF USE m
COOLING AIR FLOW m
3
/
min
Lmm
DIMENSIONS W mm
Hmm
MASS 1160 / 1260 * 1210 / 1310 * kg
TYPE
MANUFACTER
MODEL BF 4M 2012 G 2 BF 4M 2012 C
DISPLACEMENT cm
3
MAXIMUN POWER 78,9 / 57, 95,2 / 70 CV - kW
n° OF CYLINDERS
RATED SPEED rpm
SPEED CONTROL
INDUCTION SYSTEM TURBO TURBO/INTERCOOLER
FUEL
INJECTION SYSTEM
FUEL FEEDING PUMPS
FUEL TANK CAPACITY L
AUTONOMY AT 3/4 LOAD 5,5 4,5 h
COOLING
LUBRIFICATION SYSTEM
OIL SUMP CAPACITY L
COMBUSTION AIR VOLUME 3,4 4,1 m
3
/min
EXHAUST GAS MASS FLOW 4,7 5,6 m
3
/min
ELECTRIC PLANT
V
STARTING
STARTING MOTOR V - kW
STARTING BATTERY V - Ah
BATTERY CHARGER V - A
STOPPING SYSTEM
TYPE
ISOLATION CLASS
VOLTAGE REGULATOR
VOLTAGE STABILITY
FREQUENCY STABILITY
COOLING
POWER FACTOR (Cos Φ)
CONTINUOUS POWER A.C.
GENERAL FEATURES
ALTERNATOR
ENGINE
RATED FREQUENCY
-15
1000
90
0,8
400
50
±5%
MODEL
SINGLEPHASE 230V
MPL 66 S MPL 76 S
SYNCHRONOUS, 4 POLES, SELF-REGULATED
H
ELECTRONIC
±1%
40
IP 23
2600 / 3580 *
900 / 1420 *
1190 / 1455 *
4 STROKE
DEUTZ
4040
4
1500
MECHANICAL
DIESEL
DIRECT
MECHANICAL
65
WATER
FORCED
8,5
14 - 55
STOP SOLENOID VALVE
12
ELECTRIC
12 - 3,1
12 - 100
AIR
1
2.4 TABLE OF TECHNICAL CHARACTERISTICS
*WITH TOW
(1) Limited - time running power (LTP) ISO 8528-1
It is the maximum power that, under the environment conditions established by the norm ISO 3046/1, the generator group it is able to disburse for a maximum
of 500 hours for year, of which a maximum of 300 hours among the interval of maintenance prescribed by the builder. It is accepted the operation to
this power conditions the duration of the group.
An overload of the 10% is admitted only for regulation.
(2) Prime power (PRP) ISO 8528-1
It is the available maximum power for a variable power cycle that the generator group is able to disburse for a boundless number of hours for year among
the interval of maintenance prescribed by the builder and under the environment conditions established by the norm ISO 3046/1. The middle power during
a period of 24 hours, doesn't have to exceed 80% of the PRP.
An overload of the 10% is admitted only for regulation.
L2
L1
L3
N
230 V
1/3 LTP
230 V
1/3 LTP
230 V
1/3 LTP

- 17
MPL 66 S - MPL 76 S
GB
GB
2.5 NOISE EMISSION
The values listed are emission levels and not necessarily
safeoperatinglevels.Althoughthereisacorrelationbetween
emissionandexposurelevels,thiscannotbereliablyused
toestablishwhetherornotfurtherprecautionsarerequired.
Amongthefactorswhichaffecttheeffectivelevelofexposure
of the workforce are the characteristics of the workplace,
other sources of noise, such as the number of machines
andother adjacentprocesses, andthetimeanoperator is
exposed to the noise. Moreover, the permitted exposure
levelsmayvaryfrom countryto country.Nonetheless, this
informationallowsthemachineusertobetterevaluatethe
dangerandrisk.
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
withIEC34 standards, are thefollowing:
-ambienttemperature40°C
-altitude1000metresabovesealevel(674mm/Hg).
Forinstallationandoperatingambientconditionsother
thanthoseindicatedforreference,appropriate“derating”
ofthepowersuppliedbytheunitmustbeperformed.
Theimpactofeveryfactordescribedinthissectionmust
not be considered individually but in combination with
theother factors.
The derating of synchronous generators is less
demanding than for Diesel engines; inasmuch, the
deratingofthepowergeneratoringeneralcoincideswith
thederating ofthe Dieselengine.
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 coefficients K1andK2 mustbothbe multipliedtothe rated powerofthe generatortoobtain the powerat
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
Guaranteed acoustic power level L
WA
dB(A
)
Acoustic pressure level at the operator
station L
pA
dB(A
)
94 97
in accordance with Directive 2000/14/EC
MODEL MPL 66 S MPL 76 S
The measurements were made with the generator running and in accordance with Directive 2000/14/EC, and regarding the place of
testing, the measuring conditions and the instruments in accordance with ISO 3744 of 1995. Measurement uncertainty values: +1dB.
The measurements were made with the generator running and in accordance with Directive 98/37/EC.
78 84
in accordance with Directive 98/37/EC

- 18
MPL 66 S - MPL 76 S
GB
GB
3 INSTALLATION
3.1 GENERAL INSTALLATION CRITERIA
The installation of one or more Generating Sets must be
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.
The systems must be installed in workmanlike manner
and upon completion the installer must issue the client
with a Declaration of Conformity of the systems installed
in accordance with the design specifications and the
specific standards.
3.2 IMPORTANT INFORMATIONS
3.2.1 INSPECTION OF MATERIALS
On receiving the set, it is advisable to check that the
materials correspond to that listed on the delivery note
accompanying the shipment. Some of the packages
may be opened at random to check that no damage has
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
country of installation.
3.2.3 FOUNDATIONS
The foundations must be calculated and designed by
civil engineers, taking maximum care to avoid the
transmission of vibrations and noise to other parts of the
structure.
3.3 EXHAUST PLANT
3.3.1 EXHAUST PIPE
The exhaust pipe must convey the exhaust gas to a zone
where it will not cause damage or harm, and away from
doors, windows and air intakes.
The outlet must be provided with a fixed protection to
prevent the ingress of rainwater.
Sections of pipes passing through walls must be insulated
to prevent the transmission of heat to the walls
themselves.
3.3.2 EXHAUST PIPE DESIGN
Theback pressure onthe engine exhaustgreatly influences
the power delivered by the engine and its thermal load.
Any excessive back pressure (measured on the outlet side
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
minimun number of bends.
3.4 VENTILATION
Ventilationof theroom inwhichthe generatingset isinstalled
isoffundamentalimportancefortheproperoperationofthe
set itself (SEE ALSO PAR. 3.8).
3.5 FUEL SYSTEM
ThestandardGeneratingSets normally supplied by mase
are fitted with a complete fuel system from the engine to the
standard fuel tank incorporated.
3.6 ELECTRICAL CONNECTION
Theelectrical connection must becarriedout exclusivelyby
a specialised technician according to EN 60 204.1 (IEC
204.01)regulations.
Thegeneratingsetsaresuppliedalreadyset-upforconnection
to the user.
The function of the generating set is to substitute the mains
electricity supply, and as such, must be considered as an
externalsourceof energy.Inthe executionoftheconnections
must be respected the suitable connections in the wiring
diagram furnished with the group.
3.6.1 POWER CABLES SIZES
The choice and size of cables to use is the responsibility
of the plant installer.
It should be emphasised that using smaller sections
than that recommended would cause excessive voltage
drops and lead to dangerous overheating of cables.

- 19
MPL 66 S - MPL 76 S
GB
GB
43
5
6
2
1
2
3.6.2 POWER CABLE CONNECTION
The set of generator-utility-network connection cables
must be properly arranged in a suitable duct or underground
passage (also see para 3.7/3.8).
For installation, use the following procedure:
1) Remove the small panel (ref.1).
2) Open the hatch (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
terminal board (ref.5).
4) Clamp with specific cable retainers.
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
other reasons, may become live, must be connected to a
ground system.
To connect to ground, use the procedure given in par.3.6.2,
then connect the ground cable to the respective terminal
indicated by the icon (ref.6).
The sizing of the ground wires to the ground system and the
relative contact resistance must comply with current laws
and standards.
Do not tamper with the active protections, thermal
switches and differential magnetothermal switches.
• In the event of malfunctioning, do not remove the
panel to attempt repairing it. Contact Mase specialised
personnel.
• Take the necessary precautions to prevent the danger
of electrocution; check that the earthing system has
been installed and constructed in accordance with
regulations.
• For the safety of the users, the earth connection of the
generatormustalways be carried out paying particular
attention to the cable cross-section used. For the
connection of the earth cable use the dedicated
terminal on the generator.
The manufacturer is NOT responsible for any damage
caused by failure to earth the system.
The earthing system must be located as far as possible
from railway/tram lines in order to prevent electro-
corrosion of the internal components of the engine in
contact with water.

- 20
MPL 66 S - MPL 76 S
GB
GB
3.7 OUTDOOR INSTALLATION
For units in outdoor installations, it is advisable to ensure
a position that provides maximum protection against
atmospheric agents, 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.
For permanent or long-term installations, it is advisable
to prepare a concrete foundation.
The area where the power set is installed must be
suitably fenced off in order to prevent access by
unauthorized persons.
No admittance and Hazard signs must be installed
as required by current legislation.
Key:
1 - Casing in painted sheet metal
2 - On board control panel
3 - Foundation
4 - Air expulsion
5 - Cable duct
6 - Air intake
7 - Gas exhaust pipe
8 - Metal protection enclosure
9 - Distribution panel not supplied as
standard (automatic start remote
control switches-Optional)
Outdoor installation