Manual Gesan
Manual Gesan
Manual Gesan
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1.- WELCOME
The purpose of this manual is to familiarize the user on how to use and work
with the electrical generator, its components and maintenance.
Save this manual for future reference and if the generator set is resold be
sure to include the manual along with the unit.
The following is a general description of the unit and the information necessary
for installation, operation and preventive maintenance.
Additionally, you should have received a specific user manual for the engine
and alternator, electrical setup, a set of keys, ATS (upon order), silencer or
exhaust tube and flexible tube (supplied separately for open-skid units).
Should you have any problem with the equipment provided, please contact
the distributor directly.
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2.- BASIC SAFETY RULES
Safety precautions and recommendations for handling the generator set supplied by GESAN.
1) Do not allow the unit to be used by non-authorized personnel or minors not accompanied by an adult.
2) Use the necessary Individual protection equipment.
3) Ground the machine and ATS panel.
4) Make sure there is sufficient lighting on the control panel.
5) Do not install the open-skid electrical generator outdoors: risk of electrocution and non-functioning.
6) The connection should be made by a qualified electrician in accordance with current norms and regulations. An
incorrectly made connection can cause electrical feedback with electrocution hazards for anyone working with the
mains power supply. The mains connection should always be made using an automatic transfer switch (ATS); if
none has been supplied, contact your distributor or GRUPOS ELECTRÓGENOS GESAN, S. A.
7) The supply line between the generator set and the consumers should be protected by means of a differential relay
for protection against earth leakage.
8) The electrical installation between the generator unit and ATS should be protected using electromagnetic circuit
breaker for protection against short circuits. The circuit breaker is supplied optionally by GRUPOS ELECTRÓGENOS
GESAN, S.A.
9) Do not operate the unit with the doors open: risk of electrocution, burns or entrapment.
10) The exhaust system produces enough heat to ignite certain materials.
11) Do not inhale exhaust gases produced by the unit.
12) Do not touch the engine or the exhaust while the generator set is operating as this could produce serious burns.
13) Ensure proper ventilation in the area where the generator is installed in order to guarantee sufficient flow of cooling
air.
14) Do not refuel while the engine is running or in poorly ventilated areas.
15) Know how to stop the unit in case of emergency.
16) The fuel used is flammable and volatile.
17) Do not overfill the tank and make sure it is closed properly after filling. Use extreme precaution if fuel is spilled: the
vapors and the fuel itself are flammable. Clean the area completely before starting up the unit.
18) Do not smoke or bring any flames or sparks in the vicinity of the generator set: risk of explosions.
19) If you notice abnormal behavior by the generator set, stop the unit, locate, examine and resolve the potential failure
of the unit prior to restarting. Contact our technical services department if needed.
20) Keep the unit at least one meter away from buildings or other units.
21) Be cautious when switching or installing batteries as they contain acids which are highly hazardous. Avoid spills
and use protection to avoid contact with the skin and eyes. In case of contact, rinse thoroughly with water and
contact a doctor immediately.
22) In case of ingestion of battery acid, drink large amounts of water and milk and contact a doctor immediately.
23) Use only distilled water in the battery: tap water reduces its life expectancy.
24) If a battery is filled above the maximum level, the electrolytes will spill out; if this happens, clean the area quickly to
avoid corrosion of the parts it has come in contact with.
25) Frequently clean the unit to avoid obstructions or the entry of foreign elements into the unit (dust, moisture, etc.).
26) Regularly inspect the unit’s electrical cables.
27) Prolonged contact with used oil can cause skin cancer. Wash your hands after working with the generator.
28) Avoid oil spills on both the inside and outside of the generator. In case of an oil spill on the inside of the unit, clean
it properly as it could potentially become a flammable material.
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3.- DESCRIPTION OF GENERATOR SET
General overview of the generator set and its different configurations manufactured by GRUPOS
ELECTRÓGENOS GESAN, S.A.
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1 9
2 10
3
11
12
4
13
5
14
15
6
16
17
8
5
1 7
10
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3.1 .- SOUND INSULATION
The supplied unit may be:
• Soundproofed. Includes sound-insulating canopy.
• Open skid. Please keep in mind that compliance with current regulations requires that proper sound insulation
be provided for this model. (See 4.2 INSTALLATION).
Each generator set is provided with a sticker indicating the level of noise output produced and the need to use
hearing protection.
The noise level has been measured according to the european directive 2000/14/EC and in compliance with the
maximum levels established by directive 2005/88/EC.
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3.2.- CONTROL UNITS
The unit provided may be controlled by different modules depending on the type of function it has been designed
to perform.
The following is a generic control panel, which contains all of the electrical and mechanical options available.
A Hz V
LOCK
HOURS
VOLTMETER
AUTOMATIC SWITCH
CONTROL F
ENGINE BLOCK
UNIT HEATER PILOT
BATTERY
VOLTMETER
LOCK
DIFFERENTIAL
AUTO FUEL
REFILL SWITCH
TEMP AND
FUEL GAUGE BUTTON
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3.2.1.- GECO / GPM-2 analog control module
If you purchased a generator unit with a GECO control module, the electrical panel will look like the following
diagram:
A Hz V
LOCK
HOURS
VOLTMETER
SWITCH
F
ENGINE BLOCK
HEATER PILOT
BATTERY
VOLTMETER
ALTERNATOR BATTERY
VOLTMETER PILOT
LOCK
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If you purchased a generator unit with a GPM-2 control module, the electrical panel will look like the following
diagram:
A Hz V
LOCK
HOURS
VOLTMETER
SWITCH
F ENGINE BLOCK
HEATER PILOT
BATTERY
VOLTMETER
LOCK
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3.2.2.- DEEP SEA digital control Module
If you purchased a generator unit with a DEEP SEA control module, the electrical panel will look like the following
diagram:
ENGINE BLOCK
HEATER LIGHT
(YELLOW)
Note: The button on the control module performs the same function as the diagnostic button (while in OFF/AUTO mode).
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3.2.3.- INTELIGEN digital control module
If you purchased a generator unit with an INTELIGEN control module, the electrical panel will look like the following
diagram:
A A A V Hz
LOCK
HOURS HOUR
METER
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3.3.- ELECTRICAL CONFIGURATION
The supplied unit may be one of three types:
• The generator unit is supplied with ATS.
• The generator unit is supplied without ATS. Note that its installation is required.
GENERATOR
SET
MAIN POWER
PCS ATS
SUPPLY
UTILIZATION
(CONSUMERS)
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3.4.- RETENTION BATH
The generator set may include a built-in galvanized drip pan to prevent spills from the unit—such as fuel, oil or
coolant—with a capacity of 110% with respect to the total volume of liquids in the generator set.
1 3
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4.- INSTALLATION OF THE GENERATOR SET
4.1.- UNLOADING AND TRANSPORT
When unloading an generator set, certain minimum conditions should be observed in terms of safety and efficiency.
The loading and transport of the unit should be done by qualified personnel.
• The ground must be capable of supporting the full weight of the generator and the forklift.
• Make sure that the battery is disconnected.
• Make sure that the fuel tank is empty..
• Place the open arms of the forklift below the chassis at an equal distance with respect to the lifting frame.
• With a hoist, raise the unit using the lifting frame eyebolt.
The image below shows a drawing of a generator unit which includes a frame with a single lifting point.
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4.2.- INSTALLATION
This manual describes the installation of a “generic” generator set comprised of a diesel engine, an alternator and
an electrical panel. Our technicians can advise you on each of the specific applications.
4.2.1.- Premises
The following considerations must be kept in mind: the fuel supply, ventilation of the premises, the output and direction
of the exhaust gases and the noise produced.
• Dimensions
The dimensions should allow for the various required maintenance or disassembly operations. A minimum of one
meter should be left on all sides of the generator to allow for the doors to be opened.
• Openings
The premises should have an entrance that is large enough for the generator to pass through and allows for ventilation
(fresh-air intake, hot-air exhaust), with the appropriate surface area based on the generator’s output, the premises’ cooling
system and the soundproofing system used.
GRUPOS ELECTRÓGENOS GESAN, S.A., does not recommend installing canopied units in closed spaces.
If the unit must be installed in a enclosed space, it is recommended to use an open-skid model and soundproof the
work area, in keeping with the current fire-prevention regulations.
The following image shows a typical installation of an open-skid unit in a closed space.
1 2 3 4 5
6 7 8
1) Air intake grill. Will be at least 1.4 times the surface area of the engine’s radiator panel.
2) Smoke exhaust line. This will be explained in more detail later.
3) Silencer. Must be firmly installed and fastened to a stable structure.
4) Smoke exhaust outlet. Smoke must flow out through a point which impedes its reentry into the space where
theworking unit is installed.
5) Radiator air outlet grill. Will be at least 1.25 times the surface area of the engine’s radiator panel.
6) Channeling duct for cooling air. Prevents re-entry of hot air into the space where the unit is installed.
7) Optional fuel tank. The tank may or may not be supplied by GRUPOS ELECTRÓGENOS GESAN, S.A.
8) Auxiliary fuel pump, SAB-BE system. Optional accessory for filling of the electrical generator’s day tank from
large-capacity tank.
9) Fuel line, adequate for transporting fuel and complies with current regulations.
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4.2.3.- Ventilation and cooling
The heat produced by the generator’s thermal engine must be evacuated from the premises.
The heat is generated by the cooling of the cylinders, the radiation from the engine block, the exhaust passage, the
cooling of the alternator and the radiator air output.
Insufficient ventilation could produce an increase in the atmospheric temperature of the premises and cause the
generator to lose engine power or even shut down.
4.2.4.- Fuel
In keeping with current legislation, special attention should be paid to the storage of fuel, which is classified as a
hazardous product. The installation of the generator will include a day tank and an optional fuel storage tank.
Depending on the output of the generator, the fuel tank may be external instead of being built into the base frame.
The tank should be installed within a maximum distance (see the engine manufacturer’s manual). The installation
will be carried out according to current legislation.
The unit may include a self-suction, eccentric fuel transfer pump (SAB-BE) with self-adjusting blades. Includes a
recirculation bypass valve. The pump has an internal removable 352 micron filter, which must be used.
PARAMETER VALUES
OUTPUT 1/3 H.P.
ENGINE SPEED 3,000 R.P.M.
FUEL SUPPLY 230 ACV
FREQUENCY 50 Hz, SINGLE PHASE
COOLING FAN
BYPASS PRESSURE From 2 to 2.5 bar
LINE IN/OUT 1” diameter
PROTECTION LEVEL IP-25
MAX AIR FLOW 50 l/min.
PUMP INTENSITY 1.5 A
ASPIRATION 2.7 meters
N�
Note: The pump will function if the generator set is running; it has an ON/OFF switch located on the door of the unit’s electrical panel.
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4.2.5.- Exhaust
Given the importance of complying to environmental regulations, special attention must be given to gas emissions.
Preventable load loss, insulation, suspension, sound levels and air contamination should all be taken into account.
The compensators and flexible tubing used in the installation will absorb the displacement of the unit (due to dilations
and vibrations).
The units supplied by GRUPOS ELECTRÓGENOS GESAN, S.A., may or may not include a rain cap. The units are
equipped with two holes on the underside to prevent internal water accumulation.
The potimun muffler locations are, first, directly behind the exhaust manifold, and secondly at 2/5 or 4/5 of the total
exhaust system length. The reason for this are the existing standing waves, especially for long exhaust systems, when the
natural tube frequency is in resonance with the fundamental engine frequency or one of its harmonics. The worst muffler
locations in order of valve are 1/3, 3/5 or at the end of the system.
The best muffler locations in order of values are The worst muffler locations in order of value are
Note: In installations where it needs long exhaust system. It will must have bigger diameter. If the installation isn´t correct.
The startup system used by the generator set is electrical and consists of a 12 or 14 V electric engine powered by
one or more batteries, usually lead.
If the unit has been shipped to somewhere outside Spain, the placement into service of the dry-charged batteries
should be done by removing the vent caps, filling each cell using sulfuric acid with a density of 1.28 (or 1.23 in tropical
countries). Let it sit for at least 20 minutes and check the electrolyte level (25 mm above the plates); never fill to the brim.
Put the caps back on.
It is recommended that protective eyewear and gloves be worn when adding battery acid. Make sure that there is nearby
access to running water in order to wash any areas that come into contact with the acid.
All operations must be performed with the utmost precaution and safety as indicated in this manual. (Be especially careful with
potential short circuits that could occur when coming in contact with the unit’s metallic objects).
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4.2.7.- Electrical connection
These connections should be made while following a number of safety measures:
1) Use the proper individual protection equipment to ensure complete safety while performing the electrical
installation.
6) Before beginning the installation of the unit provided, make sure that it meets your particular needs for
voltage and frequency.
8) The installation of the electrical generator must be performed correctly and the ATS ground connection should be
identified by the following icon:
The unit manufactured by GRUPOS ELECTRÓGENOS GESAN, S.A., may or may not be supplied with ATS
(depends on electrical configuration: see section 3.3); if it is not supplied, it must be added by the customer.
The ATS is comprised of contactors or a motorized switch supplier. The ATS will prevent simultaneous supply by
the mains and the electrical generator.
The following diagram shows the ATS setup.
GENERATOR MAIN
SET POWER SUPPLY
AUTOMATIC
TRANSFER
SWITCH (ATS)
CONSUMERS
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The electrical installation of the ATS is performed in two separate steps: first, the installation of the CONTROL
section (control and management of mains and ATS) and second, the ELECTRICAL POWER section (transmission of
electrical energy).
The following diagram shows the connections of a typical ATS manufactured by GRUPOS ELECTRÓGENOS
GESAN, S.A.
GECO
module only
R S T N 37 38 39 40 41 42 43 44 45 46 47
KM1 KM2
KM2 KM1
QM1
A1 A1
KM2 KM1
> > > > A2 A2
1 3 5 7 1 3 5 7
A1 A1
KM2 KM1
A2 A2
2 4 6 8 2 4 6 8
R S T N X Y Z N U V W N
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4.2.7.1 Installation of CONTROL section:
The installation of the control section can be done in three different ways:
1) ATS supplied by GESAN
2) ATS not supplied by GESAN
3) Unit is the “Standby by signal” type
In making these connections, you must use an 8-wire conductor (or 11-wire for the GECO module) of 1.5mm²,
the length of which will depend on the distance separating the two panels; this cable is not provided with the
generator set.
The maximum distance between the electrical panel and the and the ATS panel should be 25m for a 1.5mm² section
and a voltage of 650 kVA. In case of higher voltage, use the same maximum distance and a 2.5mm² section.
2) If the ATS was not supplied by GRUPOS ELECTRÓGENOS GESAN, S.A., check the user manual of the
corresponding ATS and follow these steps:
- Connect the terminals R S T N of the control panel (referential Mains Voltage) to the input of the electric
company mains.
- Connect the terminals numbered 37 to 47 to the ATS control panel (check the electrical setup on
the electrical generator control panel).
- Make sure that the electrical and mechanical interlocking is completed correctly. Also make sure that
the ATS that you want to install is compatible with the generator unit provided. Assembly is typicall y done
with contactors; for motorized switches please check with GRUPOS ELECTRÓGENOS GESAN, S.A.
- The conductor section must be adequate for installation.
3) If your generator unit is the “Standby by signal” type, it will not monitor the mains or control the ATS:
these must be controlled by the user’s management system.
The terminals through which the generator set receives the startup signal are 184 and 185, which should be
volt-free.
The generator set uses terminals 120 and 121 to return a volt-free signal when the voltage and frequency of the
generator set are correct.
Terminals R S T N should be connected to a mains input prior to the ATS, as these terminals provide the power
supply for the engine block heater and battery maintainer. The conductor section should be appropriate for
your installation.
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4.2.7.2 4.2.7.2 Installation of ELECTRICAL POWER section:
- Then connect terminals X Y Z N to the installation for which you want to guarantee electrical power.
2) ATS not supplied by GESAN or the generator set is the “Standby via signal” type.
- Connect the generator’s current output terminals U V W N to the input of the ATS on the generator set.
This installation should be performed by qualified personnel, who should determine the conductor section to be
used.
Remember that you must ground the unit according to the current regulations in effect where the installation is performed.
4.3.- STORAGE
If you think your generator will be inactive for a long period of time, follow these instructions:
2) Press the emergency stop button to avoid future involuntary startups when connecting.
5) Avoid storing the unit in spaces with high dust accumulation or excessive humidity.
7) Check your engine manual for care instructions; the manual has been provided together with this document.
8) Check your alternator manual for care instructions; the manual has been provided together with this document.
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5.- STARTUP
To start up the generator set, follow these steps listed below:
4) Connect to the mains power and verify that the voltage indicator is giving an adequate reading.
6) After completing the pre-startup tasks, make sure that the generator’s control module switch is in the desi
red position. For this reason, the user should carefully read about the operation of the control module in section
7) It is recommendable to run a simulation of mains failure to verify that the unit is functioning properly.
Note: It is not advisable to operate the generator set at low load for extended periods of time. The generator is considered to be running
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6.- OPERATION MANUAL
The generator set you purchased was designed for standby use, which means that it will mainly be operational
when the mains voltage is inadequate.
Therefore it is necessary to connect the outside mains to the unit’s ATS as well as to the generator set (see
section 4 – Installation).
The following is a description of the different variable elements, according to the generator set chosen.
A AMMETER:
Measures the Intensity (A), by means of a switch, of the different phases of the generator set.
Hz FREQUENCY METER:
Indicates the frequency of the generator set (Hz).
V VOLTMETER:
Indicates the voltage (V) of the main power supply or generator set, depending on the position of the voltmeter
switch.
VOLTMETER SWITCH:
This switch allows for voltage measurement by phase of the main power supply or the generator set.
HOUR METER:
HORAS
Indicates number of hours worked by the generator set.
The two digits in red on the right indicate hundredths of hours. Hours are indicated in white from the third digit
on.
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V BATTERY VOLTMETER:
Indicates current voltage of battery.
Oil pressure
Intensity of battery voltage Activated by temperature and fuel button when
Engine temperature generator set is stopped. When the generator
Fuel level is operating, the gauges show the corresponding
levels.
DIAGNOSTIC BUTTON:
Allows engine parameters to be checked when generator set is stopped (electronically controlled engines).
Also gives a readout of the generator’s different alarms.
DIFFERENTIAL:
Protection against earth leakage of one phase, setting off the generator’s set primary protection switch.
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6.2.- GECO ANALOG CONTROL MODULE
1 2 3 4 5
19 9
18 10
11
12
17 13
16 15 14
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The following is an explanation of each of the items shown on the GECO control module; this module is for generator
units with/without ATS:
3 High temperature/
Low coolant level
Red LED
7 Test mode
8 Automatic mode
Different module
operational modes
9 OFF/RESET mode
10 SERV-1/START mode
11 SERV-2/START mode
14 Vac
Mains correct Green LED
18-19 Vac Hz
Generator voltage and frequency
correct
Green LED indicates correct
voltage and frequency
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The GECO module has six operating modes, differentiated in automatic mode (AUTO) and manual mode (MAN),
which can be configured using the module switch (numbers 6-11 on the control module’s descriptive panel).
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INDICATOR LIGHTS:
This control module includes a 2 ampere battery charger; receives power supply from external
BAT transformer connected to the mains power. LED will turn on when battery voltage is correct.
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LED is lit while batteries are charging. Lit only when connection with the mains power exists. LED
illuminated intermittently when battery voltage is correct.
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ALARMS:
The various alarms of the GECO module are LED indicators 1 through 5. There are two alarm
types, one which issues the stop command and one which does not; if it is the first of these, move
the switch to the OFF position (9) and fix whatever caused the alarm and select the desired
option.
Indicates startup failure. Either voltage or frequency is not detected or the emergency stop button
has been pressed; in both cases the LED indicator (1) will turn on and the control module will
issue a stop command to the generator unit. To stop the alarm, turn the control module switch to
1 the OFF/RESET position (9).
Indicates low oil pressure. LED indicator (2) will turn on and the control module will issue a stop
command to the generator unit. To stop the alarm, turn the control module switch to the OFF/RESET
position (9).
2
Indicates high engine coolant temperature or low coolant level. LED indicator (3) will turn on
and the control module will issue a stop command to the generator unit. To stop the alarm,
turn the control module switch to the OFF/RESET position (9).
3
Indicates overload of the generator unit. LED indicator (4) will light up and the control module will
issue a stop command to the generator unit.
4
To stop the alarm, turn the control module switch to the OFF/RESET position (9).
Open the electrical panel door and check the status of the motor guard. Check the reason for the
overload and reset. Close the electrical panel door.
Put the module in AUTO mode.
Indicates low fuel level; LED indicator (5) will be lit. System warning; must respond accordingly.
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6.3.- GPM-2 ANALOG CONTROL MODULE
This module is for “Standby by signal” type generators.
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2 8
3 9
4 10
5
11
6
17 16 14 13 12
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NUMBER SYMBOL DESCRIPTION IDENTIFICATION
8
AUTO
Remote startup mode Green LED
TEST
11 Maintenance signal
Flashing blue light;
maintenance required
14 Fuel
Manual mode MAN
17 Programmable alarm
Flashing or continuous red light;
user-defined.
The GPM-2 control module has three positions: STOP, automatic (AUTO) and manual
(MAN). Key selectable (numbers 14 through 16 of the descriptive chart on the control
module).
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• AUTOMATIC mode (AUTO):
When key is turned to the automatic mode position, unit will sit idle until receiving an external startup command. If
mains failure occurs, the external mains monitoring system will issue a signal to the electrical generator, which will begin
At the moment in which the external startup signal is received, while the key is in the AUTO position, the LED indicator
for low oil level will light up, as well as the alternator battery voltage indicator and AUTO TEST
LED (numbers 3, 2 and 8 of the descriptive panel on the control module, respectively).
There will be a maximum of three startup attempts lasting 10 seconds each, with a 10 second pause between
each.
After three unsuccessful startup attempts, LED indicator (1) will turn on.
If the unit was operating in automatic mode and the mains failure is resolved, once the external signal disappears 60
seconds will pass in order for the engine to be cooled; during these 60 seconds the LED indicator (10) will flash
and later it will be continuously displayed and the engine will stop, with the LED indicator light remaining for 20 seconds.
If the mains power falters during the shutdown sequence, the operating cycle will be repeated, thus guaranteeing
When key is turned to the manual mode position, LED indicators for low oil level (3) and alternator
battery charge indicator (2) will be turned on. To start up the unit, press the START button (13). If the
key selection has been made on the generator unit and this button is not pushed in 20 seconds, the control module will shut
off the system; the startup signal will be cut off when LED indicators for low oil level (3) and alternator battery
charge (2) turn on; the startup signal will also be cut off when the frequency exceeds 20 Hz.
Must be done using the external ATS controller with the control module in automatic mode.
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INDICATOR LIGHTS:
Indicates remote startup; continuous green light turns on when unit is operating remotely.
AUTO
TEST
Indicates unit is warming up; continuous yellow light turns on when unit is being heated.
Indicates maintenance; flashing light; the first time the light turns on after 50 operating hours and
afterwards every 150 hours.
To reset the maintenance hour meter, the generator set must be running; turn the key to the
STOP position while pressing down the button (12) until the control module becomes
11
completely deactivated.
Contact button.
If service is needed, engine contact must be maintained. With the key turned to the STOP position,
press button (12) and without releasing it turn the key to the MAN position.
12
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ALARMS:
The following is a chart describing the possible alarms of the GPM-2 module:
Note: If at any point 3 or more LED indicators turn on, it could indicate low battery level.
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6.4.- DEEP SEA 5210/5220 DIGITAL CONTROL MODULE
9
7
10
11 6
12
1 2 3 4 5
Z V
Y U
X T
W S
35
NUMBER SYMBOL DESCRIPCIÓN IDENTIFICATION
12 Status of ATS for mains and generator Left LED indicator: mains closed /
set Right LED indicator: Generator closed
36
The Deep Sea 5220 control module is an automatic module that controls the main power supply; if a mains failure
occurs, generator set will start up. Loads are transferred when the mains supply fails. This control module also gives the
option of manual startup. The user can also control all of the generator unit’s parameters as well as the status of mains
power supply. This module is supplied with automatic generator set with or without ATS.
The Deep Sea 5210 control module is supplied in “standby by signal” type units.
Automatic mode will be activated by pressing the button (4). The LED at the top of the button will turn on,
(5220) If the mains power supply fails for longer than the unit’s programmed period, the LED (11) indicating
(5210) If a mains failure occurs, the external management system should send a startup signal to the generator
set, at which point the LED indicating remote startup active (7) turns on and the startup process of the generator set begins.
V Hz
Once the generator unit is up and running, the display V Hz
(6) lights up.
If a startup failure occurs, there will be a maximum number of startup attempts (3); after three failed startup attempts,
the flashing stop signal will appear along with the startup failure indicator
When mains power is restored (or when the remote startup signal disappears) there will be a period of time in which
the engine will continue operating at no load to cool down before stopping completely.
If a mains failure occurs during the no-load operating period (cool-down period), the generator set would begin the
Press (1) or the emergency stop button to intentionally stop the unit.
The no-load test mode is activated by pressing the button (2), at which point the LED at the top of the button
If a mains failure occurs or a remote startup signal is received, loads will be transferred to the generator set. (5220,
the unit will continue operating with a load, regardless of the status of the mains power supply).
Once button (4) is pressed and there is adequate mains power supply (without the remote startup signal activated),
Press (1) or the emergency stop button to intentionally stop the unit.
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• LOAD TEST mode (Manual):
Select by pressing (3). Test to check proper functioning of the generator set.
In this operating mode, a mains failure is simulated, with the loads being transferred to the generator set.
Once button (4) is pressed and there is adequate mains power supply (without the remote startup signal
activated), the shutdown sequence will begin as described in the automatic mode. After this period of time, the load will be
Press (1) or the emergency stop button to intentionally stop the unit.
The status screen of the Deep Sea 52XX control module will indicate all of the possible events of the generator
set.
This image shows all of the indications of the LCD screen (8).
kW kVAr CosØ
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ICON DESCRIPTION
Warning = , Stoppage =
If Lx-Lx is displayed:
Indicates measurement of phase-phase voltage.
Bar Rpm psi Hz Kpa If Lx-N is displayed:
Indicates measurement of phase-neutral voltage.
L1-L2N L2-L3N L3-L1N Bar, rpm, PSI, Hz, kPa:
Indicate measurement units for the corresponding parameter.
The lock icon indicates keypad is locked.
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To view the values of the various parameters, press and the LCD indicator (8) will display the items listed
below in the following order:
The following is an example of what the LCD screen (8) will look like when the various parameters are checked:
The third measurement screen will appear, indicating the voltage readings
L1- L2 397.0
between phases.
L2- L3 401.0
L3- L1 408.3 To measure the next parameter, press
Pressing afterwards, we move from one parameter to the next in the order specified on the previous page.
WARNING/STOP DESCRIPTION
Warning = , Stoppage = .
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ALARMS:
The following chart describes each alarm:
X Emergency stop.
W Engine overspeed.
T If engine does not start after three attempts, the unit will stop and this icon will
be displayed.
Hz
H Alternator frequency outside established limits.
Hz
If it is detected during a long period of time that the generator’s output current
Note: If the established limits defined as warning or stop are exceeded, the module will display the corresponding alarm. None of these
will be shown if not detected by the system.
Note: The Deep Sea 52XX module will show a Warning displaying this icon as well as the identifying alarm icon. If the warning leads
to the unit stopping, this icon will turn on as well as the corresponding icon, both of which will flash
41
- Event log:
To view the event log, press the following button repeatedly (10).
“On November 1, 2002, at 08:17, the unit detected that the oil pressure was below the minimum level and has
shut down the generator.”
The date and time are adjustable. When the battery is disconnected, the date and time are frozen; when the battery
is reconnected, the date and time shown will be from the time the battery was disconnected.
The date and time reflected in the event log will be taken from the configuration according to the following steps:
Press (1) and (10) simultaneously. This icon will flash, indicating that “configuration mode”
is active. The calendar will be shown.
Once the desired value has been set, press (4) to save.
42
LIST OF POSSIBLE INDICATORS:
43
6.5.- DEEP SEA 5310/5320 DIGITAL CONTROL MODULE
19
10 RUNNING IN AUTO
8
Warming 10s
L-N 240V DA 50Hz
11 L-L 415V OkW
12 7
13
1 2 3 4 5 6
RUNNING IN AUTO
Warming 10s
L-N 240V DA 50Hz
L-L 415V OKW
44
NUMBER SYMBOL DESCRIPTION IDENTIFICATION
RUNNING IN AUTO
9 Warming 10s
L-N 240V DA 50Hz
L-L 415V OKW
Screen indicating the status of the
generator set
45
Deep Sea 5320 control module is an automatic module that controls the main power supply; if a mains failure
occurs, generator set will start up. Loads are transferred once the mains supply fails. This control module also gives the
option of manual startup. The user can also control all of the generator unit’s parameters as well as the status of mains
power supply.
When mains power is restored (or when the remote startup signal disappears) there will be a period of time in which
the engine will continue operating at no load to cool down before stopping completely.
If a mains failure occurs during the no-load operating period (cool-down period), the generator set would begin the
startup process again.
Press (1) or the emergency stop button to intentionally stop the unit.
The no-load Test mode is activated by pressing the button (2), at which point the LED at the top of the button
will turn on, indicating that it is operational.
Press (1) or the emergency stop button to intentionally stop the unit.
46
• LOAD TEST mode (Manual):
(5320) Select by pressing (3). Test for proper functioning of the generator set.
Once button (4) is pressed and there is adequate mains power supply (without the remote startup signal
activated), the shutdown sequence will begin as described in the automatic mode. After this period of time, the load will be
carried by the mains power.
Press (1) or the emergency stop button to intentionally stop the unit.
ALARMS:
Press (5) to silence the audible alarm and the common alarm LED.
Running in auto
Generator on load
L-N 230v 240A 50Hz
L-L 400v 133KW
If shutdown occurs while a warning is active, the screen will cycle through the active alarms:
47
INCIDENT ALARM DESCRIPTIONS
ALARM
Warning Alternator voltage not detected
Charge fail
ALARM
Warning
Low battery volts
Battery voltage beyond established limits
ALARM
Warning
High battery volts
ALARM
After shutdown command, engine continues running.
Fail to stop Could also indicate faulty oil pressure sender
ALARM
Warning Fuel level below established limits
Low fuel level
ALARM
Warning Low oil pressure, below established limit
Low oil pressure
ALARM
Warning
High temperature
Engine temperature beyond established limits
ALARM
Warning
Low coolant temp
ALARM
Warning
Overspeed
Engine speed beyond established limits
ALARM
Warning
Underspeed
ALARM
Warning
Over frequency
Alternator frequency beyond established limits
ALARM
Warning
Under frequency
ALARM
Warning
AC overvolts
Alternator voltage beyond established limit
ALARM
Warning
AC undervolts
ALARM
Warning Intensity of the alternator output beyond established limits
High current
48
INCIDENT DESCRIPTION OF SHUTDOWNS
ALARM
Shutdown Engine does not start, three attempts made
Failed to start
ALARM
Controlled shutdown of the unit. It will not be functional until the emergency stop button
Shutdown has been reset
Emergency stop
ALARM
Shutdown Oil pressure below established limit
Low oil pressure
ALARM
Shutdown Engine temperature above established limit
High temperature
ALARM
Shutdown
Overspeed
Engine speed beyond established limits
ALARM
Shutdown
Underspeed
ALARM
Shutdown
Over frequency
Alternator frequency beyond established limits
ALARM
Shutdown
Under frequency
ALARM
Shutdown
AC overvolts
Alternator voltage beyond established limit
ALARM
Shutdown
AC undervolts
ALARM
Shutdown Faulty oil pressure sender
Oil pressure sender fault
ALARM
Shutdown Intensity of the alternator output beyond established limits
High current trip
Note: If the established limit for shutdown is exceeded, a corresponding alarm screen will be displayed and on the configurable
LED indicator (8) the common shutdown alarm will appear.
49
- Typical LCD display screens
Indicates that the generator set will respond to either a mains failure or an active remote
Waiting in auto start
Mains on load
Indicates that generator set is in automatic mode and has been initiated after a mains
Starting in auto 10s failure has been detected.
Mains on load
Cranking attempt 1
Indicates generator set running normally in automatic mode. Also indicates the average
Running in auto line to neutral voltage (L-N), the highest of the three phase currents, the nominal
Generator on load
L-N 230V 240A 50Hz
frequency, average line-to-line voltage (L-L) and total kilowatts.
L-L 440V 133kW
- Event log:
“On September 10, 2003, at 21:15, the unit detected that the oil pressure was below the minimum level and has
shut down the generator.”
50
To move from one event to the next, press
- Displaying information:
It is possible to scroll through the different display screens by pressing the next page button: Once selected,
the instrument will remain on the screen until the user selects a different instrument or after a period of inactivity for the control
module, at which point the default display appears.
Alternatively, by holding down on the user can autoscroll through all the instruments on a particular screen.
To disable scroll, stop pressing the page down button and press it again for a few seconds or press . When
autoscroll is disabled, if no buttons are pressed the display will return to the alarms page.
If an alarm becomes activated while viewing instruments, the alarms page will be automatically displayed.
- Engine speed.
- Oil pressure.
- Coolant temperature.
- Engine hours run.
- Number of starts.
- DC battery voltage.
- Generator AC voltage L-N.
- Generator AC voltage L-L.
- Generator Line Current.
- Fuel level (%).
- Nominal voltage L-N.
- Nominal voltage L-L.
- Nominal frequency (Hz).
If the following appears in an instrument display: *****, this means that the engine cannot provide this parameter;
the control module, however, does provide this option.
If the following appears in an instrument display: ####### with the generator set in OFF/AUTOMATIC mode (with
the engine stopped), this means that the control module is not connected to the engine.
Overload pre-alarm
Common alarms
Common shutdown
The date and time are adjustable. When the battery is disconnected, the date and time are frozen; when the battery
is reconnected, the date and time shown will be from the time the battery was disconnected.
The date and time reflected in the event log will be taken from the configuration according to the following steps:
When date and time screen appears, press the button. The minutes will start to flash.
Press the button to confirm the value entered. The hour will begin to flash; press or again
52
Press the button to confirm the value entered and select the day. The day will begin to flash; press
Press the button to confirm the selection made and select the month. The value will start to flash; press
To input the year, press . The year will start to flash; press or to adjust to the desired
value.
The screen will display the date and time entered. Date and time
19 Sep 2003 10:00
53
6.6.- INTELIGEN DIGITAL CONTROL MODULE
1 2 3 4
18 6
8
17
16 15 14 13 12 11 10 9
54
NUM. SYMBOL DESCRIPTION IDENTIFICATION
1
Horn
reset
Deactivates audible alarm
modes
3 OFF→MAN→AUT→TEST
4
Fault
reset
Fault reset Acknowledges faults and alarms
5 Start
I Start button In manual mode
6 Stop
0 Stop button In manual mode
9 State of GCB
Green → GCB is closed. Flashes
during synchronization with mains
10 GCB ON/OFF
Opens and closes GCB in manual
mode
11 State of MCB
Green is MCB is closed flashes
during synchronization with mains.
12 MCB ON/OFF
Opens and closes MCB in manual
mode
15 Enter
Enter button Confirms on-screen value
16 Increases value
Selects on-screen value
17 Decreases value
18
Page
Button to cycle through the →MEASUREMENT
menus →ADJUSTMENT
→HISTORY
55
The InteliGen module contains the following three menu screens:
- Measurement Page
To display the different instruments on each screen menu, press (17) and (16).
The measurement screen displays the parameters measured by the engine; if the engine uses an electronic
management system, many additional parameters can be displayed. In addition to these parameters, measurements can
be displayed for fuel level, oil pressure, current, voltage, frequency, run hours and battery charge level.
The adjustment menu screen displays the adjustment parameters already configured; it is not necessary to edit any
of these.
The history screen menu displays the log of alarms that have occurred in the generator unit. It also logs the opening
and closing of the mains circuit breaker as well as the starting and shutting down of the generator unit.
lit and the controller closes the GCB (generator circuit breaker). Once mains power has been restored, synchronization
between mains and generator occurs; then the MCB is closed, causing the generator to discharge, followed by the opening
of the GCB. When mains power is restored, there will be a period of time during which the engine continues operating at
no load to cool down before stopping completely.
Fault
reset
Not
limits, the LED indicator (7) will be lit. Next press the GCB ON/OFF button (10). The loads will be transferred
Stop
directly to the generator set. To stop the unit, press STOP 0 (6).
load. To transfer the loads to the unit, press the MCB ON/OFF button and after press the GCB (12). At
this time synchronization occurs between the generator set and the mains for 60 seconds to assume the loads.
56
ALARMS:
The InteliGen control module includes the following warnings:
Some GCB in group was opened (in MINT) Other GCB trip
STARTUP INFO
AMF startup GenSetMF start
ENGINE
EVENT SPECIFICATION ALARM HISTORY
Generator set startup failure Sd start Fail Sd start Fail
57
GENERATOR
EVENT SPECIFICATION EVENTS RECORDED
58
PHASE SEQUENCE
59
7.- MAINTENANCE OF ELECTRICAL GENERATOR
You must make sure that the person who will perform this duty is qualified to do so and utilizes the appropriate
individual protection equipment.
To cut mains voltage, disconnect the 10 A. electromagnetic circuit breaker in the ATS panel supplied by
GRUPOS ELECTRÓGENOS GESAN, S.A. If made by another manufacturer, make sure that this cut is done properly
before handling the unit.
1) While the engine is cold, the oil level should be between the minimum and maximum values. If it is below the
minimum, add engine oil.
NOTE: With the GPM-2 and INTELIGEN modules, at 50 hours run notice will be given to change the oil. The recommended oil is 15W40.
2) The radiator water level should be adequate.
3) The fuel level in the tank should be sufficient for the service to be performed. The generator control panel is
equipped with a fuel gauge, which will be functional whenever the electrical panel is receiving power.
4) Always refuel in a well ventilated area with the engine stopped.
5) Closely inspect the connections and the electrical circuit, for both the mechanical and electrical sections.
6) Check carefully for possible liquid leaks. If a leak is detected, find its source and resolve the problem. If your unit
has a drip pan, drain the pan (see section on DRIP PAN).
7) The air inlet and outlet vents should be completely unobstructed to allow for free circulation of cooling air.
8) Check the state of the unit’s radiator and clean if necessary.
9) Make sure the exhaust tube is not obstructed.
10) Check the battery’s connection terminals and electrolyte level (if necessary, add demineralized or distilled water).
Acid should never be added. The battery should be recharged if the terminal voltage is below 12.3 V.
11) If the battery needs recharging after being taken out of the unit, remove the vent caps and charge battery
with direct current only. Connect the charger’s positive (+) cable to the battery’s positive (+) terminal and the
charger’s negative (-) cable to the battery’s negative (-) terminal. Recharge battery with a current equivalent to
1/10 the nominal capacity (Ah). Battery is fully charged when acid density is 1.28. Before completing recharging
process: turn off charger before disconnecting battery and check electrolyte level.
12) If the battery is discharged and you want to perform an emergency startup with the battery from another
generator, first check the tightness of the discharged battery’s terminals. Stop the engines of both units and
connect the two positive terminals of the batteries first and then connect the negative terminal of the charged
battery to a metal area on the disabled unit (ground). Start up the auxiliary unit and then the unit being repaired.
Disconnect the cables in reverse order to avoid a short circuit. Finally, fully charge the battery.
While performing preventive maintenance tasks it is advisable to wear protective eyewear and gloves during all operations
involving
Remember to always perform all operations with the utmost precaution and safety as indicated in this manual. (Pay special
attention to the risk of short circuits that could be caused by coming in contact with the unit’s metallic objects.)
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7.3.- MAINTENANCE CHART
Perform a mains failure simulation; the unit should supply power to consumers for one hour.
For parallel units, check the connection and the load sharing.
Review the connections of the startup battery, clean and cover with vaseline.
Make sure all of the electrical panel lights are functioning properly.
Check the state of all of the gauges and indicators on the electrical panel.
Start up the engine manually three times, noting each time the voltage and density readings for
each of the battery’s elements. If any of the voltage readings varies significantly from those of the
battery’s other elements, do not perform the remaining manual engine startups.
Clean the outside of the fuel tank and check the diesel lines.
Verify that the antivibration feet, fittings and belts are in proper condition.
Make sure that vibration and noise levels comply with the current regulations.
Make sure noise emission level is compliant with the current regulations.
61
8.- TROUBLESHOOTING
INCIDENT LIKELY CAUSE SOLUTION
Engine does not start
1.-Replace battery
1.-Defective battery
Starter does not turn 2.-Replace starting system
2.-Defective starting system
3.-Contact technical svcs
IN THE ELECTRICAL PANEL
1.-Overspeed
High voltage at no load 1.-Contact technical svcs
2.-Alternator failure
ORIGINATING IN ENGINE’S INTERIOR
1.-Underspeed
Low voltage at no load 1.-Contact technical svcs
2.-Alternator failure
Unit in operation
3.-AVR damaged
1.-Make sure nothing is preventing the unit
from functioning properly
Strange noise inside the unit 1.-Various causes
2.-Contact technical sSvcs
62
10.- WARRANTY
The generator set warranty covers an entire year, starting from the date it is installed. This should be communicated
to GRUPOS ELECTRÓGENOS GESAN, S.A. (hereinafter “the manufacturer”), in writing, via fax or email. The following
If the manufacturer is not informed of the installation within a maximum of sixty days from the invoice date, the
latter shall be considered the effective start date of the warranty period. If for any reason the installation is not possible
within the first sixty days following the invoice date, the manufacturer must be informed thereof in writing. Thus no warranty
claims shall be accepted if the manufacturer is not in possession of the aforementioned correspondence.
The warranty of the generator set will cover any faulty components or assembly not caused by improper use, han-
dling or modification. The warranty does not cover breakdowns caused by connecting the generator set to devices not
installed or supplied by the manufacturer. Also excluded are breakdowns and damages caused by prolonged or improper
storage; should this occur, please see the manufacturer’s user manuals.
The warranty for the generator set shall cover ONLY the replacement parts and labor necessary for the repair of
the generator by personnel authorized by the manufacturer. Traveling, kilometers traveled and other expenses deriving
from the repair of a generator under warranty are excluded from the warranty coverage and in no case shall the manufacturer
be responsible for these covering these expenses, which shall be paid in cash.
The decision to accept or reject a warranty shall be made by the manufacturer. In the case of engine and alternator
breakdowns, the warranty shall be granted by the provider of said components, according to the particular warranty conditions
of those components. The manufacturer reserves the option to request that the faulty element be returned. In such case, all
The warranty for a repair made during the warranty period shall have the same expiration date as the warranty for
The warranty does not cover damage caused by terrorist attacks, natural disasters, sabotage or incidents of a
similar nature.
If any of the provisions set out does not comply with the legislation of a certain country, the importer is required to
notify the manufacturer thereof prior to carrying out the sale transaction.
63
11.- NOISE LEVEL
GESAN Electrical Generators produce different acoustic levels depending on the output and soundproofing of the
generator set. The noise output is indicated on a sticker affixed to the unit’s base frame.
Note: If you work near the unit for any extended period of time, it is advisable to use hearing protection.
64
NUM LABELED ITEM DESCRIPTION
6 Product class
When withstanding an overload, engine will perform according to catalogued
response times per ISO 8528
10 CE marking indicates that generator set complies with the relevant directives
65
IMPORTANT CAUTION
PLACING IN OPERATION:
Image 26 - Placing in operation Image 27 - Caution with generator startup Image 28 - General warning
Image 29 - Undefined warning notice Image 30 - Electrical hazard 230 volts Image 31 - Electrical hazard 400 volts
Image 32 - Lifting point Image 33 - Possible battery leakage Image 34 - Electrical grounding
Image 35 - Noise output 90 dB Image 36 - Noise output 114 dB Image 37 - Use of hearing protection required
BATTERY
ISOLATOR
66
14.- ANEXO 2: INDICE DE IMÁGENES
67
N O T E S
68
GRUPOS ELECTROGENOS GESAN S.A.
Polígono Ind. Pitarco II, parcela 20
Teléfono +34 902 110 316 • Fax +34 902 110 318
50450 MUEL (Zaragoza) • SPAIN
www.gesan.com • [email protected] • [email protected]
V.2.05