Manual en

DIESEL GENERATOR
MAINTENANCE AND OPERATION MANUAL

EN
2
EN
DEAR USER OF THE EMSA GENERATOR;
First of all, we would like to thank you for choosing Emsa Generators.
Do not perform operate, maintain or repair your generator without taking general safety precautions.
Emsa Generator system properly.
AS PER THE REGULATION ON AFTER SALES SERVICES FOR INDUSTRIAL GOODS ISSUED IN THE OFFICIAL
GAZETTE NO. 29029 DATED JUNE 13, 2014, THE SERVICE OF GENERATORS ARE DETERMINED AND DECLARED
AS 10 YEARS.
Take recommended safety and installation precautions.
3
CONTENTS
EN
INTRODUCTION
2 SAFETY AND HEALTH
3 GENERAL DESCRIPTION
LIFTING, PLACEMENT, INSTALLATION AND

STORAGE
CONTENTS
EN
OTHER TECHNICAL DATA
5 DIESEL ENGINE MAINTENANCE
QUALITY STANDARDS
WARRANTY CONDITIONS AND

RESPONSIBILITIES OF THE CUSTOMER
OPERATION OF THE GENERATORS
POSSIBLE REASONS OF FAULTS AND

TROUBLESHOOTING
5
EN EN
EN EN
INTRODUCTION 1
INTRODUCTION
EN EN
ASSEMBLY PLATE
user in operating and maintaining of the generator easily. This is not

a repair manual. Generator shall operate with maximum performance
manual are followed.
Figure 1
MANUFACTURING COMPANY
Telephone: + 90 216 420 00 03

Fax: + 90 216 364 45 00
E-mail: [email protected]
Web: www.emsa.gen.tr
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INTRODUCTION
EN EN
SAFETY AND HEALTH 2

SAFETY AND HEALTH
EN EN
GENERAL PRECAUTIONS AGAINST LEAKS

during the maintenance or repair procedures of the
WARNING
•
• FIRE EXTINGUISHERS
or operating the generator.
•
• Do not operate the generator in case of a known unsafe condition.

•
USING PROTECTIVE EQUIPMENT

generator until the condition is corrected. •
•
You may put warning signs for this purpose. •
•
while the generator is operated.
cleaning on the generator. •
• USE
is operated. PROTECTIVE
EQUIPMENT
•
•
•
emergency conditions.
•
PLACEMENT, HANDLING AND DRAWING
PRESSURIZED AIR AND VAPOUR
•
use safety goggles while cleaning the cooling system.
WARNING
•
•
• • Ensure that the fuel storage system designed for the generators
of dirt and hot water, thus it may cause injuries.
•
• Engine exhaust gases are dangerous for the staff. Exhaust gases of all
goggles or face shield.
•
and the staff. Ensure that the exhaust gases are discharged safely.
opening the radiator cap completely to ensure
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SAFETY AND HEALTH

SAFETY AND HEALTH
EN EN
• Do not lift the generator using alternator and engine lifting •
•
•
• • Do not operate the generator in case of a fuel leakage in the fuel

system.
•
•
• Do not refuel while the generator is running.
generator and the truck.
• Do not use aerosols for starting aid. Otherwise,
•
explosions and injuries may occur.
•
EXPLOSION AND FIRE •
and explode. Taking proper precautions for the storage

MECHANICAL
Generator is designed with its housings in order to protect against
of these extinguishers.
generator area.
WARNING
•
WARNING
• harmful to health.
• Your generator is designed with housings in order
•
other mechanical risks while working in around the
generator set.
•
• Ventilate the generator room properly. not attempt to access under or around the housings for any reason
while the generator is operated.
•
• Keep your hands, long hair, loose clothes and
•
and rotating parts.
•
generator is operated.
•
•
are used. exhaust installation, hot surfaces, sharp edges and
corners against risk of injury.
•
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SAFETY AND HEALTH

SAFETY AND HEALTH
EN EN
CHEMICAL WARNING
not used properly.
WARNING USE
• Do not contact fuel, oil, coolant and PROTECTIVE
electrolyte to the skin and do not touch these EAR BUDS
materials. Get medical attention immediately ELECTRICAL
USE
PROTECTIVE
your skin, wash with soapy water. GLOVES
• Do not wear clothes contaminated with fuel WARNING
•
•
•
shall not contact the skin, too. •
•
from the generator.
• Do not attempt to make the load connection or disconnecting the
load when the generator is on a wet or humid surface.
• • Do not contact to the conductors, connection
• Electrolyte is an acid. Electrolyte can cause

personal injury. Electrolyte shall not contact •
making the load connection or disconnecting the load. Do not operate
USE
• PROTECTIVE
•
GOGGLES
power and electrical characteristics of the generator.
NOISE •
.
terminals that are worn, corroded or discoloured. Keep the terminals
clean and ensure that the connections are tight.
•
•
occupational safety rules during operation and
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SAFETY AND HEALTH

SAFETY AND HEALTH
EN EN
FIRST AID FOR ELECTRIC SHOCKS 2.
WARNING 3.
• locked.
disconnecting the power source.
•
• 5.
Opening the Respiratory Tract

HEALING POSITION
2. 2.
keep the respiratory tract open.
3.
RESPIRATION
WARNING
BLOOD CIRCULATION
consciousness again.
IF THE VICTIM CANNOT BREATH, BUT PULSE IS
PRESENT
2.
3.
5.
IF THE VICTIM CANNOT BREATH, AND NO PULSE IS

PRESENT
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SAFETY AND HEALTH

SAFETY AND HEALTH
EN EN
PROTECTION AGAINST FIRE •
properly.
protection systems.
•
•
• WATER
• Do not refuel the fuel tank while engine is running. •
•
of other sources of ignition near the fuel tank or generator set. may damage the generator or cause injuries that may lead to the
death of the personnel.
•
•
•
EXHAUST GASES operate the generator after taking necessary precautions and
• Do not connect exhaust systems of two or more engines together.
•
COOLANT AND FUEL
•
•
the radiator.
• Do not use exhaust gases for heating a room.
•
• pressure. Do not open the radiator cap while the engine is running.
• Open the radiator in a controlled way after the diesel engine has
•
•
•
MOVING PARTS •
•
•
Keep them away.
DANGEROUS VOLTAGE
•
•
•
•
•
•
causes injuries to the personnel or deaths.

• Do not unlock electrical locks.
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SAFETY AND HEALTH

EN EN
GENERAL DESCRIPTION 3
EN EN
GENERAL DESCRIPTION
EN EN
DESCRIPTION AND EXPLANATION OF THE FUEL TANK AND CHASSIS

GENERATOR Engine and alternator are installed on a steel chassis. There is a fuel
Figure-2 and Figure-2a show main parts of a typical

VIBRATION ISOLATORS
the generator is placed on the installation area.

MUFFLER AND EXHAUST SYSTEM
DIESEL ENGINE
the generator.
and directs the exhaust gases for safe discharge.

CONTROL SYSTEM
ENGINE ELECTRICAL SYSTEM Manual or automatic control system and panel placed on the generator
of the manual.
COOLING SYSTEM
engine in order to cool the engine.
and thermostat.
ALTERNATOR
alternator.
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GENERAL DESCRIPTION
GENERAL DESCRIPTION
EN EN
9
7
8
6
Figure 2
1. 4. 8.
2. 5. 9.
3. 6. ANTI-VIBRATION MOUNT
7.
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GENERAL DESCRIPTION
GENERAL DESCRIPTION
EN EN
12
14
13
Figure 2a
12. 15. 17.
13. 16. 18.

14.
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GENERAL DESCRIPTION
EN EN
20
EN EN
LIFTING, PLACEMENT, INSTALLATION AND STORAGE 4

LIFTING, PLACEMENT, INSTALLATION AND STORAGE
EN EN
GENERAL
Figure 3
•
•
•
•
•
•
•
•
WARNING
slipping and falling in case of oil leaks, etc.
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22 LIFTING, PLACEMENT, INSTALLATION AND STORAGE

EN EN
GENERATOR WITH CANOPY
Figure 4
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EN EN
TRANSPORTATION OF THE GENERATOR

damages on the parts.
FORKLIFT BLADE CHANNELS
Figure 5
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EN EN
LIFTING AND/OR LOWERING THE GENERATOR
Figure-6
WARNING SELECTION OF THE LOCATION OF THE GENERATOR

• Do not lift the generator using alternator or engine lifting lugs.
• •
• Keep staff away from the generator when the generator is lifted •
for transportation.
• •
•
•
the generator set.
• •
lifted from the ground. such as trees or poles.
• •
• of the generator.
•
• the generator to the room.
•
limited.
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EN EN
Ground
•
• Bury the grounding plate or rod to the nearest location to the
generator.
Inlet-Outlet Noise Cancelling Barriers and Shutters
INSTALLATION OF SOUNDPROOF CANOPY
Generator Foundation and Base
engineer.
inside the shutters.
CONCRETE BASE
COMBUSTION AIR INTAKE
for further details.
COOLING AND VENTILATION
Concrete Resistance: 2000 kg/cm²
m
m
0
15 m
m
80
76 mm 45
280 mm
150 mm
3050 mm
Basic Functions of the Base Concrete

• Bear whole weight of the generator
•
Vibration
Figure-7 Direction of air discharged from the radiator with air ducts
generator set such as air duct, exhaust installation and fuel installation.
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EN EN
is not operated. Thus hot air that facilitate initial operation and loading
Figure-8
immediately when engine is started and that shutters are closed
when the engine is stopped.
Figure-9 Basement installation plan of a typical generator set
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EN EN
ROOM INSTALLATION DIMENSIONS FOR A GENERATOR WITHOUT CABINET
H
D
K
E
C
F
Figure-10
HOT AIR EXIT AREA DIMENSIONS MUFFLER EXIT DOOR DIMENSIONS
ROOM DIMENSIONS (mm)
(mm) DIAMETER (mm) (mm)
MODEL
WIDTH LENGTH HEIGHT
(D) (E) (F) (G) (H) (K)
(B) (A) (C)
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
2500 350 50 2000
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EN EN

MODEL
WIDTH LENGTH HEIGHT
(D) (E) (F) (G) (H) (K)
(B) (A) (C)
2500 350 50 2000
2500 350 50 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3000 2500 300 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3200 2500 350 2000
3500 3000 2000
3500 3000 2000
3500 3000 2000
3500 3000 2000
3500 3000 2000
3500 3000 2000
3500 3000 2000
3500 3000 2000
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EN EN

MODEL
WIDTH LENGTH HEIGHT
(D) (E) (F) (G) (H) (K)
(B) (A) (C)
3500 3000 2000
3500 3000 2000
3000 350 2500 2500
3000 350 2500 2500
3000 350 2500 2500
3000 350 2500 2500
3000 350 2500 2500
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 3000 3000
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 2500
3000 350 2500
3500 350 3000 3000
3500 350 3000 3000
3500 350 3000 3000
3500 350 2500 3000
3500 350 200 2500 3000
3500 300 200 3000 3000

3500 300 200 3000 3000
2250 3500 2000 2000 200 3000 3000
2250 3250 2000 2000 200 3000 3000
2000 2000 200 3000 3000
WARNING
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EN EN
EXHAUST
corrosion of some parts in the fuel system.
Engine exhaust system is intended to direct the exhaust smoke to
SPECIFICATIONS OF THE FUEL
Viscosity:
Cetane Number:
WARNING Sulphur Content:
• Engine exhaust gases are dangerous to inhale. Exhaust gases of all Water and Sediment:
Density:
as per the standards. Acid Content:
• Viscosity:
material and ensure that they are secure for the safety of the staff.
•
WARNING
• Fuel storage systems of the generators shall comply with the
standards.
•
•
DAILY FUEL TANK:
the daily fuel tank (except for powers over 900 kVA or special
and exhaust pipe system. applications).
• Note:
MAIN FUEL TANK:

used for this purpose.
• Exhaust system components installed inside the generator room placed in a proper place outside the room to facilitate the refuelling
pipe.
•
FUEL SYSTEM FUEL LINE:
Directly from the fuel tank on its chassis

2. From the prismatic or cylindrical external fuel tank outside the
chassis
One of the most important issues for diesel engine is using clean fuel
that does not contain foreign material. Dirt in the fuel causes damage of the fuel tank and from a point away from the fuel return line.
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EN EN
WARNING
•
•
•
•
•
•
•
Figure-11
1. 11.
2. Filling line to the main fuel tank 12.
3. Vent 13.
4. 14.
5. Main fuel tank 15.
6. 16.
7. 17.
8. 18.
9. 19.
10. Electric fuel transfer pump 20. Engine fuel pump
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EN EN
FUEL PIPE RECOMMENDATIONS

Generator Power Maximum Length of Maximum Vertical Maximum Number of Recommended Pipe
Stand-By (kVA) the Fuel Pipe (m) Height (m) Pipe Fittings Diameter (inch)
0-800 6 0.9 6 1“
800-1500 6 0.9 6 1 1/2”
1500-2200 6 0.9 6 2”
Table-1
CHECK VALVE
MAIN
FUEL
0-1500 mm
TANK
Figure-12b
0-1800 mm
CHECK VALVE
DAILY
FUEL
TANK
0-7800 mm
VALVE
Figure-12a
FILTER
the engine
MAIN
hydraulic locking. FUEL
TANK
Figure-12c
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EN EN
BATTERIES
MAINTENANCE TYPE BATTERIES:
WARNING
•
DAILY PUMP
FUEL spills on the skin or the cloth.
TANK
•
FILTER
•
CHECK VALVE
MAIN •
FUEL
TANK
•
Figure-12d
OIL AND ANTIFREEZE USED IN THE GENERATOR ADDING ELECTROCLYTE TO THE BATTERY FOR THE FIRST TIME
•
•
•
reduces operation costs.
Recommended oil;
•
Antifreeze;
VISCOSITY-TEMPERATURE DIAGRAM:
You may check if the oil used is proper for the temperatures in your •
•
BATTERY MAINTENANCE
•
•
carefully.
• Tighten the terminals securely.
•
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EN EN
TESTING THE BATTERY •

•
•
•
• Do not allow loose connections.
HYDROMETER TEST
•
Rubber injector
•
Glass tube
=
1,300
water only.
• Hydrometer
1,100
buoy
Rubber nozzle
Evaluation is as follows:
MAINTENANCE-FREE TYPE BATTERIES:

A= formula
maintenance other than this.

A= L.P
ELECTRICAL CONNECTIONS:
A 2
WARNING
and standards.
k
WIRING
P
•
U
•
PROTECTION:
current.
•
temperature, placement method and proximity to the other wires
LOADING:
VDE standards.
•
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EN EN
connected to the grounded part on the star point.
POWER FACTOR:
While creating a project for the grounding facility;

•
•
resistance.
•
GROUNDING/CONDITIONS FOR GROUNDING: is determined.
•
• Dissipation resistance is calculated.

•
•
•
What is expected from a good grounding?

• That it is continuous and uninterrupted
• <
•
•
• The most important issue while grounding is that the areas for the
network types. Thus, power companies around the world select the
systems affecting each other.
grounding rods, the lengths of the grounding rods used and the distance
the length of a rod. For a grounding operation where a grounding rod
current at least.
Figure-13
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EN EN
> 20 m
Figure-14
PARALLEL OPERATION: NOISE ABSORBERS
generator under control.

INSULATION TEST:
applications.
operated for a long period of time. Test the insulation resistance WARNING
•
EXHAUST SILENCERS:
CABINETS:
. Dry the alternator
.
OTHER NOISE SUPPRESSORS:
and personnel only.
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EN EN
TOWING THE GENERATORS WITH TRAILERS STORAGE OF THE ENGINE:

PREPARATION FOR TOWING:
STORAGE OF THE ALTERNATOR:

work.
operation.
STORAGE OF THE BATTERY:
ENGINE BLOCK COOLANT HEATER
feature is optional for manual generators.

TOWING:
stopping distance while towing the generator with trailer.
WARNING
•
•
•
•
•
PARKING:
DIMENSIONS
STORAGE Height (H) Depth (D) Weight
215 mm 135 mm 795 gr
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EN EN
DIESEL ENGINE MAINTENANCE 5

DIESEL ENGINE MAINTENANCE
EN EN
Burroughs Indicator
clean. Do not allow materials such as water, fuel and oil collect on
BLEEDING THE FUEL SYSTEM
Figure-16a
Fit the gauge at the center of the longest free length and check the
Adjustment
Pivot Bolt
Figure-15
INSPECTION/ADJUSTMENT/REPLACEMENT OF
CHARGE GENERATOR AND FAN BELTS
Inspection
Figure-16b
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EN EN
REPLACEMENT OF COOLING SYSTEM COOLANT

Connection Bolt
WARNING
Do not drain the coolant while the engine is hot and system is under
pressure as dangerous hot coolant may come out.
Note: Following information is a general procedure for the replacement
procedure.
Figure-16c
REPLACEMENT OF THE BATTERY
•
•
• “-” “-”
“-” terminal on the starter. Disconnect the wire from
“-”
Drain Plug
• “+” “+”
“+” terminal on the starter. Disconnect the wire from
“+” Figure-17a
Note: •
•
• •
• the engine. Ensure that the drain hole is not restricted.
Note: •
• “+”
terminal.
the radiator.
• “-” “-”
• Flush the coolant system with clean water.
WARNING •
•
cap.
•
WARNING
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EN EN
Engines with no Coolant Return Tank Servicing the Air Cleaner Elements
Note:
WARNING
Pressurized System:
• •
the pressure.
• •
operations.
Cooling System
Filler Cap
Dual Element Air Cleaners
of cleaning operations.
Figure-17b
•
replacement.
•
CLEANING/REPLACEMENT OF ENGINE AIR
FILTER ELEMENT
WARNING
•
pleats, gaskets or seals. Dirt entering the engine may cause serious Figure-18a
1
and foreign materials to the intake manifold.
2
•
dust ingress to the engine. 3
4
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EN EN
•
•
•
•
•
•
•
Cleaning of the External Air Filter Elements Figure-18b
WARNING Note:
•
•
• the pleats.
Vacuum Cleaning
•
Dirt entering the engine may cause damage to engine compartments.
• Inspection of the External Air Filter Elements
WARNING
This may damage the seals. Do not use elements with damaged pleats,
may cause engine damage.
•
• Vacuum cleaning
Pressurized Air
Figure-18c
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EN EN
REPLACEMENT OF ENGINE OIL AND FILTER

with damaged pleats, gasket or seal. Discard any damaged external WARNING
Single Element Air Cleaners of hot oil and components with skin.
WARNING
the engine is off. Drain the oil pan while the oil is hot. This method
gaskets or seals. Dirt entering the engine may cause serious damage to ensures that the waste particles in the oil are drained properly.
Failure to follow this recommended procedure will cause the waste
materials to the intake manifold.
with the new oil.
dust ingress to the engine.
Drain the Engine Oil
Note:
collect the waste oil.
AIR FILTER INDICATOR

Inspection
indicator.
Typical Service Indicator
Figure-19a
Figure-18d
•
•
•
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EN EN
Fill the Engine Crankcase

Replacement of Spin-on Type Oil Filters •
of oil.
WARNING
WARNING
may cause engine damage.

•
•
engine. Do not crank the engine for more than 30 seconds.
not damaged. •
•
WARNING •
premature wear on engine parts.

•
per local regulations.
Figure-20a
Figure-20b
•
Figure-19b
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EN EN
TYPE 3 SPIN-ON FUEL FILTER •
•
•
at the same time.
• Manually pump fuel to the fuel system.
Figure-21a
•
Figure-21b
•
•
•
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RADIATOR MAINTENANCE
EN EN
This maintenance instruction must be fully Weekly Scheduled Maintenance:

implemented periodically to maintain radiator • It must be checked whether the cooling liquid level is
efficiency and warranty support coverage. If sufficient.
any maintenance steps are missed, any • The fan blade must be checked for any damage or
warranty issues may not be covered by deterioration.
• The fan belts must be checked for defects, and the
EMSA. tightening values of the belts must also be checked.
• The radiator must be filled slowly and carefully, leaving no • The distance between the fan blades and the inner
air space inside. edge must be visually checked.
• Balance and order must be ensured by checking the physical • The radiator must be checked for any coolant leaks.
condition of the fan blades. • It must be checked if the hoses and their connections
• The tension of the belts connecting the engine and radiator are tight enough.
ulleys must also be checked for looseness, cracks, damage or • The connections between the radiator and the chassis
defects. After the checks, loose belts must be tightened and (rubber and connection points, etc.) must be checked.
damaged belts should be replaced.
Monthly Scheduled Maintenance:
High voltage values on belts/pulleys will shorten • The steps in weekly scheduled maintenance must be
repeated.
their life. Low tension values will cause • The radiator core must be checked and any dirt/dust
deformation in the bands, causing the speed to cleaned with compressed air or water.
decrease (cooling performance to decrease) or • The tightness of the connecting bolts must be checked
the radiator to be damaged. and tightened if necessary.
• Lubricating oil in bearings must be renewed.
• In order not to make any adjustments at the bottom of the
radiator and to ensure that the coolant remains homogeneous, Annual Scheduled Maintenance:
he engine must be started at predetermined intervals (by the
engine manufacturer) and the radiator's coolant must be • Steps in weekly and monthly scheduled maintenance
circulated periodically. must be repeated.
• No foreign substance or any substance other than the coolant • Radiator cap must be replaced with a new one.
mixture (antifreeze, water, some protective chemicals…) must be
Other Essential Maintenance Activities:
placed or dripped into the radiator.
• Radiators that have not been used for 6 months or more must be • All radiators with rotating parts and greasing ports
washed and cleaned inside before use. must be greased every 250 hours.
• Necessary measures must be taken against vibration, especially • The tightness of the connection bolts must be checked
between the radiator and chassis connection. every 250 hours.
• Lifting lugs must be used as handles when lifting the radiator. • Radiator coolant must be changed periodically according
• The radiator cap must be replaced once a year. to the engine manufacturer's instructions.
• While carrying the radiator, the user should be very careful to
avoid damage to the radiator's connection points (welding, bolts,
etc.).
• Radiators must be protected from humidity and similar conditions.
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DIESEL ENGINE MAINTENANCE 47

EN EN
48
EN EN
OPERATION OF THE GENERATORS 6
49
EN
INSPECTIONS AND OPERATIONS REQUIRED OPERATION OF THE GENERATOR WITH

BEFORE THE OPERATION OF THE GENERATOR AUTOMATIC CONTROL
•
the operation of the generator and issues a warning when a fault is

• detected.
To operate in automatic mode;
•
•
•
•
window shutter and fresh air intake shutters of the radiator open.
•
spanners, tools, rags, papers, etc.
• such a case, engine of the generator operates for 2 more minutes
to cool down and then stops.
AUTOMATIC TRANSFER DEVICES
•
SMART 500 AUTOMATIC TRANSFER DEVICE
•
a mains fault, and transfers the load to the generator automatically.
•
•
Do not add tap water, acidic water, or acid to the cells.

•
terminals and keep the terminals clean. power outages.
•
GENERATOR CONTROL SYSTEMS

Electronic control systems are used to control and monitor generator
and stopping of the generator and monitoring of operation conditions
conditions.
DEVICE SETTINGS
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50 OPERATION OF THE GENERATORS

EN EN
BUTTON FUNCTIONS
BUTTON DESCRIPTION
1
the load.
2
waits without taking the load.
6
7
9
mode
10 BUTTON FUNCTIONS
mode
6 and 7
are pressed for 5 seconds.
5 and 8
are pressed for 5 seconds simultaneously.
BUTTON DESCRIPTION
On/Off Switch
1
is off and does not use power when the switch at
position 0.
Start Button
2 This is used to start the generator and to make changes
on the program parameters.
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EN
BUTTON DESCRIPTION BUTTON DESCRIPTION

Start LED Engine Operating Hours
3 Operation of the engine from the start operation until
12
Stop Button
4 This is used to stop the engine and to make changes
on the program parameters.
Speed Fault
Stop LED
5
13
Enter Button
for 5 seconds. Charging Alternator Fault
6 14
next parameter in the program menus are performed General Alarm
Value Screen 15
7
are displayed here.
Starting fault
MAINTENANCE OF THE DEVICE
8
High Temperature Fault
Low Oil Pressure Fault POINTS TO BE CONSIDERED IN OPERATION

10
Generator Frequency and Speed

11
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EN
DKG-155 If a fault condition occurs, the FUEL solenoid will be deenergized
Manual Start Unit and the led associated with this condition will turn on. Only the
first occurring fault will be indicated. To reset the fault condition,
turn the switch to the OFF position for a few seconds.
The Charge Fail condition is treated as a warning and do not
cause the engine to stop. The input monitors the D+ terminal of
the charge alternator.
The limits for the correct generator frequency are 30 to 57 Hz for
50 Hz operation and, 30 to 68Hz for 60Hz operation.
The unit uses high current two part connectors for easy
replacement.
Features
Microprocessor controlled
Manual fuel control and start
Automatic shutdown on fault condition
Survives cranking dropouts
Digital display of generator frequency
High engine temperature protection
Low oil pressure protection
Overspeed-underspeed protection
Spare fault input
Alarm output
Two part connectors for easy replacement
Description Standard panel dimensions (72x72mm)
Low cost
The DATAKOM model DKG-155 is a microprocessor controlled Low failure rate
unit designed to start and stop the genset manually using the
key switch on the front panel.
In the OFF position, the DC supply is removed from the module,
thus zero power consumption is achieved.
The unit powers up when the RUN position on the front
panel is selected. This will also energize the fuel solenoid relay.
The engine is started using the next spring-loaded position
marked START.
Once the engine has started, the switch should be released.
To shut down the engine, select the OFF position on the switch.
When the engine is running, the unit monitors fault conditions
and shuts-down the engine automatically in the occurrence of
an alarm.
The alarms are identified by a group of LEDs displaying only the
first occurring one.
The alarm checking is only enabled after the protection hold-off
timer is expired. This timer is set to 45 seconds when the unit is
powered up, it resets to 10 seconds if the engine gets running.
The occurrence of below fault conditions will cause the engine
to be stopped immediately:
-Overspeed,
-Underspeed,
-High engine temperature,
-Low oil pressure,
-Auxiliary shutdown.
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EN EN
Typical Connection Diagram
Inputs Technical Specifications

DC SUPPLY: 12 or 24 volts DC, (+) and (-) terminals. Alternator Voltage: 15 to 300 V-AC
L1: Generator phase voltage. Alternator Frequency: 50 or 60 Hz nominal.
NEUTRAL: Generator neutral terminal. Overspeed: nominal frequency + 14%
HIGH TEMP SWITCH: Negative closing switch input. (+24% overshoot)
LOW OIL PRESSURE: Negative closing switch input. Underspeed: 30 Hz
AUX: Spare fault input. A negative supply connection DC Supply Range: 9 to 33 V-DC.
to this input will cause the engine immediately stopped Current consumption: 150mA max.
and an alarm given (independent of the protection (Relay outputs open).
hold-off timer). Charge fail threshold: 6 V-DC.
CHARGE: Connect the charge alternator’s D+ end to Charge excitation current: via 220 ohms resistor
this terminal. This terminal will supply the excitation connected to the FUEL output.
current and measure the voltage of the charge alternator. Operating temp.: -20°C (-4°F) to 70 °C (158°F).
Storage temp.: -30°C (-22°F) to 80 °C (176°F).
Outputs Maximum humidity: 95% non-condensing.
Dimensions: 72x72x52mm (WxHxD)
FUEL SOLENOID : 16amps@28V-DC. Panel cutout dimensions: 68x68 mm
START : 16amps@28V-DC. Weight: 220g (approx.)
ALARM : 16amps@28V-DC. Installation: Flat surface mounting on a Type 1 enclosure.
Retaining steel spring provided.
Options
STANDARD FEATURES: 50Hz nominal
OPTIONAL FEATURES (SUBJECT TO SPECIAL ORDER):

60Hz nominal.
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EN
LOCATION AND PLACEMENT OF THE AUTOMATIC TRANSFER SWITCH PANEL
•
•
•
•
•
•
GENERATOR MAINS
COUNTER MAIN FUSE MAIN SWITCH

J.K. S.K.
G.C. M.C.
GENERATOR PANEL
(GTP)
L1 L2 L3 N L1 L2 L3 N
COMPENSATION
LOAD
PANEL
Figure-
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EN EN
ATS SYSTEMS OVERVIEW
controlled automatically.
www.emsa.gen.tr

EN EN
STATUS
MAINS
9
ALARM
WARNING
SERVICE
REQUEST
LOAD
5 6 7 8 10
GENSET
PGM
1 2 3 4
TEST/RUN AUTO STOP
(X-4) (X-4)
30 31 32 33 34 35 36 30 31 32 33 34 35 36
A5 15 11 14 A2 5 12 A5 15 11 14 A2 5 12
TO THE GTP PANEL TO THE CONTROL PANEL
Generator and Transfer Panel Connection
www.emsa.gen.tr

EN
Contactor systems;
the mains contactors.
MAINS GENERATOR
LOAD LOAD
GENERATOR MAINS
Wall Type / Contactor Transfer Panel
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EN EN
ATS MATERIAL LIST
ENGINE CONTACTORS OR BREAKERS

ESP
Imax (A) ABB 3P ABB 4P LG 3P LG 4P
(kVA)
10 15 ABB Contactor AF26-30-01 (45A) (1SBL237001R1300) ABB Contactor AF26-40-00 (45A)(1SBL237201R1300) Contactor LG METASOL MC-18 /3b 1NA+1NK (32A) Contactor LG METASOL MC-18 /4b (32A)
27 39 ABB Contactor AF26-30-01 (45A) (1SBL237001R1300) ABB Contactor AF26-40-00 (45A)(1SBL237201R1300) Contactor LG METASOL MC-32 /3a 1NA+1NK Contactor LG METASOL MC-32 /4a (50A)
30 44 ABB Contactor AF26-30-01 (45A) (1SBL237001R1300) ABB Contactor AF26-40-00 (45A)(1SBL237201R1300) Contactor LG METASOL MC-32 /3a 1NA+1NK Contactor LG METASOL MC-32 /4a (50A)
33 48 ABB Contactor AF40-30-11 (70A) (1SBL347001R1311) ABB Contactor AF40-40-00 (70A) (1SBL347201R1300) Contactor LG METASOL MC-32 /3a 1NA+1NK Contactor LG METASOL MC-32 /4a (50A)
55 80 ABB Contactor AF52-30-11-13 (100A) (1SBL367001R1311) ABB Contactor AF52-40-00 (100A) (1SBL367201R1300) Contactor LG METASOL MC-65 /3a 1NA+1NK Contactor LG METASOL MC-65 /4a (100A)
88 127 ABB Contactor AF80-30-11 (125A) (1SBL397001R1311) ABB Contactor AF80-40-00-13 (125A) (1SBL397201R1300) Contactor LG METASOL MC-85 /3a 1NA+1NK Contactor LG METASOL MC-85 /4a (135A)
100 145 ABB Contactor AF116-30-11-13 (160A)(1SFL427001R1311) ABB Contactor AF116-40-11 (160A) (1SFL427101R1311) Contactor LG METASOL MC-100 /3a 1NA+1NK Contactor LG METASOL MC-100 /4a (160A)
135 195 ABB Contactor AF190-30-11 (275A)(1SFL487002R1311) ABB Contactor AF190-40-11 (275A) (1SFL487102R1311) Contactor LG METASOL MC-225 /3a 2NA+2NK Contactor LG METASOL MC-225 /4a 2NA+2NK (275A)
190 275 ABB Contactor AF265-30-11 (400A) (1SFL547002R1311) ABB Contactor AF265-40-11 (400A) (1SFL547102R1311) Contactor LG METASOL MC-330 /3a 2NA+2NK Contactor LG METASOL MC-330 /4a 2NA+2NK (350A)
300 433 ABB Contactor AF305-30-11-13 (500A)(1SFL587002R1311) ABB Contactor AF305-40-11-13 (500A)(1SFL587102R1311) Contactor LG METASOL MC-500 /3a 2NA+2NK Contactor LG METASOL MC-400 /4a 2NA+2NK (450A)
385 556 ABB Contactor AF370-30-11-13 (600A) (1SFL607002R1311) ABB Contactor AF370-40-11 (1SFL607102R1311) Contactor LG METASOL MC-500 /3a 2NA+2NK Contactor LG METASOL MC-500 /4a 2NA+2NK (580A)
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EN EN
ENGINE CONTACTORS OR BREAKERS

ESP
Imax (A) ABB 3P ABB 4P LG 3P LG 4P
(kVA)
415 599 ABB Contactor AF460-30-11 (700A)(1SFL597001R7011) ABB Motorized CB E1.2B 630A 4P (1SDA071331R1) Contactor LG METASOL MC-630 /3a 2NA+2NK Contactor LG METASOL MC-630 /4a 2NA+2NK (660A)
550 794 ABB Contactor AF580-30-11 (800A) (1SFL617001R7011) ABB Motorized CB E1.2B 800A 4P (1SDA071371R1) Contactor LG METASOL MC-800 /3a 2NA+2NK Contactor LG METASOL MC-800 /4a 2NA+2NK (900A)
600 866 ABB Motorized CB E1.2B 1000A 3P (1SDA070781R1) ABB Motorized CB E1.2B 1000A 4P (1SDA071411R1) Motorized CB LG AN-10 D3-10H 250-1000A 3P electronic prot Motorized CB LG AN-10 D 4P-10H 400-1000A e/elec.prot.motor
1250 1804 ABB Motorized CB E2.2N 2000A 3P (1SDA071031R1) ABB Motorized CB E2.2N 2000A 4P (1SDA071661R1) Motorized CB LG AS-20 E3 20H 2000A 3P
1500 2165 ABB Motorized CB E2.2N 2500A 3P (1SDA071061R1) ABB Motorized CB E2.2N 2500A 4P (1SDA071691R1)
2500 3608
2550 3680
2700 3897
2750 3969 E4.2N 3P 4000A (1SDA071195R1) E4.2N 4P 4000A (1SDA071825R1)
EMSA reserves the right to make changes in this list. Please contact your Sales Representative for an updated info.
www.emsa.gen.tr

EN
Inverter switch systems;
MAINS
MAINS GENERATOR
GENERATOR
LOAD
LOAD
Wall Type / Inverter Switch Transfer Panel
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EN EN
MAINS
GENERATOR
LOAD
MAINS
GENERATOR
LOAD
Standing Type / Inverter Switch Transfer Panel
Air Circuit Breakers (ACB) systems;
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EN EN
GENARATOR
GENARATOR
0 1
0 OFF CHARGED
LOAD
LOAD
0 1
0 OFF CHARGED
MAINS
MAINS
Standing Type / Inverter Switch Transfer Panel
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EN EN
64
EN EN
POSSIBLE REASONS OF FAULTS AND

TROUBLESHOOTING
7
65
POSSIBLE REASONS OF FAULTS AND TROUBLESHOOTING
EN EN
ALTERNATOR FAULTS AND TROUBLESHOOTING FAULT:

FAULT: •
• REASON:
REASON: • One terminal of regulator connected to a phase is disconnected.
•
•
• •
and similarly whether the terminal ends are loose. •

• Balance the load.
FAULT:
connections.
•
• Fault in rotating diodes.
REASON:
multimeter, and replace the faulty diodes. •
• Engine speed is too low.
• Disconnection in the stator coils.
•
FAULT: FAULT:
•
• Voltage is lowered as the alternator is loaded.
REASON: REASON:
•
•
Operate at nominal load.
•
is loaded after this setting.
• FAULT:
•
•
REASON:
•
•
•
FAULT:
• Voltage is increased as the alternator is loaded. circuit is present in case of difference in resistance.
REASON: •
•
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66 POSSIBLE CAUSES OF FAULTS AND TROUBLESHOOTING

EN EN
DIESEL ENGINE FAULTS AND TROUBLESHOOTING FAULT:

FAULT: • Oil pressure is too high
• REASON:
REASON: •
• Battery discharged • Oil pressure indicator is faulty
• FAULT:
• •
• REASON:
FAULT: • Fuel pipe clogged
• Oil pressure is too low •
REASON: •
• •
• •
• •
• •
•
FAULT:
• Engine temperature is high
• Blue or white exhaust smoke
• Engine temperature is low
REASON:
•
•
•
•
• Fuel timing setting is incorrect
• Diesel engine is cold
•
•
FAULT:
• Fuel timing setting is incorrect
• Engine operation is irregular
FAULT:
REASON:
•
• Fuel pipe clogged
REASON:
•
•
•
• Fuel circuit has air in it
• Fuel pump is faulty
• Fuel tank is empty
•
•
•
• Fuel control solenoid is faulty
•
•
•
•
•
•
•
•
•
•
•
•
•
•
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POSSIBLE CAUSES OF FAULTS AND TROUBLESHOOTING 67

EN EN
FAULT: REASON:
• •
REASON: •
• •
• •
• •
• •
• •
• FAULT:
• •
• REASON:
• •
FAULT: •
• •
REASON: •
• •
• •
FAULT: •
• FAULT:
REASON: •
• Fuel pipe clogged REASON:
• • Fan is damaged
• •
• Fuel pump is faulty •
• •
• •
• FAULT:
• • Engine stops after starting
• REASON:
FAULT: •
• Engine is pinking •
REASON: •
• •
• •
• Fuel pump fault
•
•
•
FAULT:
• Fuel consumption is high
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68 POSSIBLE CAUSES OF FAULTS AND TROUBLESHOOTING

EN EN
OTHER TECHNICAL DATA 8
69
EN MODEL CODES AND GENERAL INFORMATION
EMSA DIESEL GENERATOR
E BD ST 0275
Standby power (kVA)
Abbreviation for Alternator brand (eg. Stamford)
Abbreviation for Engine brand (eg. Kubota)
Emsa brand abbreviation
OIL AND WATER CAPACITIES OF THE GENERATOR
Engine
Engine
Fuel Total
ESP (kVA) PRP (kVA) Fuel Total
EMSA Cons. Fuel Tank ENGINE ENGINE Lubrication
@ cos phi : @ cos phi : Tank Coolant
MODEL @ Type BRAND MODEL System
0,8 0,8 (l) Capacity
PRP Capacity
(lt)
(lt)
E PR XX 0010 10 9 82 3,6 IN-BUILT PERKINS 403A-11G1 4,9 5,2
E YD XX 0011 11 10 82 3,1 IN-BUILT YANGDONG YD380D 4,5 11
E YD XX 0013 13 11 82 3,55 IN-BUILT YANGDONG YD385D 4,5 11,1
E PR XX 0015 15 13 82 4,1 IN-BUILT PERKINS 403A-15G1 6 6
E YD XX 0017 17 15 82 4,22 IN-BUILT YANGDONG YD480D 5 11,3
E BD XX 0022 22 20 82 4,7 IN-BUILT BAUDOUIN 4M06G20/5 11,5 8,6
E MH XX 0022 22 20 82 5,9 IN-BUILT MITSUBISHI S4Q2-61SDB 6,5 9
E PR XX 0022 22 20 82 5,3 IN-BUILT PERKINS 404A-22G1 10,6 7
E YD XX 0022 22 20 82 4,71 IN-BUILT YANGDONG YND485D 5,5 12,5
E YD XX 0030 30 27 82 6,43 IN-BUILT YANGDONG Y490D 8 14
E IV XX 0033 33 30 101 7,1 IN-BUILT FPT - IVECO 80313AM1P.S550 8,8 14
E PR XX 0033 33 30 101 7,2 IN-BUILT PERKINS 1103A-33G 8,3 10,2
E YD XX 0040 40 36 101 7,05 IN-BUILT YANGDONG Y4102D 13 16,2
E YD XX 0044 44 40 101 8,94 IN-BUILT YANGDONG Y4105D 13 15,1
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70 OTHER TECHNICAL DATA

EN
Engine
Engine
Fuel Total
PRP Capacity
(lt)
(lt)
E IV XX 0050 50 45 101 11,3 IN-BUILT FPT - IVECO NEF45AM2.S500 12,8 18,5
E PR XX 0050 50 45 101 12 IN-BUILT PERKINS 1103A-33TG1 7,9 10,2
E YD XX 0050 50 45 101 8,8 IN-BUILT YANGDONG Y4102ZLD 13 15,1
E IV XX 0055 55 50 101 12 IN-BUILT FPT - IVECO NEF45SM1A.S500 12,8 18,5
E IV XX 0066 66 60 139 13,7 IN-BUILT FPT - IVECO NEF45SM1A.S500 12,8 18,5
E PR XX 0066 66 60 101 15,4 IN-BUILT PERKINS 1103A-33TG2 7,9 10,2
E BD XX 0072 70 65 139 14,6 IN-BUILT BAUDOUIN 4M10G70/5 13 17,9
E PR XX 0072 72 65 139 14,8 IN-BUILT PERKINS 1104A-44TG1 8 13
E YD XX 0088 88 80 139 16,9 IN-BUILT YANGDONG LR4N5LP-D 13 15,8
E IV XX 0090 90 80 139 19,3 IN-BUILT FPT - IVECO NEF45SM3.S500 12,8 18,5
E SD XX 0100 100 90 139 14,8 IN-BUILT SDEC SC4H95D2 13 17
E IV XX 0110 110 100 275 22 IN-BUILT FPT - IVECO NEF45TM2A.S500 12,8 18,5
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EN
Engine
Engine
Fuel Total
PRP Capacity
(lt)
(lt)
E PR XX 0110 110 100 139 24,9 IN-BUILT PERKINS 1104C-44TAG2 8 12,6
E YD XX 0110 110 100 139 21 IN-BUILT YANGDONG LR4N5LP-D 14 18
E SD XX 0135 135 125 275 25 IN-BUILT SDEC SC4H160D2 13 25,5
E IV XX 0138 138 124 275 27,6 IN-BUILT FPT - IVECO NEF45TM3.S500 12,8 18,5
E BD XX 0150 150 135 275 30,4 IN-BUILT BAUDOUIN 6M11G150/5 19 21
E PR XX 0165 165 150 275 36,1 IN-BUILT PERKINS 1106A-70TAG2 16,5 21
E IV XX 0176 176 160 275 36 IN-BUILT FPT - IVECO NEF67TM3A.S500 17,2 25,5
E IV XX 0190 190 170 275 36,6 IN-BUILT FPT - IVECO NEF67TM4A.S500 17,2 25,5
E PR XX 0200 200 180 275 44,6 IN-BUILT PERKINS 1106A-70TAG3 16,5 21
E IV XX 0220 220 200 275 42,1 IN-BUILT FPT - IVECO NEF67TM7.S500 17,2 30,5
E PR XX 0220 220 200 275 44,5 IN-BUILT PERKINS 1106A-70TAG4 21 16,5
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EN
Engine
Engine
Fuel Total
PRP Capacity
(lt)
(lt)
E PR XX 0250 250 225 415 53,5 IN-BUILT PERKINS 1206A-E70TTAG2 25,5 16
E SD XX 0250 250 225 415 48,6 IN-BUILT SDEC SC9D280D2 41 29,6
E DT XX 0275 275 250 459 48,5 IN-BUILT DEUTZ BF6M1015-LA GA 38 62
E IV XX 0275 275 250 415 51,5 IN-BUILT FPT - IVECO NEF67TE8P.S550 17 26
E PR XX 0275 275 250 415 55,5 IN-BUILT PERKINS 1206A-E70TTAG3 25 16
E SD XX 0275 275 250 415 50,6 IN-BUILT SDEC SC9D310D2 19 40
E DT XX 0290 290 264 459 48,5 IN-BUILT DEUTZ BF6M1015C-LA-G1A 38 62
E SD XX 0290 290 275 415 54,1 IN-BUILT SDEC SC9D340D2 25 42
E PR XX 0300 300 275 415 60,2 IN-BUILT PERKINS 1506A-E88TAG4 41 33,2
E IV XX 0330 330 305 846 66,6 IN-BUILT FPT - IVECO CURSOR87TE4.S550 28 58
E PR XX 0330 330 300 415 64,9 IN-BUILT PERKINS 1506A-E88TAG5 41 33,2
E SD XX 0330 330 300 846 60,8 IN-BUILT SDEC SC10E380D2 41 73,2
E IV XX 0385 385 350 846 70 IN-BUILT FPT - IVECO CURSOR13TE2A.S551 35 68
E PR XX 0400 400 350 819 71 IN-BUILT PERKINS 2206A-E13TAG2 40 51,4
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EN
Engine
Engine
Fuel Total
PRP Capacity
(lt)
(lt)
E DT XX 0415 415 380 730 65,8 IN-BUILT DEUTZ BF6M1015CP-LAG 38 67
E DT XX 0440 440 400 730 76,5 IN-BUILT DEUTZ BF6M1015CP-LAG 38 67
E IV XX 0440 440 400 846 85,8 IN-BUILT FPT - IVECO CURSOR13TE3A.S551 35 68
E SD XX 0440 440 400 846 81,2 IN-BUILT SDEC SC15G500D2 41 80,2
E PR XX 0450 450 400 819 81 IN-BUILT PERKINS 2206A-E13TAG3 40 51,4
E BD XX 0500 500 450 846 100 IN-BUILT BAUDOUIN 6M21G500/5 34 47
E PR XX 0500 500 455 819 95 IN-BUILT PERKINS 2506A-E15TAG1 62 58
E DT XX 0550 550 500 1020 94 IN-BUILT DEUTZ BF8M1015C-LA G2 48 87
E IV XX 0550 550 500 846 101 IN-BUILT FPT - IVECO CURSOR13TE7W.S550 35 38,1
E SD XX 0550 550 500 1263 114 IN-BUILT SDEC SC25G610D2 65 147
E DT XX 0630 630 570 1020 114 IN-BUILT DEUTZ BF8M1015CP-LA G4 48 93
E DT XX 0660 660 600 1020 119 IN-BUILT DEUTZ BF8M1015CP-LA G5 48 93
E IV XX 0660 660 600 846 116 IN-BUILT FPT - IVECO CURSOR16TE1W.S550 38 52,5
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EN
Engine
Engine
Fuel Total
PRP Capacity
(lt)
(lt)
E PR XX 0660 660 600 1086 132 IN-BUILT PERKINS 2806A-E18TAG1A 62 61
E PR XX 0785 785 715 1600 162 IN-BUILT PERKINS 2806A-E18TTAG4 72 110
E PR XX 0850 850 770 1600 162 IN-BUILT PERKINS 2806A-E18TTAG5 110 68
E SD XX 0850 850 785 1410 164 IN-BUILT SDEC SC33W990D2 75 109,5
E PR XX 0900 900 800 1574 175 IN-BUILT PERKINS 4006-23TAG3A 113,4 105
E PR XX 1002 1002 911 2175 195 IN-BUILT PERKINS 4008TAG1A 153 149
E SD XX 1010 1010 910 1410 194 IN-BUILT SDEC SC33W1150D2 75 109,5
E SD XX 1100 1100 1000 1754 188 IN-BUILT SDEC 6WTAA35-G31 100 146
E PR XX 1110 1110 1010 2175 215 IN-BUILT PERKINS 4008TAG2A 153 149
www.emsa.gen.tr

EN
Engine Engine
Fuel Total
0,8 0,8 (l) Capacity Capacity
PRP
(lt) (lt)
E MH XX 1125 1125 1022 3000 216 IN-BUILT MITSUBISHI S12H-PTA 200 245
E PR XX 1250 1250 1125 2138 244 IN-BUILT PERKINS 4008-30TAG3 153 140
E PR XX 1385 1385 1250 3000 258 EXTERNAL PERKINS 4012-46TWG2A 177 210
E BD XX 1400 1400 1250 2072 259 DAH L BAUDOUIN 12M33G1400/5 160 303
E MH XX 1425 1425 1285 3000 261 EXTERNAL MITSUBISHI S12R-PTA 180 335
E MH XX 1500 1500 1400 3000 280 EXTERNAL MITSUBISHI S12R PTA2 180 305
E PR XX 1500 1500 1350 3000 281 EXTERNAL PERKINS 4012-46TWG3A 177 201
E PR XX 1656 1656 1505 3000 310 EXTERNAL PERKINS 4012-46TAG2A 177 210
E MH XX 1660 1660 1510 3000 309 EXTERNAL MITSUBISHI S12R PTAA2 180 368
E MH XX 1700 1700 1530 3000 309 EXTERNAL MITSUBISHI S12R-F1PTAW2 180 368
E PR XX 1880 1880 1710 3000 370 EXTERNAL PERKINS 4012-46TAG3A 177 210
E BD XX 1900 1900 1750 3000 364 EXTERNAL BAUDOUIN 16M33G1900/5 175 542
E MH XX 1905 1905 1750 3000 342 EXTERNAL MITSUBISHI S16R PTA 230 368
E MH XX 2028 2028 1844 3000 387 EXTERNAL MITSUBISHI S16R PTA2 230 445
E PR XX 2028 2028 1844 3000 383 EXTERNAL PERKINS 4016TAG1A 237,2 316
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EN
Engine
Engine
Fuel Total
PRP Capacity
(lt)
(lt)
E MH XX 2200 2200 2000 3000 402 EXTERNAL MITSUBISHI S16R PTAA2 230 400
E MH XX 2220 2220 1998 3000 402 EXTERNAL MITSUBISHI S16R-F1PTAW2 230 400
E BD XX 2250 2250 - 3000 429 EXTERNAL BAUDOUIN 16M33G2250/5 175 542
E PR XX 2250 2250 2050 3000 434 EXTERNAL PERKINS 4016TAG2A 237,2 316
E MH XX 2500 2500 2273 3000 500 EXTERNAL MITSUBISHI S16R2 PTAW 290 500
E PR XX 2500 2500 2250 3000 470 EXTERNAL PERKINS 4016-61TRG3 237,2 270
E BD XX 2550 2550 2304 3000 464 EXTERNAL BAUDOUIN 12M55G2550/5 560 N/A
E MH XX 2700 2700 2450 3000 513 EXTERNAL MITSUBISHI S16R2-PTAW-E 290 190
E BD XX 2750 2750 2500 3000 514 EXTERNAL BAUDOUIN 12M55G2750/5 560 N/A
E MH XX 2750 2750 2500 3000 526 EXTERNAL MITSUBISHI S16R2 PTAW2-E 290 715
WARNING
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EN EN
CROSS-SECTIONS OF CABLES TO BE USED

in such cases.
Stand By power power power power power power power power
(kVA) max. cable cable cable cable cable cable cable cable
A 1 pc. / 2 pcs. / 3 pcs. / 4 pcs. / 5 pcs. / 6 pcs. / 7 pcs. / 8 pcs. /
min. max
phase phase phase phase phase phase phase phase
25 2
25 33 2
33 2
25 mm2
35 mm2
50 mm2
220 2
355 2
50 mm2
2 2
333 2 2
333 2 2
2 2
2 2
2 2 2
2 2 2
2 2 2 2
2 2 2 2 2
2 2 2 2 2
2 2 2 2 2
2 2 2 2
2 2 2
2 2
WARNING
•
•
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EN EN
GENERATOR DIMENSIONS
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EN EN
.
GENERATOR MAINTENANCE SCHEDULE
MAINTENANCE TIME
IN CHARGE
MAINTENANCE OPERATION Once
every 12 OF THE
months OPERATION
O to
n 1 year, after 1 year 150 hours ma ntenance shall be performed.

O to
O to
Check th l En Tempe e O to
D ch ge F nt l Clean F el R
O to
Th o gh the F l lte
O to
Check th a o n
A t z S ce
t
Check th l En lt
A t z S ce
na Wea
( ) Check n l
A t z S ce
O l Level
Change the D l l an l lte
A t z S ce
(w th 15W l)
Change the lF ( on the Ga ) Check the Gauge A t z S ce
Pe lve Clea ce A j tment an

A t z S ce
Cont l
Change D l Eng l F lte A t z S ce
Clean the C nkca e A ge Mech m A t z S ce
After n t al ma ntenance, f the 150 work ng hours s not up

Pe Inject Te t an A tment A t z S ce
Pe Comp e on P e Check A t z S ce
Check the C la mp A t z S ce
A t z S ce
Pe F el P p Te t a j tment A t z S v ce
Check the C l Cove . A t z S v ce
Check the Jacket Wea A t z S v ce
Clean the Coo ng W Pa age

A t z S v ce
Pe Ma n Be Ro
A t z S v ce
Bea ance Check
Check the on Wea A t z S v ce
Check the C n ha Wea A t z S v ce
Check the C nk M Wea A t z S v ce
Check D ve Ge G Wea A t z S v ce
Yap n z
Pe Gene l Ma c mp A t z S v ce
Replace the D l Eng e p A t z S v ce
Replace the C Seal A t z S v ce
Replace Alte at Bea g A t z S v ce
80
ELECTRIC DIAGRAMS EN EN
2 3 4 5 6 7
SMART500 MKII
IN - R.START
SND - TEMP
IN - E.STOP
IN - SPARE
IN - SPARE
IN - SPARE
IN - SPARE
IN - TEMP
SND - OIL
CHARGE
HEATER
MN - L1
MN - L2
MN - L3
IN - OIL
MN - N
MN - C
SGND
G - L1
G - L2
G - L3
BAT+
G-N
G-C
BAT-
A
I1+
I2+
I3+
I1-
I2-
I3-
59 60 61 62 63 64 52 54 56 58 20 21 12 11 10 4 5 6 7 22 18 8 9 1 3 19 13 73 71 69 67 51 74 14 15 16 17 18
40 41 42 43 44 45 6 7 8 9 37 38 31 32 35 21 33 27 3 34 36 19 19 39 15 11 14 10 1 12 2
1R3 1R1 1R2 1R4
1E1
B
- 10
+ 1CR1 15
1F3 1F4 1F5 1F6
1E2
1R4
1F7 1F8 1F9 1F2
6A 6A 6A 6A
6A 6A 6A 16A
1R1
1R3
1E3
NC FOR DT
1R2
NO FOR BD
1F1
1E3
C
32A
40 41 42 43 44 45 6 7 8 9 37 38 31 32 35 21 A3 A1 A4 29 34 A5 A2 A5 36 30 19 A5 15 11 14 A2 5 12 19 2
X-1 X-2 X-3 X-4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37 38
26-27
40 41 42 43 44 45 6 7 8 9 37 38 31 32 35 21 A3 A1 A4 29 34 A5 A2 A5 36 30 19 ONLY FOR A5 A5 11 14 A2 5 12 19 2
R.START IN
R.START COM
1R5 1FL1 DT
P C
-
G
+
TO ATS BOX
D
1TC11PC1 C
R.START
1R5
50C° 50C°
ALTERNATOR D+
A B+ M
1WH1 1WH2
E
Onaylayan / Approved by
AÇIKLAMALAR / DESCRIPTIONS
NO KLMNS NO C.NO 30 A5
1 SMART500 MKII 1 40 L1 CT(S1) 31 15
2 1CR1 2 41 L1 CT(S2) 32 11
3 1R1 3 42 L2 CT(S1) 33 14
4 1R2 4 43 L2 CT(S2) (X-4) 34 A2
5 1R3 5 44 L3 CT(S1) 35 5
6 1R4 (X-1) 6 45 L3 CT(S2) 36 12
7 1R5 7 6 37 19
8 8 7 38 2
9 9 8
10 1FL1 10 9
11 1TC1
12 1PC1
11 37
13 1WH1
12 38
14
15
13 31 ENGINE
16
(X-2) 14 32 BRAND
17 1ATS1
15 35 ---&---
16 21
18 S.COIL
17 A3
MARKA
NO SYM. 18 A1
1 A1
2
19 A4
2 A2
2
20 29
3 A3
2
21 34
4 A4
2
22 A5
5 A5
2 (X-3) 23 A2
6 A6
2
24 A5
7 A7
2
25 36
26 3
27 19
28 4
www.emsa.gen.tr

EN EN
ATS ABB 3K ACB TYPE
6
7
8
A8
15
11
14
6 15
Z4 Z3 Z2 Z1
6 40 40 40 31 32 6 1 6 15 41 41 41 3 35 36 15 15 15 15 6 6
1 3 K20 K20 K21 K21

1 3 4 D1 C11 C1 U1 11 21 1 3 4 D1 11 C11 C1 U1 21
J.K. S.K. 1 2 3 4
1 G.C. K21 K20 2 M.C.
2 5 D2 C12 C2 U2 12 24 2 5 D2 12 C12 C2 U2 24 Z1 Z2 Z3 Z4
7SN 1SN 7SN 1SN
9 43 43 9 12 2 4 10 42 42 5 10
6 7 8 11 14 15
10 9
K20 K21
9 10
9 9 10 10 10 9
9
10
A5 15 11 14 C2 5 12
(X-4)
30 31 32 33 34 35 36
A5 15 11 14 C2 5 12
(X-4)
www.emsa.gen.tr

EN EN
ATS ABB 4K ACB TYPE

1F1
6
G-L1
7
G-L2
8
G-L3
A5 A5
1F2
15
MN-L1
11
MN-L2
14
MN-L3
15
1F3
1Z1
1Z3
1Z4
1Z2
16A 15 15 6 6
6 40 40 40 7 32 31 8 1 3 14 35 36 11 41 41 41 15
K21
K21
K20
K20
D1 C1 C11 21 11 11 21 C11 C1 D1 4 3 1
1 2 40 41 42 43
K21
K20
5 D2 C2 C12 24 12 12 24 C12 C2 D2 5 2 # MCB-7 MCB-7 MCB-7 MCB-7
7S 13S 7S 13S
9 43 43 9 9 9 24 12 5 27 10 10 10 42 42 10 1Z1 1Z2 1Z3 1Z4
2 4
6 7 8 15 11 14
K20 K21
1LB1
1LB2
1LB3
1LB4
1LB5
1LB6
1LB7
1LB8
9 9 9 10 10 10 9 9 9 10 9 10 10 10 10 9
M-N 10
A5 15 11 14 A2 5 12
( X-4 )
30 31 32 33 34 35 36
A5 15 11 14 A2 5 12
A5
A2
K20 , K21
1Z1-1Z4
1LB1-1LB6
1LB7 , 1LB8
1F1 , 1F2
1F3

EN EN
GENSET
CONTROL
PANEL
JENERAT R
KONTROL C HAZI
SMART 500
GENSET CONTROLLER
A TO MAINS
READY
ALARM
WARNING
SER ICE
RE EST LOAD
GENSET
PGM
AC L D RD RMA
For ComAp and Deep Sea AMF applications, please contact your Sales Representative for updated drawings.
For Smart500, ComAp and Deep Sea Synchronization applications, please contact your Sales Representative for updated drawings.
Software downloads for;
Datakom :
"Parameter Setup and Monitoring Software: Rainbow Plus"
https://datakom.com.tr/d-500-advanced-genset-controller/74/55/ProductDetails?lang=5
ComAp IL4-AMF25;
First, you must sign-up and register.
Then, enter https://www.comap-control.com/products/controllers/single-gen-set-controllers/intelilite/intelilite-4-amf-25/
Find Software and install "InteliConfig Installation Suite 2.36.1 Web-"
Deep Sea DSE 6120;
First, you must sign-up and register.
Then, enter https://www.deepseaelectronics.com/genset/auto-mains-utility-failure-control-modules/dse6120/software
"DSE CONFIGURATION SUITE SOFTWARE INSTALLER" and download.
www.emsa.gen.tr

EN EN
QUALITY STANDARDS 9
85
QUALITY
EN
86
EN
WARRANT CONDITIONS AND

RESPONSIBILITIES OF THE CUSTOMER
10
9
87
WARRANTY CONDITIONS AND RESPONSIBILITIES OF THE
EN CUSTOMER
DEAR USER OF THE EMSA GENERATOR;
88
WARRANTY CONDITIONS AND RESPONSIBILITIES OF THE
CUSTOMER EN
WARRANTY CONDITIONS / RESPONSIBILITIES OF THE CUSTOMER

•
•
EN
• The guarantee period for the generators sold start with the date of
of the customer.
•
•
for commissioning after performing the installation of the generator

performed and for the point where the electrical connections are
or completed.
generator and to resume the warranty period.
•
• outlet and to ensure that dimensions of the generator room complies
with the norms.
•
documents again if these maintenance manuals and charts are lost.

•
•
out of warranty.
•
•
when genuine spare parts are not used.
•
drawing more current than the nominal current of the generator
• through the mains contactor selected as per the generator power.
•
•
where our generator and the installation of the customer may operate
•
•
similar structures made to access the generator, for rental cranes or
89
EN EN
TS
www.emsa.gen.tr
90
WARRANTY CERTIFICATE
EN EN
WARRANTY CERTIFICATE
Manufacturer's or Importer's Seller's:
PRODUCT
WARRANTY CONDITIONS
arising from issues regarding using the warranty rights.
www.emsa.gen.tr
91
NOTES
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www.emsa.gen.tr

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DIESEL GENERATOR

MAINTENANCE AND OPERATION MANUAL

DEAR USER OF THE EMSA GENERATOR;

Emsa Generator system properly.

Take recommended safety and installation precautions.

2 SAFETY AND HEALTH

LIFTING, PLACEMENT, INSTALLATION AND

OTHER TECHNICAL DATA

5 DIESEL ENGINE MAINTENANCE

WARRANTY CONDITIONS AND

OPERATION OF THE GENERATORS

POSSIBLE REASONS OF FAULTS AND

user in operating and maintaining of the generator easily. This is not

manual are followed.

Telephone: + 90 216 420 00 03

SAFETY AND HEALTH 2

GENERAL PRECAUTIONS AGAINST LEAKS

• Do not operate the generator in case of a known unsafe condition.

USING PROTECTIVE EQUIPMENT

SAFETY AND HEALTH

• Do not lift the generator using alternator and engine lifting •

• • Do not operate the generator in case of a fuel leakage in the fuel

and explode. Taking proper precautions for the storage

SAFETY AND HEALTH

not used properly.

• Electrolyte is an acid. Electrolyte can cause

occupational safety rules during operation and

SAFETY AND HEALTH

FIRST AID FOR ELECTRIC SHOCKS 2.

Opening the Respiratory Tract

IF THE VICTIM CANNOT BREATH, AND NO PULSE IS

SAFETY AND HEALTH

PROTECTION AGAINST FIRE •

causes injuries to the personnel or deaths.

SAFETY AND HEALTH

DESCRIPTION AND EXPLANATION OF THE FUEL TANK AND CHASSIS

Figure-2 and Figure-2a show main parts of a typical

the generator is placed on the installation area.

and directs the exhaust gases for safe discharge.

engine in order to cool the engine.

12. 15. 17.

13. 16. 18.

LIFTING, PLACEMENT, INSTALLATION AND STORAGE 4

slipping and falling in case of oil leaks, etc.

22 LIFTING, PLACEMENT, INSTALLATION AND STORAGE

GENERATOR WITH CANOPY

LIFTING, PLACEMENT, INSTALLATION AND STORAGE 23

TRANSPORTATION OF THE GENERATOR

FORKLIFT BLADE CHANNELS

LIFTING, PLACEMENT, INSTALLATION AND STORAGE

LIFTING AND/OR LOWERING THE GENERATOR

WARNING SELECTION OF THE LOCATION OF THE GENERATOR

LIFTING, PLACEMENT, INSTALLATION AND STORAGE 25

for further details.

COOLING AND VENTILATION

Concrete Resistance: 2000 kg/cm²

Basic Functions of the Base Concrete

LIFTING, PLACEMENT, INSTALLATION AND STORAGE

Figure-9 Basement installation plan of a typical generator set