Masse SILENT 5001DM User manual

SILENT 5001DM
SILENT 6001 DT
SILENT 8002 DM
SILENT 9002 DT
Rev. 1 S.S. 23/10/02 cod.41327
masemase masemase
mase
GENERATORS
IMANUALE USO E MANUTENZIONE
GB USE AND MAINTENANCE MANUAL
NL GEBRUIKS-ENONDERHOUDSHANDLEIDING
D GEBRAUCHSANWEISUNG UND WARTUNGSVORSCHRIFTEN
F MANUEL D’UTILISATION ET D’ENTRETIEN

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CONTENTS
FAILURETOADHERETOTHEINSTRUCTIONSAND
SPECIFICATIONSCONTAINEDINTHIS
USE AND MAINTENANCE MANUAL WILL
INVALIDATETHE PRODUCT GUARANTEE.
Figures................................................................... 2
Wiring diagrams ................................................... 9
1. General information ..................................... 21
1.1 Scope of the manual...................................... 21
1.2 Attached documentation ................................ 22
1.3 Manufacturer-machineidentification ............... 22
1.4 Instrument panel ............................................ 22
2. Technicalspecifications .............................. 23
3. Safety regulations ........................................ 24
3.1 Precautions ................................................... 24
3.2 Earthing the generator ................................... 24
4. Using the generator...................................... 24
4.1 Preliminary checks ........................................ 24
4.2 Start-up ......................................................... 24
4.3 Stop .............................................................. 24
4.4 Hook up to the automatic control panel.......... 24
5. Protections .................................................... 25
6. Maintenance ................................................. 25
6.1 Ordinary engine maintenance ........................ 25
6.2 Changing the engine oil ................................. 25
6.3 Venting the system ....................................... 25
6.4 Replacing of air filter ...................................... 26
6.5 Cleaning the air intake grids .......................... 26
6.6 Period of inactivity ......................................... 26
6.7 Table of scheduled operations ....................... 26
6.8 Troubleshooting ............................................. 26
Wiring diagrams list ............................................. 27

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1.GENERALINFORMATION
Read this manually carefully before using the machine.
1.1 Scope of the manual
Thank you for having chosen a MASE product.
This manual was prepared by the Manufacturer and is an integral part of the components supplied with the machine.
Thisinformation has been prepared for usersand the personnel assigned to performmaintenance on such equipment.
The manual defines the scope for which the machine was built and contains all the information needed to ensure safe
and correct use.
Strict compliance with these instructions will guarantee the safety of persons and the machine and will ensure
economic operation and extended machine service life.
This manual has been divided into sections which identify the main concepts. Consult the table of contents for a quick
guide to the various subjects.
The most important parts of the text are indicated in bold and are preceded by the symbols illustrated and described
below.
This indicates that operators mustbe very careful to avoidserious consequences which might lead
to the death of personnel or create possible health hazards.
A situation that might occurduring the useful life of theproduct, system or plant whichis considered
at risk in terms of injury to persons or damage to property and the environment or economic losses.
This indicates that careful attention is needed to avoid serious consequences that might damage
material goods such as resources or the product.
Particularly important instructions.
The drawings are supplied for the sake of examples. Even if your machine differs greatly from the illustrations included
in this manual, machine safety and information are still guaranteed.
Sincethe manufacturer is constantly developing and updating the product,changes may be made without prior notice.

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1.2 Attached documentation
The following documentation is an integral part of this
manual:
- EEC conformity declaration (fig.1);
- Engine operation and maintenance manual;
- SERVICEhandbook;
- Warranty certificate;
- Warranty card.
1.3 Manufacturer-machine identification
See FIG. 2
1 - Machine code
2 - Year of manufacture
3 - Power factor
4 - Rated frequency
5 - Continuous output
6 - Nominal voltage
7 - Rated current
8 - Mass
9 - Series number
See FIG. 3
1 - Exhauste outlet
2 - Instrument panel
3 - Tank chassis
4 - Socket panel
5 - Lifting hook
6 - Frontal engine access door
7 - Battery space
8 - Back engine access door
9 - Cooling air discharge grid
10 - Cooling air intake grid
Every request for information, spare parts, etc. must
bear the machine identification data, machine number
and year of manufacture.
1.4 Instrument panel
FIG. 4 Key
1 - Hour meter
2 - Voltmeter
3 - Magnetothermal switch 3p
4 - Magnetothermal switch 1p
5 - Emergency stop button
6 - Connector for hook up to the automatic
control panel
7 - Single-phase socket
8 - Terminal for ground connection
9 - Three-phase socket
10 - Ignition key
11 - Engine protection module
12 - Running engine lamp
13 - Low oil pressure lamp
14 - Level fuel lamp
15 - Battery charger lamp
16 - Higth engine temperature
17 - Emergency stop button lamp
The generating units in this series Silent have been
designed for industrial use and are driven by highly
reliable, 3000 r.p.m. air-cooled diesel engines. Special
attention has been paid to: the degree of protection
againstforeignbodies;safeguardingtheengine;protecting
the electrical components from surges or excessively
hightemperatures. This is achieved through an automatic
system able to shut down the unit if any malfunction
arises. The Silent units are particularly silent thanks to a
fully insulated, sound-proofed cabin and to an advanced
system for soundproofing the exhaust discharge of
combustion fumes.
Synchronous, self-exciting alternators with electronic
voltage regulator, are employed which can provide
extremely high peak currents with a voltage stability of
less than 5%.

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2.TECHNICAL SPECIFICATIONS
MODEL SILENT 5001 DM SILENT 6001 DT SIELNT 8002 DM SILENT 9002 DT
GENERATOR
Type synchronous - 2-ph synchronous - 3-ph. synchronous - 2-ph synchronous - 3-ph.
Power VA 3700 4600 6500 8100
Voltage V 230 400 230 400
Frequecy Hz 50 50 50 50
Current A 20 6,6 28,2 11,7
Power factor cos.f 1 0,8 1 0,8
Degree of protection IP
ENGINE
Type
Model
No. of cylinders n.
Fuel
Power supply HP
Displacement cm3
Intake
r.p.m.
Tank capacity l.
Hourly consumption l/h
Electrical system V
Size (LxWxH) mm
Weight kg
1000x570x780
205
Atmospheric
3000
7,8 12,6
426 654
12
Diesel
RUGGERINI
MD 95 MD 150
23
20
1,5 2,9
12 12

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3.SAFETYREGULATIONS
3.1 Precautions
CarefullyreadtheInstructionandMaintenance Manuals
before starting up and using the machine.
The manufacturer declines any responsibility for dam-
agestopersons or things stemming from noncompliance
with the safety standards.
Carefully examine the safety panels applied to the
machine and follow their contents to the letter.
- Donotallowunqualifiedorinadequatelytrainedpersonnel
to use the generator.
- Keepchildren oranimalsaway fromthegenerator when
it is running.
- Do not approach the generator with wet hands as it is
apotential source of electrical shockifimproperlyused.
- Donotperformanyoperationsonthegeneratorunless
the motor is off; tests which require the motor to be
running must only be performed by specialized
personnel.
When the generator is connected
to an automatic start-up panel, before any tests or
maintenancecan be performed, it mustbelockedout
- by selecting the BLOCK function - or disconnected
- by disengaging the connector.
- Theexhaust fumes contain carbonmonoxide and other
harmfulsubstances;neverruntheunitinaninadequately
ventilatedarea.
- Do not run the unit in the vicinity of areas where there is
the risk of explosion or fire.
- Refuellingmustonlybeperformedwhentheengineisoff.
- Theunitisgroundedusing anadequate diametercopper
cable.
When using the generator, bear in
mind that in wet or very damp places and in confined,
conductive spaces the following regulations must be
compliedwith: Chap. 11,sect.IV ofCEIregulation 64-8.
3.2 Grounding the unit
Forusersafety the unit must always be grounded paying
particular attention to the section of the cable used.
Connect the ground cable with the special terminal
located on the outlet panel (Fig. 4 Ref. 8). Make ground
connections following the table indicating the cable
sectionsto be used; these depend onthe power rating of
thegenerator:
Power KVA 1-10 10÷20 20÷40 40÷60 60÷80
Section mm² 520304050
4.SINGTHE GENERATOR
4.1 Preliminary checks
The first time the unit is started up after maintenance, a
good rule of thumb is always to make certain that:
- the oil is at the required level. This is done using the dip
stick (fig. 5 ref. 1): see table for the suggested oils.
- the electrical devices are off so that the generator will
not start up under a load.
- the fuel pipes are in good condition and properly
connected.
- no electrical connections are in poor condition.
4.2 Start-up
Before starting up the generator, make certain that all
devicesare off so as toprevent forcing the engine whenit
is cold. Proceed with start-up by rotating the START key
(fig. 4 ref.10) clockwise one click. All the LEDs will light
up for approximately 2 seconds as the self-check is
performed. The battery recharge LED (fig. 4 ref. 15) and
thelow oil pressure LED (fig.4 ref. 13)willthen remain on.
Start up the unit by turning the ignition key clockwise all
the way; only release it when the engine has cut in.
However,in no case should the key be helddownformore
than 5 seconds in an attempt to start up the engine.
All protections cut in 15 sec. after the unit is started up
and, in case of malfunction, the unit will shut down and a
warning light will go on indicating the malfunction.
Before turning on any of the devices, leave the engine
runningwithout any load for at least fiveminutes. This will
allow it to reach operating temperature gradually thus
ensuring maximum engine life and preventing seizing.
4.3 Shut down
Theunit is shut down byturning the ignition key (fig. 4ref.
10) all the way counter-clockwise.
Before shutting down the unit, it is advisable to let it run
for a few minutes without any load thus lowering the
temperature inside the engine and the alternator.
4.4 Hook up to the automatic control panel
The Silent series units are prepared for connection to an
automatic control panel able to automatically start up the
generator, to switch lines when line power cuts out and
switch back when the line voltage is returned.
In addition, the automatic control panel maintains the
charge in the generator start-up battery, even when the
generatoris off.

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Theunitishookeduptotheautomaticcontrolpanelthrough
the 6-pin connector found on the unit instrument panel
(fig.4ref. 6) and a power supply plug inserted in the outlet
located on the generator instrument panel (fig. 4 ref.9).
Whenthegeneratorisconnectedto
the automatic control panel the ignition key located in
theinstrumentpanelmust remainin theOFFposition.
SelecttheBLOCKfunctionwhenever
maintenance or repairs are being performed on the
unit. This will prevent the generator from being
accidentallystartedupincasethe linepower cutsout.
5.PROTECTIONS
The units are equipped with a series of protections to
safeguardthemfromimproperuseandfrom failureswhich
could compromise their function. These protect against:
-Low oil pressure
This cuts in, turning off the unit, whenever there is
inadequatepressureinthelubricationcircuit;whenitcuts
in a LED (fig. 4 ref. 13) goes on.
Inthiscase,addingadditionaloilisusuallyenoughtostart
up the unit once more.
Thelowoilpressureprotectiondoes
notprovideanyindicationas to the oil level. To prevent
damagingtheengine,itisessentialtochecktheoillevel
periodically.
-High engine temperature
This protection cuts in, turning off the unit whenever the
engineoperatingtemperatureistoohigh.Whenactivated
a LED (fig. 4 ref. 16) goes on.
Inthiscase,theunitcanonlybestartedupagainafterthe
cause has been identified and eliminated.
-Short circuits and overloads
To protect against short circuits and overloads, the
unit is equipped with magnetothermal and differential
breakers which cut off the power supply when the
alternator is overloaded or there is a short circuit.
Before powering the unit again by flipping the
magnetothermalbreaker levers (fig. 4 ref. 3-4) back to
the ON position, the problem which caused it to trip
must be removed.
For this purpose the following breakers are used:
- thegeneral differentialmagnetothermalcircuitbreaker:
in the case of short circuit, overload and current
leakage to ground, this cuts off the power supply to all
outlets (fig. 4 ref. 3).
- Magnetothermalcircuitbreakerstothelowvoltageoutlets;
these break the circuit whenever the voltage at a given
outletishigherthanthenominalvoltageforthatparticular
outlet.
6.MAINTENANCE
Allmaintenanceoperationsonthe
generatormustbeperformedbyauthorized personnel.
Maintenancemust be performed after the engine has
been turned off and has cooled down sufficiently.
6.1 Ordinary engine maintenance
The periodic maintenance required for the engine is
reported in the table. For more detailed information, see
the manual supplied by the engine manufacturer and
attached supplied with the generator.
Checktheoillevelusingthespecial,
graduated dip stick (fig. 5 ref. 1 ).
The oil level must always be between the MAX and
MIN level notches on the stick.
6.2 Changing the engine oil
Use AKROS TURBO 15 W 40 oil
The oil tank is filled and topped up through the hole
indicated in fig. 5 ref. 2.
For more detailed information, see the engine use and
maintenance manual provided with the machine.
To change the engine oil, first remove the lower hatch
closing the soundproofing case. Then withdraw the cap
located on the oil sump and drain it into a container
placed under the body.
It is advisable to drain the oil when it is still sufficiently
warm as it will flow more easily.
Do not disperse spent oil in the
environment as it causes pollution.
Deliver spent lubricating oil to special Collection
Centerswhich handle disposal.
6.3 Venting the system
The presence of air bubbles in the fuel system can cause
theengine to run irregularly or prevent it from reaching its
nominal r.p.m. Air can penetrate the fuel circuit through
imperfectly sealed joints (i.e. piping, filters, tanks) or
when the level of fuel in the tank is at a minimum. To
eliminate air bubbles from the fuel circuit one must first
eliminate the failure which allowed the air to enter in the
first place. The following operations must then be
performed:
1 - Loosen the vent screws located on the fuel filter (fig.5
ref.3) and on the injection pump (see the engine use
andmaintenance manual).
2 - Manually manipulate the AC fuel pump lever (fig.5
ref.5) until the all the air in the system has been
eliminated through the vent screws (fig. 5 ref. 4).

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3 - Tighten the vent screws once more and start up the
engine.
4 - Repeat the above operations if the engine is stillnot
functioningproperly.
Consult the engine use and
maintenance manual for further details on the fuel
system.
6.4 Replacing the air filter
To ensure proper functioning and long engine life it is
important to clean and periodically replace the air filter
oil(fig.6 ref. 1). An inefficient filter can cause loss of
engine power and can give rise to excessively smoky
exhaust.
To replace the air filter oil operate as follows:
- Remove the oil tank (fig.6 ref.1) from the air filter after
having unblock the securing springs.
- Remove the oil inside tha air filter and refill new oil
respecting the maximum level;
- Replace the oil tank and look the securing springs.
Cleantheairfiltercartridgeevery100hoursofoperation.
Shorten this interval if the generator is operated in a
particularlydusty environment.
Replacethe cartridge when it isexcessivelyfouled or
damaged.
6.5 Cleaning the air intake grids
Periodicallycheckthecoolingairintakeanddischargegrids
(fig. 3 ref. 9-10) and the cylinder cooling fins for fouling.
These must be free of any foreign bodies which could
obstructtheflowofcoolingair(i.e.leaves,paper,rags,etc.).
6.6 Periods of inactivity
If the unit will not be used for a long period of time, the
following operations must be performed:
- replace the engine oil sump;
- replace the fuel filter;
- remove the injector, insert a few drops of oil inside the
combustion chamber and manually rotate the drive
shaft a few times; reinstall the injector and close the
suction and delivery openings.
6.7 Table of scheduled operations
OPERATION HOURS
Check the level of the oil in the sump 8
Clean the air filter 8
Replacing the oil inside the air filter 50
Cleaning engine cooling fins 100
Check the level of the electrolytes
and thebattery charger status 150
Cleaning the oil filter 200
Replacing the fuel filter 200
Replacing the oil sump (*) 200
Replacing fuel filter 200
Regulate the play in the rocker lever 200
Calibrate and clean the injectors 500
Partial overhaul 2500
General overhaul 5000
(*) The first oil changing after 50 hours of running
6.8 Troubleshooting
The starter motor turns but the main engine does not
cut in.
- Make certain there is fuel in the tank (refill).
- MakecertainthattheStopsolenoid is powered (contact
theService Center)
- Make certain that the fuel pump is functioning (contact
theService Center)
The control panel does not cut in when the ignition
key is turned.
- Check the protection fuse (replace)
- Check the connection cable and electrical connectors
(reconnect)
- Make certain that the battery is operative (recharge or
replace)
The unit cuts out during operation.
- Check whether the protection has been activated and
thewarninglightis on (remove the cause and try to start
up again)
- Make certain there is fuel in the tank (refill)
The engine is running irregularly.
- Check the fuel filters (replace)
- Make certain that the fuel pump is operating properly
(replace)
- Checkcalibration of the injectors(contactanAuthorized
ServiceCenter)

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7.WIRING DIAGRAM LIST
Fig.8
1 - Rotor
2 - Stator
3 - Electronic voltage regulator
4 - Hour counter
5 - Voltmeter
6 - Earth fault device and magnetothermal switch
7 - Three phase socket
8 - Singol phase socket
9 - Earth connection terminal
10 - Connector
11 - Engine protection module
12 - Starting key
13 - Emergency stop button
14 - Starter
15 - Low oil pressure switch
16 - Engine high temperature switch
17 - Fuel floating
18 - Stop solenoid
19 - DC alternator
20 - Battery
Fig.9
1 - Rotor
2 - Stator
3 - Electronic voltage regulator
4 - Hour counter
5 - Voltmeter
6 - Magnetothermal switch
7 - Singol phase socket
8 - Three phase socket
9 - Earth connection terminal
10 - Connector
11 - Engine protection module
12 - Starting key
13 - Emergency stop button
14 - Low oil pressure switch
15 - Low oil pressure switch
16 - Engine high temperature switch
17 - Fuel floating
18 - Stop solenoid
19 - DC alternator
20 - Battery
Fig.10
1 - Rotor
2 - Stator
3 - Electronic voltage regulator
4 - Hour counter
5 - Voltmeter
6 - Magnetothermal switch
7 - Magnetothermal switch
8 - Singol phase socket
9 - Three phase socket
10 - Earth connection terminal
11 - Connector
12 - Engine protection module
13 - Starting key
14 - Emergency stop button
15 - Low oil pressure switch
16 - Engine high temperature switch
17 - Fuel floating
18 - Stop solenoid
19 - DC alternator
20 - Battery
21 - Starter
Fig.11
1 - ALTERNATOR
2 - BATTERY CHARGER FLYWHEEL ALTERNATOR
3 - BATTERY
4 - IGNITION KEY
5 - STOP ELECTROMAGNET
6 - FUSE
7 - RESERVE FLOAT
8 - PILOT LIGHT
9 - 4-POLE MAGNETOTHERMAL SWITCH
10 - STARTER MOTOR
11 - SCHUKOSOCKET
12 - OIL PRESSURE SWITCH
13 - EMERGENCYSTOPBUTTON
14 - BATTERY CHARGEREGULATOR
15 - ELECTRONIC VOLTAGEREGULATOR
16 - START RELAY
17 - ROTOR
18 - STATOR
19 - ENGINETHERMOSTAT
20 - VOLTMETER
21 - OUTLET3P+N+GND16A
22 - PREHEATING
23 - RELAY
24 - CONNECTOR
25 - EARTH CONNECTION SCREW
26 - TERMINAL BOARD
27 - ALTERNATORTHERMOSTAT
28 - COMMANDSELECTRICFORTHEAUTOMATIC
CONTROL
29 - CARDFORTHEAUTOMATICEXCHANGE