HIPOWER Yanmar Generators Manual

Generating Sets
Manual
Yanmar
HIPOWER builds a
wide range of Power
Plants available for
standby or primer
power applications
providing a safe, reliable and dependable
source of energy
where ever is needed.
Industrial Range
Industrial Generator Sets

feature a robust construction with strict adherence
to quality, while maintaining a minimal impact to
the environment.
Rental Range
HIPOWER Rental Generators Sets have been
developed from the user
and service point of view
thanks to the input of
the premium class rental
companies.
Contents
Forward........................................................................................................ 2
1. Safety...................................................................................................... 5
1.1 General Safety Information ......................................................................... 5
1.2 Installation And Transporting ..................................................................... 6
Hazards.................................................................................................................. 6
2. Identification.......................................................................................... 8
2.1 Generator Identification View...................................................................... 8
3. Installation.......................................................................................... 10
3.1
3.2
3.3
3.4
General Information.................................................................................... 10
Control Of Material...................................................................................... 10
Outdoor Installations.................................................................................. 10
Indoor Installations..................................................................................... 10
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.3.7
3.3.8
Exhaust Installation............................................................................................. 12
Ventilation............................................................................................................. 15
Remote Fuel Tank................................................................................................ 15
Heating.................................................................................................................. 16
Electrical Connections........................................................................................ 16
Three Phase Generator Sets............................................................................... 17
Single Phase Generator Sets.............................................................................. 18
4. Prestart Checks................................................................................... 19
4.1 Prestart Checks........................................................................................... 19
5. CEM7 Control Panel............................................................................ 20

5.1 Introduction................................................................................................. 20
5.1.1 Display Module (Control Panel).......................................................................... 20
5.1.2 Measurements Module........................................................................................ 20
5.2 Control Panel............................................................................................... 21

5.3 Control Panel Push Buttons...................................................................... 22
5.3.1 Operating Mode Buttons..................................................................................... 22
5.3.2 Command Buttons............................................................................................... 22
5.3.3 Display Buttons.................................................................................................... 22
5.4 Data LEDs................................................................................................... 23

5.4.1 Contactor Status LEDs........................................................................................ 23
5.4.2 Engine Status LEDs............................................................................................. 23
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1
HIMOINSA POWER SYSTEMS
Forward
5.4.3 Alarm LEDs........................................................................................................... 23
5.5 Starting And Stopping Genset................................................................... 24

5.5.1 Starting - Manual Mode........................................................................................ 24
5.5.2 Stopping - Manual Mode...................................................................................... 24
5.5.3 Starting And Stopping - Automatic Mode.......................................................... 24
5.6
5.7
5.8
5.9
Interruption Of Function Mode.................................................................. 24

Working Mode............................................................................................. 24
Transfer Fuel Pump.................................................................................... 25
Alarms.......................................................................................................... 25
5.9.1 Reseting Alarms................................................................................................... 26
5.10 Engine Alarms........................................................................................... 27

5.11 Genset Alarms........................................................................................... 28
5.12 Programmable Alarms And Inputs.......................................................... 28
6. M6 Control Panel................................................................................. 30
6.1 Control Panel - M6...................................................................................... 30
6.2 Starting And Stopping Genset - M6 Control Panel.................................. 31
6.2.1 Starting - Manual Mode........................................................................................ 31
6.2.2 Stopping - Manual Mode...................................................................................... 32
6.2.3 Starting And Stopping - Automatic Mode.......................................................... 32
6.3 Engine Alarms............................................................................................. 33
7.
DSE3000 Series Control Panel......................................................... 34

7.1 Description Of Controls............................................................................... 34
7.2 Quickstart Guide........................................................................................... 34
7.1.1 Starting The Engine............................................................................................... 34
7.1.2 Stopping The Engine............................................................................................. 34
7.3 Graphical Display.......................................................................................... 34

7.4 Controls......................................................................................................... 35
7.5 Automatic Mode Of Operation..................................................................... 35
7.5.1 Waiting In Auto Mode............................................................................................. 35
7.5.2 Starting Sequence.................................................................................................. 35
7.5.3 Stopping Sequence................................................................................................ 36
7.6 Manual Operation.......................................................................................... 36

7.6.1 Waiting In Manual Mode........................................................................................ 36
7.6.2 Starting Sequence.................................................................................................. 36
7.6.3 Stopping Sequence................................................................................................ 36
2
7.7 Warnings........................................................................................................ 36
7.8 Shutdowns..................................................................................................... 37
7.9 Module Display.............................................................................................. 37
7.9.1 Timer Icon............................................................................................................... 37
7.9.2 Stopped Icon.......................................................................................................... 37
7.9.3 Running Icon.......................................................................................................... 37
7.9.4 USB Icon................................................................................................................. 37
7.9.5 Memory Corruption................................................................................................ 37
7.9.6 Backlight................................................................................................................. 37
7.10 Fault Icons................................................................................................... 38
8. DSE5310 Series Control Panel........................................................... 39

8.1 Description Of Controls............................................................................... 39
8.5 Typical LCD Display Screens....................................................................... 48
8.5.1 Typical Status Display........................................................................................... 48
8.5.2 Typical Instrument Display.................................................................................... 48
8.5.3 Typical Alarm Display............................................................................................ 48
8.5.4 Typical Event Display............................................................................................ 49
8.6 Viewing The Instruments.............................................................................. 49

8.6.1 Instrument Page Content...................................................................................... 50
8.6.2 Manually Selecting An Instrument....................................................................... 50
8.7 User Configurable Indicators....................................................................... 51

8.8 Controls......................................................................................................... 51
8.7 User Configurable Indicators....................................................................... 52
8.8 Controls......................................................................................................... 52
8.9 Fault Finding.................................................................................................. 53
8.10 Icons And LED Identification..................................................................... 54
7.10.1 Push Buttons........................................................................................................ 54
8.10.2 Status / Measurement Units................................................................................ 54
8.10.3 LED Indication...................................................................................................... 54
9. Routine Maintenance......................................................................... 55
9.1 Maintenance................................................................................................ 55
9.2 Periodic Maintenance................................................................................... 56
10. Alternator.......................................................................................... 57
10.1 Generator Designation............................................................................. 57
3
10.2
10.3
10.4
10.5
Serial Number Location............................................................................ 57

Rating Plate............................................................................................... 57
Lifting......................................................................................................... 57
Automatic Voltage Regulators................................................................. 58
10.5.1 Type AS440......................................................................................................... 58
10.5.2 Type MX341......................................................................................................... 59
10.5.4 Type MX321......................................................................................................... 60
10.6 Electrical Protection................................................................................. 60

10.7 Fault Finding............................................................................................. 61
10.7.1 SX460 AVR.......................................................................................................... 61
10.7.2 SX440 AVR.......................................................................................................... 61
10.7.3 SX421 AVR.......................................................................................................... 61
10.8 Alternator Maintenance............................................................................ 62

10.8.1 Winding Condition............................................................................................. 62
10.8.2 Guidance Of Typical Insulation Resistance [IR] Values................................. 62
10.8.3 Winding Condition Assessment....................................................................... 62
10.9 Replacement Parts.................................................................................... 62
11. Specifications.................................................................................... 63
11.1 Generator Set Models............................................................................... 63
11.2 Engine Models........................................................................................... 64
11.2.1
1.2.2
11.2.3
11.2.4
11.2.5
11.2.6
3TNV76................................................................................................................ 64
3TNV88.................................................................................................................. 64
4TNV84T.............................................................................................................. 65
4TNV88................................................................................................................ 65
4TNV98................................................................................................................ 66
4TNV98T.............................................................................................................. 66
Illustrations and technical detail provided courtesy of Cummins Generator Technologies.

Copyright 2010, Cummins Generator Technologies, All Rights Reserved.
4
1. Safety
1.1 General Safety Information
This manual provides information and procedures to safely

operate and maintain your Hipower Generator Set. Read,
understand and observe the safety instructions described
in this manual before installing, operating and servicing the
generator.
If you have questions about operation or service, please
contact Hipower Systems. The information contained in this
manual was based on machines in production at the time of
publication. Himoinsa Power Systems reserves the right to
change any portion of this information without notice.
All rights, especially copying and distribution rights are
reserved. Copyright 2010 by Himoinsa Power Systems.
No part of this publication may be reproduced in any form
or by any means, electronic or mechanical, including
photocopying, without express written permission from
Himoinsa Power Systems.
This manual is provided to assist in the maintenance and
operation of the generator and is not to be used in any manner
detrimental to the interests of Himoinsa Power systems.
Information in this manual represents components installed
when product was manufactured based upon the best
available information. Modifications made subsequent
to initial delivery are not included. Always verify the parts
required with Himoinsa Power Systems.
If you have any questions, please contact our Parts and
Service Department.
The safety information in this manual is denoted by the

safety alert symbol:
The level of risk is indicated by the following signal words:
^ DANGER
Indicates a hazardous situation, which, if not
avoided, will result in death or serious injury.
^ WARNING
avoided, could result in death or serious injury.
^ CAUTION
avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation that could result in damage
to the equipment or other property.
Never go under raise equipment unless properly supported.
Do not operate generator without an Operators Manual.

Treat the Operators Manual as part of the generator. Replace
the Operators Manual if it is lost, damaged or becomes
unreadable.
Use properly rated lifting equipment to lift heavy objects.
All personnel that will be operating, maintaining and working

around the generator must review these documents before
interacting with the generator.
Clean up spilt fluids and dispose of fluids, contaminated

material etc. in accordance with local regulations.
If you have any safety concerns or questions that are not

covered by this manual, please contact Himoinsa Power
Systems at 1-913-495-5557.
^ California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
Extinguish all smoking material when adding fuel or working

around generator. Engine must be stopped before adding
fuel.
Disconnect negative (-) battery cable before performing

maintenance on generator set.
Allow components
maintenance.
to
cool
before
attempting
any
Do not operate generator set with safety guard(s) removed.

Seek medical attention immediately if your skin contacts
high pressure fuel.
Battery posts, terminals and related accessories contain

lead and leads compounds, chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm. Wash hands after handling.
5
1. Safety
1.2 Installation And Transporting
Hazards
^ WARNING
Crushing hazard.

Generator set is heavy.

Use properly rated lifting devices to move
generator set.

Never enter the area under a raised generator set.
^ WARNING
The generator lifting points are designed to lift the
generator only.

Do not lift the complete generating set by the
generator lifting points.
^ WARNING
Incorrect installation and/or protective systems
can result in injury and/or equipment damage.

Installers must be qualified to perform electrical
installation work.
1.3 Operational Hazards
^ WARNING
Risk of death or serious injury.

Do not operate, work on or around this machine
while under the influence of alcohol, drugs or if
feeling ill.
^ WARNING
Entanglement hazard.

Loose fitting clothing and long hair can be
come entangled in moving or rotating parts.

Do not wear loose fitting clothing.

Long hair must be tied back or netted.

Remove neck ties.

Do not operate generator with a guard removed
or access panel removed.
^ WARNING
Carbon monoxide hazard.

Do not operate the generator in an enclosed
building or confined area.

Avoid actions or areas that expose you and
others to carbon monoxide.
^ WARNING
Risk of death or serious injury.

Do not operate, work on or around this machine
while under the influence of alcohol, drugs or if
feeling ill.
^You must adhere to local codes and regulations where

your generator is being used.
6
1. Safety
^
Do not smoke while refueling. Do not refuel near sparks

or an open flame.
^ Clean up fluid spills and contaminated material in
accordance with local regulations.
^ WARNING
Ensure that all personnel operating, servicing,
maintaining or working near this equipment
are wearing appropriate Personal Protective
Equipment (PPE) including eye and ear protection
and are fully aware of the emergency procedures
in case of any accidents.
^ WARNING

Generators emit noise.

Ensure appropriate ear protection is worn at all
times. Maximum A-weighted emissions levels may
reach 104 db.
1.4 Maintenance Hazards
Service and maintenance procedures must be carried

out by experienced, qualified engineers, familiar with
the procedures and the equipment. Before any intrusive
procedures are carried out, ensure that the engine is inhibited
and the generator is electrically isolated.
All electrical equipment can be dangerous if not

operated correctly. Always service and maintain the
generator in accordance with this manual. Always use
genuine replacement parts.
^ WARNING
Hot engine and exhaust system can cause severe
injury.

Do not touch hot engine parts.

Do not perform service or maintenance on
generator until cool to the touch.
^ WARNING
Risk of severed digits or limbs.

Generator can be started from a remote switch.

Disconnect the negative (-) battery cable from
generator battery before performing service or
^ WARNING
Electrical shock can cause injury or death.

maintaining or working near this equipment are
fully aware of the emergency procedures in case
of accidents.
^ WARNING
Do not handle Permanent Magnet Generators
(PMGs) if you have mechanically implanted
devices; ie pacemakers.
^ WARNING
Service and fault finding procedures present
hazards which can result in injury or death.
Only personnel qualified to perform electrical
and mechanical service should carry out these
procedures. Ensure engine starting circuits
are disabled before commencing service or
maintenance procedures. Isolate any anticondensation heater supply.

7
2. Identification
2.1 Generator Identification View
4
3
2
1
Open Skid Model HYW 45 T6

1 - Alternator
2 - Control Box
3 - Engine Turbocharger
8
4 - Radiator
5 - Fuel Fill
2. Identification
2.2 Data Plate The genset data plate contains the following information:
Manufacturer
Model
Serial Number
Frequency
R.P.M.
Rated Power (KW)
Rated Voltage (V)
Phase
Rated Current
Rated Power Factor
Insulation Class
Dimensions
Weight
9
3. Installation
3.1 General Information
^ WARNING
Crushing hazard.

Generator set is heavy.

Use properly rated lifting devices to lift generator
set.

Lift only by the generator devices designed
for lifting.

Never enter the area under a raised generator.
Use an adequate lifting device to unload and set the
generator in place. Lift only by the lifting devices on the
generator designed for lifting.
The generator set must be placed on level site designed to
carry the weight of the generator set.
Electrical wiring to and from the generator set must be
performed by a qualified electrician and conform to all
national and local code requirements.
Fuel supply to the generator set must be installed by a
qualified technician. If a remote fuel tank is used, tank must
be properly located and correct size fuel lines are installed.
Contact the generator engine manufacturer for proper fuel
tank location and fuel line size specifications.
3.2 Control Of Material
When the genset is delivered, check that the received material

matches the order, and to compare it with the delivery note
that is enclosed with the set. Also, check that the material is
not damaged. Proceed to open the packaging.
If any damage detected, contact the shipping company
immediately in order to report the incident to the insurance
company.
Himoinsa specifies that all deliveries are made at the
customers complete risk.
Operations prior to the installation of the automatic
genset.
During the operations prior to the installation of the
automatically-driven gensets, or when connecting the
electrical connections, or in order to avoid unfortunate
startups, etc. the battery/batteries must be disconnected and
the control panel switch must be set to the OFF position.
Safety rules for diesel gensets

The engine room and installation of the set (foundations, air
intake, gas exhaust) must match the Safety rules that exist
in the country where the genset will be installed.
Installation
For stationary gensets, two types of installation can be
considered:
Outdoor assembly
Indoor assembly
3.3 Outdoor Installations
The generator set can be temporarily placed on a firm level

surface. If possible, avoid direct exposure to the sun, rain
and dirty conditions. It is recommended that the area around
generator set be fenced to prevent unauthorized access.
For long-term installations, a concrete foundation designed
by an engineer for the generator set is required. Foundation
must be constructed to prevent generator set noise and
vibration from surround areas and buildings.
Airflow is critical for the proper operation of the generator.
Outdoor installation must allow adequate clearance to
maintain the proper ventilation for generator cooling.
Minimum clearance around generator set is 5 ft (1.5m).
^ WARNING

Engine exhaust pipe(s) must be installed to
carry exhaust gases to an area where they pose
no danger.

Engine exhaust pipe(s) must be installed to carry exhaust
gases to an area where they pose no danger.
3.4 Indoor Installations
For the correct installation of a genset in closed premises,

the size of the room must allow:
The regular operation of the genset.
An easy access to its components for maintenance and
possible repairs.
The possibility of installing the genset using the available
means of transport. The door through which the genset
will be installed must be centered, so that the set remains
centered once it is inside, and there is no need of moving
it.
The existence of holes that allow oil replacement.
The installation of the exhaust pipe with the minimum
possible number of pipe elbows.
The genset to be placed in the middle of the premises,
10
3. Installation
with respect to perimeter walls, in order
to facilitate access.
The layout of the command panel (in case it is an automatic
set) to be in a position that allows the operator to have
complete visibility over the instruments when operating it.
Open Skid Set
The recommended room dimensions are displayed in the

following pictures:
Sound Attenuated Generator
1. Generating set.
2. Control panel.
3. Air intake gap.
4. Air outlet tunnel.
5. Cable wireway.
6. Access door.
7. Reinforced concrete base.
8. Exhaust pipe.
9. Flexible pipe.
10. Exhaust silencer.
* May vary depending on the function of the outlet section of
the model (see plans of the specific model to be installed).
1. Generator set.
2. Control panel.
3. Air intake gap.
4. Air outlet tunnel.
5. Tray for cable-running.
6. Access door.
7. Concrete base.
8. Exhaust pipe.
9. Flexible sleeve.
10. Exhaust silencer.
* May vary depending on the function of the outlet section of
the model (see plans of the specific model to be installed).
The basic elements to be considered are:
Foundations
Exhaust installations
Ventilation
Fuel installation.
Electrical connections
Grounding.
Heating
3.4.1 Foundation
The foundation must be designed by an engineer experienced

in generator foundation design. The foundation must support
the weight of the generator set and all fluids, and prevent
the transmission of vibration and noise to other parts of the
11
building.
The surface on which the set will be placed must be levelled
in order to allow its correct operation.
to perform a thermal insulation of the pipes, in order to

prevent heat expansion to the walls. (3)
For cleaning reasons, it is recommended that the foundations

are approximately 10cm above the floor level, and covered
with gres industrial sandstone tiles.
3.4.2 Exhaust Installation
^ DANGER
Exhaust pipe(s) must be routed to an outdoor area where

exhaust gases pose no danger.
The joints between the different pipes must be perfectly

sealed so that there are no gas leaks. The connection
between flange and gasket is the most critical one. It is also
recommended to place a condensation collector, with drain
valve, on the bottoms point of the pipes.
The connection between the engines collector outlet (or the
turbocharger) and the pipe must be made by means of a
flexible tube, so that the engine movement and the thermal
expansions of the pipe are absorbed by the engine without
damaging any elements.
Dx0.35
60
Exhaust pipe that passes through walls, must prevent the

transmission of heat to the walls. Exhaust pipe connections
must be sealed tight to prevent exhaust gas leaks and must
end with a protection cap to protect them from water entry, or
with a similar system (1) and (2).
D
D+4mm.
Dx1.5

Generator exhaust gases must be routed to an
outdoor area where they pose no danger.

Exhaust installation must be performed by
a qualified technician, experienced in indoor
generator installation.

D
DX2
YES
NO
NO
NO
1
45
=D
x2
,5
2
In the part where they run through the walls, it is recommended
The use of flexible pipe also requires the placement of

flanges in the exhaust pipe, independent of the genset.
Therefore, the pipelines must be fixed to the walls or ceiling
of the engine room, with supports that can bear the weight
of the pipe to the engine outlet, so that it does not rest on
the parts of the engine (collector, turbocharger), and allow
its expansion.
When dealing with very long pipes, it is necessary to insert
expansion joints made of sealed flexible pipes.
12
50
65
80
100
125
150
200
250
300
0.5
0.7
0.9
1.2
1.7
2.2
2.8
4.0
5.4
6.7
Pipe Length
r=
2,
A. Exhaust pipes measurement for Standard Static Gensets
1xI 0
5xI 0
Such limits can be observed considering the dimensions that

are suitable for the exhaust installation, that is, the diameter
of the pipe and type of silencer.
The pipes must be as short as possible, and with as few pipe
elbows as possible. Whenever pipe elbows are necessary,
they must be used with a very wide angle of curvature (from
2.5 to 3 times the diameter of the pipe).
Pipes with bends of angles lower than 2.5 times the diameter
pose difficulties so they must be avoided.
In order to calculate the total length of the pipe (which is
crucial for the exhausts backpressure), the following
considerations must be taken into account:
The rectified length of the pipe elbows must be determined
according to the chart and pictures:
2,
5x
4xI 0
The engines exhaust backpressure has a remarkable

influence on the produced power and on the thermal
charge.
The limits that must not be exceeded (referred to the delivery

conditions of maximum power at full throttle) in HIMOINSA
genets must be consulted with the factory.
r=
5x
Whenever there are several gensets, it is advisable that

all exhausts do not converge on a common pipe, as there
can be problems when some gensets are in operation and
others are not. The produced exhaust gases can penetrate
in the conduits of the sets that are not in operation and may
cause damage.
Excessive backpressure values (measured at the exhaust

collector outlet for non-turbocharged engines, and at the
turbine outlet on turbocharged engines) cause reductions in
power, rise in temperature of exhaust gases, fumes, high fuel
consumption, cooling water overheat, lubricant degradation,
and the ensuing consequences on the engine parts.
Pipe I.D. (mm) 40
When establishing the trajectory of the exhaust pipe, it is

necessary that the pipe is not near the engine air filters,
in order to prevent the machine from drawing in hot air.
Otherwise, it will be necessary to insulate it.
d 10xI 0
The backpressure values due to the exhaust silencers may

vary within a wide range, depending on the type of building,
dimensions and noise abatement characteristics:
- If it is the one supplied by HIMOINSA, the length must be
multiplied by a coefficient of safety, so that the total length to
be considered due to backpressure will be: L=2 X l.
- If it has been provided by another supplier, it is recommended
to check the value of backpressure derived from the silencer
with the supplier.
Example: The exhaust pipe consists of the following parts:
- 5 metres of straight pipe stretches.
- Two pipe elbows type a)
- Three pipe elbows type c)
- A 1m long silencer.
If the inner diameter of the engine exhaust is 80mm, the total
length of the exhaust pipe is calculated as follows:
a) for the inner diameter 80mm, according to the chart,

l=1.2m.
b) total length of the pipe elbows type (a) is, 1X
l=1X1.2=1.2m. as there are two pipe elbows, 2 x 1.2=2.4m.
c) the total length of the pipe elbows type c) is 5 X l=5 x 1.2=
6m. as there are three pipe elbows, 3 x 6 = 18m.
d) the total length of the exhaust silencer is L=2X l = 2X1 =
2m.
e) the total length of the exhaust pipe is: 5+2.4+18+2=
27.4metres
13
In order to calculate the diameter of the exhaust pipe it is

possible to use the normogram below:
Dimetro tubo en mm
100
130
160
c) Continue upwards until crossing the straight line relative

to the flow of the exhaust gases, which according to the
chart is 1120 kg/h. To convert kg/h into m3/h divide the flow
expressed in kg/h by the density of the exhaust gases. As a
first approximation we can take the density of the exhaust
gases with a value of 0.42 kg/ m3 1120x0.42=2667 m 3/h.
200
300
400
500
600
700
800
Contrapresin en la tubera en mm H2O

(sin silenciador)
Aislado
3600
3200
2800
2400
2000
1600
1200
800
Caudal de gases de escape m3/h
No Aislado
400
Nmeros de codos a 90 - r=2,5xd
15
10
5
0
15
10
5
200
150
60
70
80
90
100
50
40
30
25
20
15
d) Continue horizontally to the left. After crossing the straight

line, continue upwards until crossing the straight line relative
to the overpressure of the pipe, 400 mmH2O.
e) Continue upwards until crossing the straight line.
f) Continue to the right until the straight line relative to the
insulated pipe. After crossing this last straight line, the
pipe diameter, 122 mm, is determined on the right top
part. The commercial diameter right above is the one to be
considered.
The exhaust pipe cannot have a lower diameter than the
collector pipe of the engine exhaust, and also, the straight
stretches must have a slight inclination in order to prevent
the return of condensates, as shown on the location plan of
the genset in the room.
Nmeros de codos a 90 - r=2,5xd
5
6
7
8
9
10
(straight stretches + rectified elbow length), until crossing

the straight line relative to the total number of pipe elbows in
the installation (5 elbows).
b) Continue and follow a horizontal direction to the right until
crossing again the straight line relative to the number of pipe
elbows (5 elbows).
Longitud de la tubera en m
For calculation purposes, in this normogram we will use the

following backpressure values:
- 800 mm H2O, for aspirated engines.
- 400 mm H2O, for supercharged engines.
Exhaust gases airflow in kg/h. In order to convert into m3/h,
the data must be divided by the exhaust gases density.
Request these data to the manufacturer.
Example: If we take the exhaust pipe from the previous
example, with a total length of 27.4 metres (taking into
account the rectified length of the pipe elbows and the length
equivalent to the exhaust silencer). From the following data
of the installation:
- 5 pipe elbows at 90 (2x type A and 3x type C).
- Set model: HIW-210
- Working rate: 50 Hz
- Motor: 8361 SRi 26 (supercharged).
- Insulated pipe.
a) Start from the lower part, with a total pipe length of 27.4m
When the diameter of the pipe is higher, the engine joint

must have a conic connection element with a conicity below
30 in order to avoid excessive load losses.
B. Exhaust pipes measuring for Sound Attenuated Static
Gensets.
Check with the HIMOINSA engineering department. There is
backpressure in the outlet of the genset which is caused by
the internal pipes. It is necessary to know this value so as not
to exceed the recommended backpressure when designing
the rest of the installation.
Exhaust silencer
The exhaust silencer is usually attached to the stretch of pipe
that remains inside the room where the genset is located.
Whenever possible, it can be separated from the genset.
The silencer used in industrial applications performs a 15 to
20 decibels noise reduction.
In order to reduce the noise, the position of the silencer can
be altered, by reducing the length of the tube that goes into
the engine. For example, for a 10m long pipe, the optimal
position would be half-way through the distance in relation
to the outlet. In the cases of private installations, such as
hospitals or residential areas, where a higher noise reduction
14
is required, special silencers can be used, with a reduction

of 25 to 30 decibels, and whenever possible, using special
quiet chambers.
3.4.3 Ventilation
Adequate ventilation is essential for proper operation and

durability of the generator set.
The generator set room must:
1. Allow the dissipation of the heat produced when the genset
is in operation by irradiation and convection.
2. Provide sufficient air flow for combustion and engine
cooling.
3. Allow the engine cooling by means of the radiator, keeping
the operating room temperature within the safety limits in
order to guarantee a good aspiration of the supply air.
A good ventilation solution applicable to most cases is the
one indicated in the charts of the sections of the installation,
in which the engine fan draws in the cooling air from the
engine room, whereas the hot air is expelled through the
expulsion tunnel placed between the radiator and the room
window.
The expulsion window must be bigger or same size as the
radiator in case of standard static gensets, and bigger or
same as the expulsion grid in case of sound attenuated
sets.
Prevent the radiator exhaust hot air from coming back to the
engine room, making sure the expulsion conducts are leakproof. Therefore, the air in the engine room is constantly
renovated, and the dimensions of intake grilles must be big
enough for the cooling and combustion.
In order to achieve a correct air flow, the cool air must be
introduced through the grilles that are located on the lower
part of the engine room wall. This wall should be the one
located opposite the radiator, so that the air flows all over the
set before being expelled through the fan.
Make sure there are no areas in the engine room where the
air is deposited. This usually happens in rooms with several
engines. In those cases, and whenever possible, each group
should have its own air intake grille.
In case you need more details about the air flow required for
the different types of HIMOINSA gensets, please contact to
the manufacturer.
For safety reasons, in those premises where there are
sets in continuous operation, or in those areas where the
room temperature is high, it is advisable to use an auxiliary
extractor fan that has enough power to achieve a suitable
ventilation. Such extractor fan must be located on top of the
room, as close to the radiator as possible.
3.4.4 Remote Fuel Tank
The generator set is supplied with an integrated fuel tank.

In some situations, a remote fuel tank may be required. The
remote fuel tank must be properly connected to the engine
so the fuel transfer pump can draw fuel properly.
The remote tank must be located no more than 65.5 ft (20
m) from the engine and no more than 16.5 ft (5 m) below the
engine.
Generator sets supplied by HIMOINSA include a complete
fuel installation, since the fuel tank is located on the bedplate
of the genset.
The fuel tank is connected through flexible tubes in order
to guarantee their operating durability, depending on the
model.
For longer run times, and in order to satisfy special demands,
it may necessary to use a special tank that is fitted separately.
It will be necessary to connect the engine to the new tank,
and install flexible connections and new suitable pipes that
must be firmly connected. The new fuel tank must be located
according to the following criteria, so that the engine injection
pump is able to draw in fuel from the new tank:
Closer than 20m from the engine, in case they are both at
the same level.
Less than 5m deep.
The usual connections are:
For fuel injections to the engine injection pump.
For fuel excess returns from the injection pump.
For drain return of the injectors.
The pipes must not have any welds. They can be made
of steel, iron or cast iron. Galvanized steel pipelines must
not be used. Flexible connections must be fitted in order to
isolate the static parts of the plant from the new fuel tank, in
order to avoid the possible vibrations caused by the engine.
Depending on the type of engine, these can be made using
the following:
Stretches with a suitable length made of reinforced rubber
pipes with flexible insertions that are resistant to gas oil. For
the connections with the terminal rubber holders with edges
and screw clamps.
Flexible low-pressure type tubes, suitable for gas oil,
protected with metal mesh and with screwed terminals for
tightly-sealing. Synthetic resins must be avoided.
In complementary areas of the plant, maximum attention
15
must be paid to the following issues:

- Fix pipes by means of holders, at regular intervals in a
way that vibrations and inflexions caused by pipes weight
are avoided, especially those made of copper tube.
- Couplings must be avoided. In case of using them they
must be tightly-sealed, especially in depression conditions
parts (fuel aspiration intake), in order to avoid air filtrations
that make the startup more difficult.
- Aspiration pipes below the fuel level must be placed at
a distance of 20-30mm from the bottom, in order to avoid
a possible deactivation of the circuit due to insufficient air.
Also, these must be conveniently separated from each other,
in a way that the fuel return flow does not block the supply
due to the gas oil impurities from the bottom of the tank or
mixed air.
- Thorough cleaning of the used pipes.
- Avoid abrupt variations in the tube section and the use of
elbows with a wide angles in pipes.
3.4.5 Heating
In cold climates, automatic starting generator sets may need

an engine room heater to keep the engine room above 50 F
(10 C) to ensure the generator starts when needed.
Electric heaters with thermostatic controls ranging from 500
to 1500W, depending on the genset, have also been supplied
with those sets. They maintain the water temperature within
acceptable values in case a sudden start or power input may
damage the engine.
3.4.6 Electrical Connections
^ WARNING
Electrical shock hazard.

Electrical connections must be performed by
a qualified electrician and conform to local
electrical codes.
electrical panel, on the rail terminals or at the bottom of the

magnetothermal switch, either inside the panel or in the
moldeada box (check the electrical diagrams included in
the manual of the panel). For sound attenuated sets, the
connection to the grounding terminals is easily accessible
and protected with a methacrylate sheet.
Automatic Genset
The cables that come from the genset, the external power
supply and user shall be connected to their respective
terminals, located in the command panel. The power cables
of the genset shall be connected directly to alternator
terminals of the genset.
The connection to auxiliary services between the set and
the command panel shall be made with a multiple cable and
using the multiple connectors plugs provided with the set.
Cable dimensions
The choice and dimensions of the cables is responsibility of
the person who carries out the installation.
Cable positioning
Power cables, for both manual and automatic sets, must be
placed in suitable channelling, tunnels or protective conductholder. Do not include 400V and 12V (or 24V) cables in the
same channelling.
Grounding
Metal parts of installations which are exposed to human
contact, and due to an insulation flaw or other reasons,
may get in contact with voltage, must be connected to landdispersion device.
The gensets and panels have been equipped with their
respective grounding terminals. The connection of these
to the land-dispersion must be made with bare copper
wires conductors with a minimum section of 16mm2, or
if not available, galvanized iron with a 50 mm2 section.
The resistance of such conductor, including the contact
resistance, must not exceed 0.15 Ohm.
Refer to the following electrical schematics for your generator

for the proper electrical connection. The generator frame
must be grounded.
The gensets are ready for user connections. When making
the connections, you must comply with the conditions
specified in the diagrams enclosed with the genset.
Manual Genset
The user cables must be connected to the line terminals
which, for standard static gensets, are located inside the
16
3. Installation
3.3.7 Three Phase Generator Sets
17
3. Installation
3.3.8 Single Phase Generator Sets
18
4. Prestart Checks
4.1 Prestart Checks
Before starting the generator set engine, perform the

following prestart checks:
Verify all guards and covers are in place and fasten tight.
Check entire machine for loose hardware. Tighten all loose
hardware.
Fill fuel tank with fuel.
Check engine coolant hoses for damage and loose clamps.
Check level of engine oil on dipstick (1). Oil must be between
the min and max levels on dipstick. Add the recommended
oil if necessary.
Check coolant level in radiator (2). Add coolant to proper
level if low.
Check the engine and alternator for any signs of damage,
water, oil or fuel leaks.
Verify intake and outlet air vents and grills are not obstructed
or blocked.
Verify that there are no obstructions in engine intake air filter
tube.
Check fuel filter/water separator (3) (if equipped) for water or
contaminants. Drain if necessary.
Verify battery cables are properly connected and tight.
Once engine is started, warm engine with a reduced load
before applying full load. This does not apply to emergency
power generators.
19
5. CEM7 Control Panel

5.1 Introduction
The CEM7 digital control panel is a monitoring system for

the genset electrical signal and also manages the genset
engine.
The control panel consists of 2 different modules:
5.1.1 Display Module (Control Panel)
The display module provides information about the status of

the device and, at the same time, allows the user to interact
with it. The user is able to control, program and configure the
functions of the unit. This module allows checking of the last
10 failures registered in the control unit (fault history).
5.1.2 Measurements Module
The measurements module controls and monitors the control

board. Every signal, sensor and actuator is connected to this
module.
NOTE: An optional programming timer module can be added
to the display module, which would allow it to carry out startup, locking, and programmed maintenance functions.
The control panel provides the following readings of the
electric mains supply:
Phase to neutral voltage.
Phase to phase voltage.
Phase amperage.
Frequency.
Real, apparent and reactive powers.
Power factor and cos phi.
Instant power (Kwh) and historical power (day, month,
year) of the genset (with option programming timer).
The control panel provides the following engine information:
Engine alarm inputs:

- Fuel reserve.

- Oil pressure.

- Coolant temperature.

- Coolant level.

- Emergency stop (stop button).
Analogic engine inputs:

- Fuel level.

- Pressure.

- Temperature.

- Configurable input (i.e. Oil temperature).

- Battery charger alternator voltage
Configurable inputs:
Default configuration applied in the factory:

- Start disabling.

- External start.
Consult configuration with your distributor or authorized
technical service:

- Mains contactor confirmation

- Genset contactor confirmation.
- Rate change notice.
- Rate change.
- Start disabling.
- External start.
- Test.
- Manual override.
- 5 programmable alarms.
- Self-programming (S1-S2)
Engine statistics:

- Number of working hours.

- Number of starts.
Functions of the engine:

- Pre-heating or glow plug.

- Stop.

- Start.

- Coolant heater.

- Fuel Transfer pump.

- Alternator excitation.
The measurements module has outputs which allow
monitoring of the operative conditions of the generating set:
Engine running (on).
General alarm.
3 programmable outputs which monitor the control board
alarm conditions or the inputs about the engine data.
The measurements module commands ouputs to relays
for the activation of the genset contactor and the electronic
overload and short-circuit protection that trip the gensets
general circuit breaker.
The connection between the measurements and visualization
modules is made by the CAN bus communication, which
allows the interconnection of additional modules, allowing
the expansion of the CEM7 device.
With the bus CAN, additional modules can be added. If
interested, please contact your distributor.
The measurements device has 5 inputs that can be

programmed to carry on the following functions:
20

5.2 Control Panel
The control panel has a backlit display and different LEDs to control the device status. Different push buttons allow the
user to command and program the control panel.
10
NOTE: The display turns off the backlighting (low consumption mode) after 10 minutes without any detectable pulse on the
keyboard.
1 - Backlit Display
2 - Start Button
3 - Stop Button
4 - Reset Button
5 - Diesel Transfer Button
6 - Auto Button
7 - Display Buttons
8 - Contactor Status LEDs
9 - Engine Status LEDs
10 - Engine Alarm LEDs

21

5.3 Control Panel Push Buttons
5.3.1 Operating Mode Buttons

Automatic mode.
The CEM7 device monitors the status of the generating set and controls its working process and the
programmable inputs.
LED On: Automatic mode running.
LED Flashing: Automatic mode blocked.
LED Off: Manual mode running.
5.3.2 Command Buttons

START

Start engine push button (manual mode only).

Control Starts with only one push down.
LED on: Engine running.

STOP

Stop engine push button (manual mode only).

Press once, a cooling phase begins and then the engine stops.
Press twice, the engine stops immediately.
LED on: The engine is in stopping phase (with or without cooling down).

RESET

Reset push button.

Allows the user to acknowledge and clear the alarm condition.
LED flashing: There are alarms to check up.
LED on: Active alarms.

DIESEL

TRANSF

Transfer fuel pump push buttons.

In manual mode, this button activates the transfer pump if the fuel level is under the programmed levels.
LED on: Fuel transfer pumps working.
5.3.3 Display Buttons

Confirmation button (V). Allows access to menu and validates and store the entered data.
Cancellation button (X). Go back in the menu and cancels the entered data.
Up button (+). Moves along the selection displays and maintenance menus, also
increases the programmed values.
Down button (-). Moves back in the selection display and maintenance menus, it also
reduces the programmed values.
22

5.4 Data LEDs
5.4.1 Contactor Status LEDs

M

G
Mains contactor status.

On: Contactor activated.
Flashing: Alarm, confirming the contactor is activated.
Off: Contactor deactivated.
Generating set contactor status.
5.4.2 Engine Status LEDs

M

M

Engine started
On: Engine running detected.
Off: Engine stopped.

+B

+D
G
W
-B

Pre-heating
On: Pre-heating function activated.
Off: Pre-heating function not activated.
Engine starting
On: Engine starting activated.
Off: Engine starting not activated.
Battery charger and alternator status

On: The voltage supplied by the battery charger alternator is detected when the engine is running.
Off: Engine stopped or started without voltage signals in the battery charger alternator.
5.4.3 Alarm LEDs

Fuel level

Battery levels

M
High temperature
Overspeed
Low oil pressure
Starting failure

Aux. 1
Aux1 (Free to program)

Aux. 2
Aux2 (Free to program)
On: Alarm caused by analogic sensors.

Flashing: Alarm caused by digital inputs.

Off: No alarms. NOTE: See alarms section for more details.
23

5.5 Starting And Stopping Genset
Perform pre-start checks. See Section 4 in this manual.
NOTICE
Avoid electrical system damage.

Turn genset main circuit breaker off before
starting generator engine.
5.5.1 Starting - Manual Mode

Push START button to activate the engine

starting process. The start button LED
START
will be illuminated. If the engine is
equipped with a starting aid, the appropriate
LED will be illuminated and there may be a delay before the
engine starts.
If the engine fails to start at the first crank, the control panel
will wait for 5 seconds before attempting another start cycle.
It is not necessary to press start button again. The generator
will attempt to start 4 times. If the engine is still not running,
the control panel will trigger the start failure alarm.
To stop the start cycle, press the stop button.
Readings about the engine condition are shown on the
display panel and the start sequence details can be seen.
The sequence is as follows:
Genset: Stop
Genset: Starting
Genset: Started
Genset: Stabilized
Genset: Loading
The starting process in an automatic system by means
of timer, ATS signal, etc. and works in the same way as a
starting cycle in manual mode.
5.5.2 Stopping - Manual Mode

NOTICE
Avoid electrical system damage.

Turn genset main circuit breaker off before
stopping generator engine.

STOP

The generator engine can be stopped

using one of two methods. Pressing the
stop button once will stop the engine
after a 20 second cool down cycle. This is
the recommended procedure. Pressing the stop button twice

will stop the engine immediately. This is not recommended.
Use this procedure only in an emergency situation.
Push the STOP button once to stop the engine after a 20
second cool down cycle.
Push the STOP button twice to stop the engine immediately,
without cooling down cycle.
5.5.3 Starting And Stopping - Automatic

Mode

In automatic mode, the control panel

constantly controls the Gen-set operation.

In some situations, the gen-set can be

programmed to supply power, the controller
starts the generator set activating the gen-set contactor.
Programmable operational modes to start the Gen-Set:
External start.
Start controlled by timer.
Forced start.
Rate change notice.
Engine test.
Controlled by the transfer switch control board
The gen-set will stop after a 20 second cooling down cycle
after the deactivation of the command which automatically
started the genset.
5.6 Interruption Of Function Mode

When the control panel is in manual mode,

the automatic mode can be initiated by

pressing the AUTO button for 5 seconds.

This blocking function does not allow the
change of modes and the button of the mode running at that
moment will flash. To deactivate the automatic interruption
mode and allow the change of operational modes, press the
AUTO button for 5 seconds.
5.7 Working Mode
The generator engine works in the following way, once the

control panel detects an activation condition:
1. Delay in the starting: Once an activation condition
is detected, and before going on with the engine
starting process, a delay in the engine starting can be
programmed.
2. Engine pre-heating phase: The control board activates
the pre-heating output for a programmed time.
3. Engine Start Enabling (run signal): The engine run
signal is made by means of the PC (B+) output from the
measurements module. The output allows a no-excitation
stop (energized to-run) or an excitation stop (energized
24

to-stop). This output is configurable.
4. Engine starting: For a programmed period of time, the
starting output of the measurements module is activated,
waiting to detect, at least, one of the programmed starting
conditions. The possible engine starting conditions could
be:
Generator voltage: The engine would be considered
started (running) when its voltage exceeds a given value.
Alternator voltage: The engine would be considered
started (running) when the battery charger alternator
voltage exceeds a given value.
Pick up frequency: The engine would be considered
started (running) when the pick up frequency exceeds a
given value. To activate the pick up calculation through the
engine ring gear, the number of teeth of the gear must be
introduced. In case the number of teeth is 0, the frequency
of the pick up will be calculated through the generator
frequency as per the equivalence-ratio 50Hz/1500 rpm or
50Hz/3000 rpm and 60 Hz/1800 rpm.
Low oil pressure: It is not advisable to use the low oil
pressure signal as a way to detect if the engine is working,
but it is useful as a protection, in order to avoid engaging
the starter while the engine is running.
If in the programmed time the starting of the engine is not
detected, the control board waits for a short time before
attempting a new start. The start failure alarm will be raised
after a specified number of attempts without detecting any
starting condition.
In the starting cycle, the excitation of the battery charger
alternator is activated temporarily through the D+ output. Once
the excitation of the alternator is finished, the measurements
module checks if the battery charge alternator is working
properly. The battery charge alternator failure alarm is raised
in case of an output failure.
Genset stabilization: Once any of the starting conditions
is detected, the controller waits for a programmed
stabilization-time of the generator output, before monitoring
output parameters.

DIESEL
TRANSF

Once the transfer pump option is activated,

its operation modes are as follows:
Inhibited mode: The transfer pump is blocked from

operation.
Manual mode: The transfer pump is operated by pressing
the diesel transfer button, provided that the fuel level is under
the maximum threshold parameters.
Automatic mode: The transfer pump becomes operative:
According to the minimum activation parameters, under
which the relay BT is activated.
According to the maximum deactivation parameters, over
which the relay BT is deactivated.
Control board mode: The transfer pump operation is carried
out as follows:
When the controller is in automatic or test-mode, the
transfer pump is operated automatically.
When the controller is manual-mode, the transfer pump
operation is carried out in manual mode.
When the controller is in a blocked-mode, the transfer
pump operation is inhibited (CEM7+CEC7).
5.9 Alarms
The CEM7 distinguishes between anomalies which cause

the stop of the engine (alarms) and errors, which do not stop
the engine (warnings).
When an alarm or warning is detected, the controller produces
an acoustic alarm, at the same time the digital alarm output
(AL) activates and the LED of the reset button flashes; this
status will remain the same as long as the failure condition
continues for a programmable period of time.
The LED of the reset button lights when alarms or warnings
are active or in need of acknowledgement. Pressing reset
button once allows the user to see a record of alarms and
warnings that are active and needing to be acknowledged.
The up and down buttons of the display are used to go back
and forward in the failure record. A second press of reset
silences the alarm.
Nominal condition: Once the stabilization of the engine

is reached, the next step is the checking of the signal
produced by the generator. In this way, the quality of the
signal produced by the generator set is monitored (voltage
levels, frequency).

RESET

The record of warnings that are active or in

need of acknowledgement has the
following format:
*A L A R M*
EN 1/3
5.8 Transfer Fuel Pump
MIN FREQUENCY GENSET
The fuel transfer pump function can be activated in the

control panel by linking its working service to the BT relay in
the measurements module.
E: Alarm or A: Warning
N: To be checked
25

1: Number of position in the total record of errors
3: Number of errors in the record
display (which stops flashing) shows the kind of warning.

Warning A.
The LEDs on the control panel indicate alarms detected by

the sensors.
This kind of warning is automatically reset as long as nominal

working conditions are restored. It is focused on the type of
alarms related to fuel level and the alarms related with the
mains threshold.
The alarms which cause the engine to stop are not autoresetting. They must be acknowledged and re-set by the
user in order for the engine to start again, but only if the
alarm does not remain active.
The warning alarms do not stop the engine. They need to be
reset to erase them from the display, but only if the warning
does not remain active. The fuel level alarm is an exception,
as it is automatically reset.
5.9.1 Reseting Alarms
EN - Alarm with engine stop.

AN - Warning that needs to be reset, engine does not stop.
A - Warning that automatically resets.
EN Alarm with engine stop.
When an alarm is detected, the controller produces an
acoustic signal, the LED of the RESET button flashes, the
display blinks and the appropriate digital alarm output (AL)
is activated. In this case the engine stops.
The acoustic alarm is silenced by pressing the reset button
once. The reset LED turns into fixed light and the display
(which stops flashing) shows the kind of alarm.
Determine the cause of the alarm. Once the alarm is no
longer active N, press reset button and the engine can be
restarted.
AN Warning.
acoustic signal, the LED of the reset button flashes, the
is activated.
The acoustic alarm is silenced by pressing once the RESET
button. Once the RESET LED turns into fixed light and
the display (which stops flashing) shows the kind of Active
warning AN.
Determine the cause of the alarm. Once the alarm is no
longer active N, press reset button to reset alarm.
A Warning.
acoustic signal, the LED of the reset button flashes, the
is activated.
The acoustic alarm is silenced by pressing the RESET
button once. The RESET LED turns into fixed light and the
26

5.10 Engine Alarms
LED ON CONTROL
PANEL
TYPE
High water temperature (ATA) (HCT)

Immediate engine stop with no cooling.
LED flashes
Alarm
Low oil pressure (BPA) (LOP)

LED flashes
Alarm
DESCRIPTION
Emergency stop (PEM) (EMS)

Battery charge alternator failure (engine running)
Engine does not stop.
Start failure
Alarm
+D
-B
+B
W
LED off
Warning
LED flashes
Low coolant level (CL)

LED flashes
Alarm
Fuel level
LED flashes
Warning
LED on
Alarm
Overspeed
Loss of speed
Engine stops with cooling.
Alarm
Low battery voltage

Warning
High water temperature by sensor

LED on
Warning
Low oil pressure by sensor

LED on
Warning
Low fuel level by sensor

LED on
Warning
Unexpected shutdown
Stop failure
Low engine temperature
Genset voltage drops
Engine stops with cooling.
27
Warning
Alarm

5.11 Genset Alarms
DESCRIPTION
TYPE
Overload.
Engine stop with cooling.
Alarm
Genset voltage asymmetry.

Engine stop with cooling.
Alarm
Maximum voltage of the genset.

Alarm
Maximum genset frequency.

Alarm
Erroneous phase sequence of the genset.

Alarm
Inverse power
Alarm
Short circuit.
Alarm
Minimum genset voltage.

Alarm
Minimum genset frequency.

Alarm
5.12 Programmable Alarms And Inputs

DESCRIPTION
Related with programmable inputs.

According to configuration.
28
TYPE
Alarm
29
6. M6 Control Panel
6.1 Control Panel - M6
1
17
16
15
14
13
12
11
10
30
6. M6 Control Panel
1. On/Off Switch: Used to connect and disconnect the
controller.
14. Pre-Heating Indicator (yellow). The LED starts blinking in

1 second intervals during the engine pre-heating cycle.
2. Mode Selection Key: (MAN/STOP/AUTO). In MAN

position, the control panel will initiate a start engine
sequence (1 attempt to start ). In STOP position, the
controller will stop the genset. In AUT position, controller
will remain in automatic mode and will do as follows: if free
voltage contact closes, the controller will start the genset.
If the contact opens, the genset will stop.
15. Auxiliary Alarm Indicator (yellow). Indicates that the

alarm condition established in the auxiliary input of
the controller has been detected. The LED will remain
illuminated while the alarm condition is active.
3. Emergency Stop: Press to stop engine immediately. The

LED will be illuminated until the emergency stop button
has been reset.
4. Overspeed Indicator (Red). The LED will illuminate if
one of the following conditions occur: During the over
speed programming, to indicate that the programming
was successful, and also when the internal overspeed
protection device trips. When the overspeed protection
device trips, the controller initiates a stop cycle and the
warning indicator will be illuminated until reset.
5. Low Oil Pressure Indicator (red). Indicates that the
engine oil pressure switch has detected an anomaly. This
protection activates an engine stop cycle. The LED will
remain illuminated until the alarm condition is reset.
6. High Water Temperature Indicator (red). Indicates that
the engine coolant temperature sensor has detected an
anomaly. This signal activates an engine stop cycle. The
LED will remain illuminated until the alarm condition is
reset.
16. Battery Charger Failure Indicator (D+) (yellow). Indicates

that the generator battery charger is not charging the
battery. The LED will remain illuminated while the alarm
condition is active.
17. Fuel Reserve Indicator (yellow). Indicates low fuel level
in the tank. The LED will remain illuminated while the
alarm condition is active.
6.2 Starting And Stopping Genset - M6

Control Panel
6.2.1 Starting - Manual Mode
Move on/off switch to the on position (1). The controller will run
an internal diagnosis and lamp checking program, lighting all
LEDs on the control panel. The controller remains on hold,
as long as the mode operation key is in the stop position.
Move mode section key (2) to the man position. The controller
initiates an immediate start of the engine. After a programmed
warm up cycle, the genset contactors automatically close.
1
7. Engine Failure Indicator (red). Indicates that the engine

has stopped without a stop signal from the controller.
8. Fail To Start Indicator (red). Indicates that the controller
completed 5 attempts to start the engine, but the engine
did not start.
9. Power Supply On Indicator (green). Indicates that the

controller is on when illuminated.
10. Reset Button. Push to restart the operation cycle of the
controller.
11. Engine Running Indicator (green). Indicates that the
engine is running when illuminated.
12. Activated LT Contactor (green). This LED is illuminated
when the free-voltage contact is closed. The LED goes
out when the contact is opened.
13. Cooling Stop Indicator (yellow). This led starts blinking
in 1 second intervals when the controller initiates a stop
engine cycle. The LED will stop blinking when the engine
has stopped.
31
6. M6 Control Panel
6.2.2 Stopping - Manual Mode
Move mode selection key (2) to the stop position. The

controller initiates the stop of the genset and holds for a
mode change. Move on/off switch to the off position (1)
NOTE: If the controller disconnects, resets, or fails power

supply, once it is restored, if set to manual or automatic mode
with the free-voltage contact closed, the genset will start.
Note: Under no circumstances can the generator be stopped

by switching the controller off or by pushing the reset button.
The only way to stop the engine is by turning the key to the
stop position.
6.2.3 Starting And Stopping - Automatic

Mode
Move on/off switch to the on position (1). The controller will run
an internal diagnosis and lamp checking program, lighting all
LEDs on the control panel. The controller remains on hold,
as long as the mode operation key is in the stop position.
Move mode section key (2) to the auto position. In this mode,
the engine start is co-ordinated with the closing of the freevoltage contact. When this contact is closed, the controller
initiates up to 5 attempts to start in sequence as long as there
is no engine running detection. Every attempt is 5 seconds
long and the time in between attempts is 10 seconds.
1
When the free-voltage contacts opens, the controller initiates

to stop, and holds before the contact closes again or waiting
for a change of operation mode.
32
6. M6 Control Panel
6.3 Engine Alarms
DESCRIPTION
High water temperature
Engine stops.
Low oil pressure
Engine stops
LED ON CONTROL
PANEL
TYPE
LED flashes
Alarm
LED on
Alarm
Emergency stop
Engine stops.
Battery charge alternator failure (engine running)
Alarm
LED on
Warning
Start failure
LED flashes
Fuel level
LED flashes
Warning
LED on
Alarm
Overspeed
Unexpected shutdown
LED flashes
High coolant temperature

Engine stops.
LED flashes
33
Warning
7.
7.1 Description Of Controls
DSE3000 Series Control Panel
7.1.2 Stopping The Engine
1. Select Stop/Reset mode (1). The generator is stopped.
The following section details the function and meaning of the

various controls on the module.
7.3 Graphical Display

1 - Navigation Buttons
3 - Common Alarm Indicator
5 - Select Auto Mode
2 - Main Status Display

4 - Start engine.
6 - Select Stop Mode
7.2 Quickstart Guide
This section provides a quick start guide to the modules

operation.
7.1.1 Starting The Engine

1. First press Stop/Reset (1).
2. Then, press the Start button to crank the engine. Depending

upon module configuration, two presses may be required.
A 32x132 pixel LCD (35mm / 1.4) is available for the display

of generator instrumentation and alarm conditions. The
display is segmented into areas for instrumentation, unit,
alarm icons and for Front Panel Editor (FPE) use.
When not in the Front Panel Editor (FPE) mode the FPE
area of the display is used to display the currently active
configuration. The letter M is displayed for main configuration
active, the letter A for alternative configuration active.
VIEWING THE INSTRUMENTS
It is possible to scroll to display the different pages of
information by repeatedly operating the scroll button.
Once selected the page will remain on the LCD display until
the user selects a different page or after an extended period
of inactivity, the module will revert to the status display.
When scrolling manually, the display will automatically return
to the Status page if no buttons are pressed for the duration
of the configurable LCD Page Timer.
If an alarm becomes active while viewing the status page,
the display shows the Alarms page to draw the operators
attention to the alarm condition.
Page order:
Engine Speed
Generator Volts
Generator Frequency
Engine Run Time
Battery Volts
34
7.
7.4 Controls
Stop / Reset
This button places the module into its Stop/Reset mode.
This will clear any alarm conditions for which the triggering
criteria have been removed. If the engine is running and
the module is in Stop mode, the module will automatically
instruct the changeover device to unload the generator
(Close Generator becomes inactive (if used)). The fuel
supply de-energizes and the engine comes to a standstill.
Should a remote start signal be present while operating in
this mode, a remote start will not occur.
Auto
This button places the module into its
Automatic mode. This mode allows the
module to control the function of the generator
automatically. The module will monitor the
remote start input and once a start request
is made, the set will be automatically started
and laced on load. Upon removal of the starting signal,
the module will automatically transfer the load from the
generator and shut the set down observing the stop delay
timer and cooling timer as necessary. The module will then
await the next start event.
Start
Pressing this button in auto mode will start the
engine and run off load. Pressing this button
in STOP/RESET mode will turn on the CAN
engine ECU (when correctly configured and
fitted to a compatible engine ECU)
Page
Pressing this button scrolls the display to show
the various instruments.
7.5 Automatic Mode Of Operation

NOTE:- If a digital input configured to panel lock is active,
changing module modes will not be possible. Viewing the
instruments and event logs is NOT affected by panel lock.
Activate auto mode by pressing the AUTO
pushbutton. The line/arrow icon around AUTO
is displayed to indicate Auto Mode operation if
no alarms are present.
Auto mode will allow the generator to operate fully
automatically, starting and stopping as required with no user
intervention.
7.5.1 Waiting In Auto Mode
If a starting request is made, the starting sequence will begin.

Starting requests can be from the following sources:
Activation of an auxiliary input that has been configured to
remote start.
7.5.2 Starting Sequence
To allow for false start requests, the start delay timer

begins.
Should all start requests be removed during the start delay
timer, the unit will return to a stand-by state.
If a start request is still present at the end of the start delay
timer, the fuel relay is energized and the engine will be
cranked.
NOTE: If the unit has been configured for CAN, compatible
ECUs will receive the start command via CAN.
If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the crank rest duration
after which the next start attempt is made. Should this
sequence continue beyond the set number of attempts, the
start sequence will be terminated and the display shows Fail
to Start.
When the engine fires, the starter motor is disengaged.
Speed detection is factory configured to be derived from
the main alternator output frequency but can additionally be
measured from a Magnetic Pickup mounted on the flywheel
(Selected by PC using the 3000 series configuration
software).
Additionally, rising oil pressure can be used to disconnect the
starter motor (but cannot detect underspeed or overspeed).
NOTE: If the unit has been configured for CAN, speed
sensing is via CAN.
After the starter motor has disengaged, the Safety On timer
activates, allowing Oil Pressure, High Engine Temperature,
Under-speed, Charge Fail and any delayed Auxiliary fault
inputs to stabilize without triggering the fault.
ENGINE RUNNING
Once the engine is running and all starting timers have
expired, the animated icon is displayed.
DSE3110 - The generator will be placed on load if configured
to do so.
NOTE: The load transfer signal remains inactive until the
Oil Pressure has risen. This prevents excessive wear on
the engine. If all start requests are removed, the stopping
sequence will begin.
35
7.
7.5.3 Stopping Sequence
The return delay timer operates to ensure that the starting

request has been permanently removed and isnt just a short
term removal. Should another start request be made during
the cooling down period, the set will return on load.
If there are no starting requests at the end of the return delay
timer, the load is removed from the generator to the mains
supply and the cooling timer is initiated.
The cooling timer allows the set to run off load and cool
sufficiently before being stopped. This is particularly
important where turbo chargers are fitted to the engine.
After the cooling timer has expired, the set is stopped.
7.6 Manual Operation
NOTE:- If a digital input configured to panel lock is active,

changing module modes will not be possible. Viewing the
instruments and event logs is NOT affected by panel lock.
Manual mode allows the operator to start and stop the
set manually, and if required change the state of the load
switching devices. Module mode is active when the button
is pressed.
7.6.1 Waiting In Manual Mode
To begin the starting sequence, press the button. If protected

start is disabled, the start sequence begins immediately.
If Protected Start is enabled, the icon is displayed to indicate
Manual mode and the manual LED flashes. The button must
be pressed once more to begin the start sequence.
7.6.2 Starting Sequence
NOTE: There is no start delay in this mode of operation.

The fuel relay is energized and the engine is cranked.
NOTE: If the unit has been configured for CAN, compatible
ECUs will receive the start command via CAN.
If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the crank rest duration
after which the next start attempt is made. Should this
sequence continue beyond the set number of attempts, the
start sequence will be terminated and the display shows Fail
to Start.
When the engine fires, the starter motor is disengaged.
Speed detection is factory configured to be derived from
the main alternator output frequency but can additionally be
measured from a Magnetic Pickup mounted on the flywheel
(Selected by PC using the 3000 series configuration
software).
starter motor (but cannot detect underspeed or overspeed).

NOTE:- If the unit has been configured for CAN, speed
sensing is via CAN.
After the starter motor has disengaged, the Safety On timer
activates, allowing Oil Pressure, High Engine Temperature,
Under-speed, Charge Fail and any delayed Auxiliary fault
inputs to stabilise without triggering the fault.
ENGINE RUNNING
In manual mode, the load is not transferred to the generator
unless a loading request is made. A loading request can
come from a number of sources.
Activation of an auxiliary input that has been configured to
remote start on load
Activation of the exercise scheduler if configured for on
load runs.
NOTE: The load transfer signal remains inactive until the Oil
Pressure has risen. This prevents excessive wear on the
engine.
Once the load has been transferred to the generator, it will
not be automatically removed. To manually transfer the load
back to the mains either:
Press the auto mode button to return to automatic mode The
set will observe all auto mode start requests and stopping
timers before beginning the Auto mode stopping sequence.
Press the stop button
De-activation of an auxiliary input that has been configured
to remote start on load.
7.6.3 Stopping Sequence

In manual mode the set will continue to run until either:
The stop button is pressed The set will immediately
stop.
The auto button is pressed. The set will observe all auto
mode start requests and stopping timers before beginning
the Auto mode stopping sequence.
Protections
When an alarm is present, the Common alarm LED if
configured will illuminate.
The LCD display will show an icon to indicate the failure.
7.7 Warnings
Warnings are non-critical alarm conditions and do not affect

the operation of the generator system, they serve to draw
the operators attention to an undesirable condition.
Warning alarms are self-resetting when the fault condition is
removed. The icon will appear steady in the display.
Additionally, rising oil pressure can be used disconnect the

36
7.
7.8 Shutdowns
Shutdowns are critical alarm conditions that stop the
engine and draw the operators attention to an undesirable
condition.
Shutdown alarms are latching. The fault must be removed
and the button pressed to reset the module. The icon will
appear flashing in the display.
7.9 Module Display

7.9.1 Timer Icon
When the module is controlling the engine (starting and

stopping) an animated timer icon will be displayed in the icon
area to indicate that a timer is active, for example cranking
time, crank rest etc.
7.9.2 Stopped Icon
When there are no alarms present,

an icon will be displayed to indicate
the engine is stopped and what
mode the unit is in.
Stop Auto Manual

mode mode mode
The hand is only displayed when the arming options is

enabled, otherwise the engine starts when entering the
manual mode.
7.9.3 Running Icon
When there are no alarms present, an animated icon is

displayed to indicate the engine is running.
7.9.4 USB Icon
When a USB connection is made to the module the USB

icon is displayed.
7.9.5 Memory Corruption
If either the config file or engine file becomes corrupted the

unit will display the icon.
7.9.6 Backlight
The backlight will be on if the unit has sufficient voltage on

the power connection while the unit is turned on, unless the
unit is cranking for which the backlight will be turned off.
37
7. DSE3000 Series Control Panel

7.10 Fault Icons
ICON
DESCRIPTION
AUXILIARY INPUTS
FAIL TO START
FAIL TO STOP
Auxiliary inputs can be user configured and will display the message as written by
the user.
The engine has not fired after the preset number of start attempts
The module has detected a condition that indicates that the engine is running when
it has been instructed to stop.
NOTE:- Fail to Stop could indicate a faulty oil pressure sensor - If
engine is at rest check oil sensor wiring and configuration.
UNDERSPEED
The module detects that the engine oil pressure has fallen below the low oil
pressure pre-alarm setting level after the Safety On timer has expired.
The module detects that the engine coolant temperature has exceeded the high
engine temperature pre-alarm setting level after the Safety On timer has expired.
The engine speed has fallen below the underspeed pre alarm setting
OVERSPEED
The engine speed has risen above the overspeed pre alarm setting
CHARGE FAILURE
The auxiliary charge alternator voltage is low as measured from the W/L terminal.
LOW FUEL LEVEL
The level detected by the fuel level sensor is below the low fuel level setting.
BATTERY UNDER
VOLTAGE / BATTERY
OVER VOLTAGE
The DC supply has fallen below or risen above the low/high volts setting level.
GENERATOR UNDER
VOLTAGE
The generator output voltage has fallen below the pre-set pre-alarm setting after
the Safety On timer has expired.
The generator output voltage has risen above the pre-set pre-alarm setting.
LOW OIL PRESSURE

ENGINE HIGH
TEMPERATURE
GENERATOR OVER
VOLTAGE
GENERATOR UNDER
FREQUENCY
GENERATOR OVER
FREQUENCY
CAN ECU WARNING
CAN ECU SHUTDOWN
CAN DATA FAIL
EMERGENCY STOP
The generator output frequency has fallen below the pre-set pre-alarm setting after
the Safety On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm setting.
The engine ECU has detected an alarm CHECK ENGINE LIGHT
Contact Engine Manufacturer for support.
The module is configured for CAN operation and does not detect data on the
engine Can datalink.
The emergency stop button has been depressed. This a failsafe (normally closed
to battery positive) input and will immediately stop the set should the signal be
removed.
Removal of the battery positive supply from the emergency stop input will also
remove DC supply from the Fuel and Start outputs of the controller.
NOTE:- The Emergency Stop Positive signal must be present otherwise
the unit will shutdown.
MAGNETIC PICKUP
FAILURE
INTERNAL MEMORY
ERROR
Pulses are no longer being detected from the magnetic pickup probe (3110-xxx-01
magnetic pickup version only)
Either the configuration file or engine file memory is corrupted. Contact your
supplier for assistance.
38

8.1 Description Of Controls
The following section details the function and meaning of the various controls on the module.
Scroll Down
Stop
Next page
Manual
39
Configurable LEDs
Auto
Mute/Lamp
Test
Start
Close Generator
Output LED. On When
The Generator Is
Required To Be On
Load
Generator available
LED. On When The
Generator Is Available
For Loading.
NOTE:- Generator on load LED has two modes of operation depending upon the configuration of
the controllers digital inputs.
1) Digital input configured for Generator closed auxiliary The LED will be lit when the generator
closed auxiliary input is active The LED shows the state of the auxiliary contact.
2) There is NO input configured for Generator closed auxiliary (factory default setting) The LED will
be lit when the 5310 gives the loading signal to the generator The LED shows the state of the
5310s loading request.
Perform pre-start checks. See Section 4 in this manual.
40

8.2
Automatic Mode Of Operation

NOTE:- If a digital input configured to panel lock is active, changing module modes will not be
possible. Viewing the instruments

and
is NOT affected by panel lock. If panel lock is active the
Panel lock indicator (if configured) illuminates.
This mode is activated by pressing the

action.
pushbutton. An LED indicator beside the button confirms this
If the Remote Start input (if configured) is activated the relevant indicator (if configured) illuminates.
To allow for false remote start signals, the Start Delay timer is initiated. After this delay, if the pre-heat output option
is selected then the pre-heat timer is initiated, and the corresponding auxiliary output (if configured) will energise.
NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit will return to a
stand-by state.
After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then one second
later, the Starter Motor is engaged.
NOTE:- If the unit has been configured for CAN, compatible ECUs will receive the start command
via CAN.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then the starter
motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts,
the start sequence will be terminated and Fail to Start fault will be displayed.
Alarm
Shutdown
Failed to start
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator
output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is
selected by PC using the 5xxx series configuration software). Rising oil pressure can also be used to disconnect
the starter motor; however, it cannot be used for underspeed or overspeed detection.
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
41

After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the
fault.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before
accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this then activates.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing
excessive wear on the engine.
On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out, the load Transfer
signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the engine a cooling down
period off load before shutting down. Once the Cooling timer expires the Fuel Solenoid is de-energised, bringing
the generator to a stop.
Should the Remote Start signal be re-activated during the cooling down period, the set will return on load.
42

8.3
MANUAL OPERATION
NOTE:- If a digital input configured to panel lock is active, changing module modes will not be
possible. Viewing the instruments

and event logs
is NOT affected by panel lock. If panel lock is
active the Panel lock indicator (if configured) illuminates.
To initiate a start sequence in MANUAL, press the
pushbutton. When the controller is in the manual mode
(indicated by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence.
NOTE:- There is no Start Delay in this mode of operation.
If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised.
After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, then one second later, the
Starter Motor is engaged.
NOTE:- If the unit has been configured for CAN, compatible ECUs will receive the start command
via CAN.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the
starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of
attempts, the start sequence will be terminated and Fail to Start will be displayed.
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator
output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is
selected by PC using the 52/53xx series configuration software). Rising oil pressure can also be used to
disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection.
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the
fault.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before it
can be loaded.
The generator will run off load, unless the Remote Start on load signal is applied or, if Close generator has been
selected as a control source, the appropriate auxiliary output will then activate.
The generator will continue to run On load, until the Auto mode is selected.
If Auto mode is selected, and the remote start on load signal is not active, then the Stop Delay Timer begins,
after which, the load is disconnected. The generator will then run off load allowing the engine a cooling down
period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
43

8.4
SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault removed to reset the
module.
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition
remains it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and
similar delayed alarms, as the oil pressure will be low with the engine at rest).
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will
be initiated. Alarm Shutdown Fail To Start will be displayed.
Alarm
Shutdown
Failed to start
EMERGENCY STOP, removal of the Positive DC Supply from the Emergency Stop input initiates the following
sequence. Firstly it will initiate a controlled shutdown of the Generator and prevent any attempt to restart the
Generator until the Emergency Stop push-button has been reset. Secondly it removes the Positive DC supply from
both the Fuel Solenoid and Starter Solenoid.
Alarm Shutdown Emergency Stop will be displayed.
Alarm
Shutdown
Emergency stop
NOTE:- The Emergency Stop Positive signal must be present otherwise the unit will shutdown.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure trip
setting level after the Safety On timer has expired, a shutdown will occur. Alarm Shutdown Low Oil Pressure will
be displayed.
Alarm
Shutdown
Low oil pressure
HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high
engine temperature trip setting level after the Safety On timer has expired, a shutdown will occur. Alarm Shutdown
High Engine Temperature will be displayed.
Alarm
Shutdown
High temperature
44

OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. Alarm Shutdown Overspeed will
be displayed. Overspeed is not delayed, it is an immediate shutdown.
Alarm
Shutdown
Overspeed
NOTE:-During the start-up sequence the overspeed trip logic can be configured to allow an extra
trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 53xx series
configuration software manual under heading Overspeed Overshoot for details.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is
initiated. Alarm Shutdown Underspeed will be displayed.
Alarm
Shutdown
Underspeed
GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set trip
a shutdown is initiated. Alarm Shutdown High Frequency will be displayed, it is an immediate shutdown.
Alarm
Shutdown
Over frequency
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set trip after
the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Frequency will be displayed.
Alarm
Shutdown
Under frequency
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a
shutdown is initiated. Alarm Shutdown High Volts will be displayed, it is an immediate shutdown.
Alarm
Shutdown
AC Overvolts
GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set trip
after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Volts will be displayed.
Alarm
Shutdown
AC Undervolts
45

OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender
(open circuit) a shutdown is initiated. Alarm Shutdown Sender Fault will be displayed. Sender failure is not delayed,
it is an immediate shutdown.
Alarm
Shutdown
Oil pressure
sender fault
AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate message will be
displayed as configured by the user.
Alarm
Shutdown
Bearing temp high
MAINTENANCE ALARM, will be displayed if the maintenance period is exceeded (engine running hours or date
interval whichever is configured). The engine is shutdown (if configured to do so)
Alarm
Shutdown
Maintenance alarm
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated. Alarm
Shutdown Loss Of Speed Signal will be displayed.
Alarm
Shutdown
Loss of speed
signal
NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety
on timer. If the signal is lost during normal operation the Generator will shutdown with an Under-speed
alarm.
CAN DATA FAIL If the module is configured for CAN operation and does not detect data on the engine Can
datalink, a shutdown will occur and Can data fail is shown on the modules display.
Alarm
Shutdown
Can data fail
CAN ECU FAIL If the module is configured for CAN instruments and receives a fail message from the
engine control unit, the engine is shutdown and Can ECU fail is shown on the modules display.
Example
Alarm
Can ECU fail
Fuel pressure low
The display will alternate

between the text display and the
manufacturers error codes
Alarm
Can ECU fail
SPNnnnnnnn
FMInnnnnnn
46

NOTE:- If the CAN message is a manufacturers specific code, it may not be displayed as text.
If this is the case the display will show the generic manufacturers code, which must be crossreferenced with the engine manufacturers literature. . Please contact the engine manufacturer for
further assistance.
Example
Alarm
Can ECU fail
SPNnnnnn
FMInnnn
47

8.5 Typical LCD Display Screens
8.5.1 Typical Status Display
Waiting in auto
Indicates that the module is in Automatic. The unit will respond to

an active remote start.
Starting remote
Cranking attempt 1
Indicates that the module is in automatic and that a start sequence

has been initiated, with an active remote start. The module is
attempting to crank the generator.
Running in auto
Generator on load
Indicates that the module is in Automatic, and that the generator is

running on load. This default screen also indicates the average line
to neutral voltage, highest of the 3 phase currents, generator
frequency, average line to line voltage and total kilowatts.
L-N 230V
L-L
240A 50Hz
400V 133kW
8.5.2 Typical Instrument Display

Coolant temperature
60 C 140 F
Oil pressure
6 Bar 87 PSI
600 kPa
L1
Generator Amps
L2
L3
The display of coolant temperature in both degrees centigrade and

Fahrenheit.
The display of engine oil pressure in Bar, Pounds Per Square Inch
and kilo Pascal.
The display of all three generator line currents.
238 241 241
8.5.3 Typical Alarm Display

Alarm
Warning
Low oil pressure
The module is warning that the engine oil pressure has fallen
below a pre-set level. The generator is not shut down.
Alarm
Shutdown
Low oil pressure
The oil pressure has fallen below a second pre-set value and has
shut down the generator.
Alarm
Warning
Low battery Volts
The module is warning that the battery volts is below a pre-set

value.
48

8.5.4 Typical Event Display
Event log 21:15:00
10th September 2005
Low oil pressure
Shutdown
On the 10th September 2005 at 21:15 the unit detected that the oil
pressure was below the pre-set trip level, and has shut down the
generator.
Event log 20:10:00

8th September 2005
Emergency stop
Shutdown
On the 8th September 2005 at 20:10. The emergency stop button

was pressed and the generator was shut down.
Event log 08:46:00

7th September 2005
Over Volts
Shutdown
On the 7th September 2005 at 08:46 the unit detected that the
generator out put volts exceeded pre-set trip level, and has shut
down the generator.
8.6 Viewing The Instruments

It is possible to manually scroll to display the different pages of information by repeatedly operating the next page
button.
Page order:
Status display
Instrument display
Alarms display
Event log
It is possible to manually scroll to display the different instruments by repeatedly operating the next page
. Once selected the instrument will remain on the LCD display until the user selects a different
button
instrument or after a period of inactivity for the duration of the configurable Page Timer, the module will revert to the
default display.
Alternatively, to autoscroll through all instruments on the currently selected page, press and hold the scroll
button.
To disable autoscroll, press and hold the scroll
button, or select another page with the page select
button.
When autoscroll is disabled, the display will automatically return to the Status/Alarms page if no buttons are
pressed for the duration of the configurable Page Timer.
If an alarm becomes active while viewing instruments, the Status/Alarms page will be automatically displayed to
draw the operators attention to the alarm condition.
49

8.6.1 Instrument Page Content
Engine speed
Oil Pressure
Coolant temperature
Fuel level (%)
Engine Hours Run
DC Battery Voltage
Charge alternator volts
Modem Status (GSM only)
Generator AC RMS Voltage Line-Neutral
Generator AC RMS Voltage Line-Line
AC RMS Line Current
Generator Output
Number of starts
If enhanced instrumentation is selected, the following instrumentation will become
available, if supported by the engine manufacturer.
Engine oil temperature
Inlet manifold temperature
Coolant pressure
Fuel pressure
Fuel consumption
Total fuel used
Turbo pressure
8.6.2 Manually Selecting An Instrument

Default display
Running in auto
Generator on load
L-N 230V
L-L
Pressing the DOWN button the LCD will

then show Engine speed.
Pressing the DOWN button the LCD will

then show Oil pressure.
240A 50Hz
400V 133kW
Engine speed
1500 RPM
50 Hz
Oil pressure
6 Bar 87 PSI
600 Kpa
Pressing the
button again will scroll through each individual instrument eventually returning to the original
instrument displayed.
NOTE:-Once selected the instrument will remain on the LCD display until the user selects a different
instrument or after a period of inactivity for the duration of the configurable Page Timer, the module will
revert to the initial display.
50

8.7 User Configurable Indicators
These LEDs can be configured by the user to indicate any one of 100+ different functions
based around the following: Indications - Monitoring of a digital input and indicating associated functioning users
equipment - Such as Battery Charger On or Louvers Open, etc.
WARNINGS And SHUTDOWNS - Specific indication of a particular warning or
shutdown condition, backed up by LCD indication - Such as Low Oil Pressure
Shutdown, Low Coolant level, etc.
Status Indications - Indication of specific functions or sequences derived from the
modules operating state - Such as Safety On, Pre-heating, Panel Locked, Generator
Available, etc.
8.8 Controls
Stop / Reset
This button places the module into its Stop/reset mode. This will clear any alarm conditions for
which the triggering criteria have been removed. If the engine is running and this position is selected,
the module will automatically instruct the changeover device to unload the generator (Close
Generator becomes inactive (if used)). The fuel supply will be removed and engine will be brought
to a standstill. Should a remote start signal be present while operating in this mode, a remote start
will not occur.
If configured, the 5310 controller will enter sleep mode after 60 seconds of inactivity as a power
saving feature.
Manual
This mode is used to allow manual control of the generator functions. Once in Manual mode the
module will respond to the start (I) button and start the engine and run off load. If the engine is
running off-load in the Manual mode and a remote start signal becomes present, the module will
automatically instruct the changeover device to place the generator on load (Close Generator
becomes active (if used)). Should the remote start signal then be removed the generator will
remain on load until either the STOP/RESET or AUTO positions is selected.
Auto
This button places the module into its Automatic mode. This mode allows the module to control the
function of the generator automatically. The module will monitor the remote start input and once a
start condition is signalled the set will be automatically started and placed on load (Close
Generator becomes active (if used)). If the starting signal is removed the module will automatically
transfer the load from the generator and shut the set down observing the stop delay timer and
cooling timer as necessary. The module will then await the next start event. For further details
please see the more detailed description of Auto Operation earlier in this manual.
Test
This button places the module into its Test mode. This mode allows the operator to perform an on
load test of the system. Once in Test mode the module will respond to the start I button and start
the engine, and run on load (Close Generator becomes active (if used)). The generator will
continue to run on load until Auto mode is selected. Then, If the starting signal is removed, the
module will automatically transfer the load from the generator and shut the set down observing the
stop delay timer and cooling timer as necessary. The module will then await the next start event.
For further details please see the more detailed description of Test Operation earlier in this manual.
Start
mode.
This button is only active in STOP/RESET , MANUAL or TEST
Pressing this button in manual or test mode will start the engine and run off load (manual) or on load
(test).
Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly
configured and fitted to a compatible engine ECU)
Mute / Lamp Test
This button silences the audible alarm if it is sounding and illuminates all of the LEDs. If there is no
audible alarm this button will only illuminate all the LEDs.
When correctly configured and fitted to a compatible engine ECU, pressing this button in
STOP/RESET mode after pressing the START I button (to power the ECU) will cancel any
passive alarms on the engine ECU.
51

8.7 User Configurable Indicators
These LEDs can be configured by the user to indicate any one of 100+ different functions
based around the following: Indications - Monitoring of a digital input and indicating associated functioning users
equipment - Such as Battery Charger On or Louvers Open, etc.
WARNINGS And SHUTDOWNS - Specific indication of a particular warning or
shutdown condition, backed up by LCD indication - Such as Low Oil Pressure
Shutdown, Low Coolant level, etc.
Status Indications - Indication of specific functions or sequences derived from the
modules operating state - Such as Safety On, Pre-heating, Panel Locked, Generator
Available, etc.
8.8 Controls
Stop / Reset
This button places the module into its Stop/reset mode. This will clear any alarm conditions for
which the triggering criteria have been removed. If the engine is running and this position is selected,
the module will automatically instruct the changeover device to unload the generator (Close
Generator becomes inactive (if used)). The fuel supply will be removed and engine will be brought
to a standstill. Should a remote start signal be present while operating in this mode, a remote start
will not occur.
If configured, the 5310 controller will enter sleep mode after 60 seconds of inactivity as a power
saving feature.
Manual
This mode is used to allow manual control of the generator functions. Once in Manual mode the
module will respond to the start (I) button and start the engine and run off load. If the engine is
running off-load in the Manual mode and a remote start signal becomes present, the module will
automatically instruct the changeover device to place the generator on load (Close Generator
becomes active (if used)). Should the remote start signal then be removed the generator will
remain on load until either the STOP/RESET or AUTO positions is selected.
Auto
This button places the module into its Automatic mode. This mode allows the module to control the
function of the generator automatically. The module will monitor the remote start input and once a
start condition is signalled the set will be automatically started and placed on load (Close
Generator becomes active (if used)). If the starting signal is removed the module will automatically
transfer the load from the generator and shut the set down observing the stop delay timer and
cooling timer as necessary. The module will then await the next start event. For further details
please see the more detailed description of Auto Operation earlier in this manual.
Test
This button places the module into its Test mode. This mode allows the operator to perform an on
load test of the system. Once in Test mode the module will respond to the start I button and start
the engine, and run on load (Close Generator becomes active (if used)). The generator will
continue to run on load until Auto mode is selected. Then, If the starting signal is removed, the
module will automatically transfer the load from the generator and shut the set down observing the
stop delay timer and cooling timer as necessary. The module will then await the next start event.
For further details please see the more detailed description of Test Operation earlier in this manual.
Start
mode.
This button is only active in STOP/RESET , MANUAL or TEST
Pressing this button in manual or test mode will start the engine and run off load (manual) or on load
(test).
Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly
configured and fitted to a compatible engine ECU)
Mute / Lamp Test
This button silences the audible alarm if it is sounding and illuminates all of the LEDs. If there is no
audible alarm this button will only illuminate all the LEDs.
When correctly configured and fitted to a compatible engine ECU, pressing this button in
STOP/RESET mode after pressing the START I button (to power the ECU) will cancel any
passive alarms on the engine ECU.
52

8.9 Fault Finding
SYMPTOM
Unit is inoperative
Unit shuts down
Unit locks out on Emergency Stop

Intermittent Magnetic Pick-up
sensor fault
Low oil Pressure fault operates
after engine has fired
High engine temperature fault
operates after engine has fired.
Shutdown fault operates
Warning fault operates
Fail to Start is activated after preset number of attempts to start
Continuous starting of generator
when in AUTO
Generator fails to start on receipt
of Remote Start signal.
Pre-heat inoperative
Starter motor inoperative
Engine runs but generator will not
take load
Incorrect reading on Engine
gauges
POSSIBLE REMEDY
Check the battery and wiring to the unit. Check the DC supply. Check the DC
fuse.
Check DC supply voltage is not above 35 Volts or below 9 Volts
Check the operating temperature is not above 70 C. Check the DC fuse.
If an Emergency Stop Switch is not fitted, ensure that a positive is connected
to the Emergency Stop input. Check emergency stop switch is functioning
correctly. Check Wiring is not open circuit.
Ensure that Magnetic pick-up screen is only connected at one end, if
connected at both ends, this enables the screen to act as an aerial and will
pick up random voltages.
Check engine oil pressure. Check oil pressure switch/sender and wiring.
Check configured polarity (if applicable) is correct (i.e. Normally Open or
Normally Closed) or that sender is compatible with the 5310 Module and is
correctly configured.
Check engine temperature. Check switch/sender and wiring. Check
configured polarity (if applicable) is correct (i.e. Normally Open or Normally
Closed) or that sender is compatible with the 5310 Module.
Check relevant switch and wiring of fault indicated on LCD display. Check
configuration of input.
Check relevant switch and wiring of fault indicated on LCD display. Check
configuration of input.
Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery
supply is present on the Fuel output of the module. Check the speed sensing
signal is present on the 5310 inputs. Refer to engine manual.
Check that there is no signal present on the Remote Start input. Check
configured polarity is correct.
Check Start Delay timer has timed out.
If remote start fault, check signal is on Remote Start input. Confirm input is
configured to be used as Remote Start.
Check wiring to engine heater plugs. Check battery supply. Check battery
supply is present on the Pre-heat output of module. Check pre-heat has been
selected in your configuration.
Check wiring to starter solenoid. Check battery supply. Check battery supply
is present on the Starter output of module. Ensure that the Emergency Stop
input is at Positive.
Check Warm up timer has timed out. Ensure generator load inhibit signal is
not present on the module inputs. Check connections to the switching device.
Check engine is operating correctly. Check sender and wiring paying
particular attention to the wiring to terminal 47 (refer to appendix). Check that
sender is compatible with the 5310 Module and is correctly configured.
NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the
module to be configured to provide a wide range of different features always refer to the source of your
module configuration if in doubt.
53

8.10 Icons And LED Identification
7.10.1 Push Buttons
Display
Description
Display
Description
Stop/Reset
Page scroll
Scroll
Display
Description
Auto mode
Manual mode
Start (when in
Manual or Test
mode)
Display
Description
Mute
8.10.2 Status / Measurement Units

Display
Description
L1
L1-
Phase
Display
L2
Description
Phase
Phase - Neutral
L2-
L1- L2
Phase - Phase
L2- L3
BAR
Pressure
Voltage
Amperes
kW
KiloWatts
L3
Phase
Phase - Neutral
L3-
Phase - Phase
L3- L1
Phase - Phase
KPa Oil Pressure

Units
PSI
Pressure
Temperature
Hz
Frequency
Temperature
RPM
Speed
kVA
Apparent power
KPa
Phase -Neutral
KW divided by
kVA
8.10.3 LED Indication

Display
Description
Generator
available
54
9. Routine Maintenance
9.1 Maintenance
^ WARNING
Hot engine and exhaust system can cause severe
injury.

Do not touch hot engine parts.

Do not perform service or maintenance on
generator until cool to the touch.
^ WARNING
Risk of severed digits or limbs.

Generator can be started from a remote switch.

Disconnect the negative (-) battery cable from
generator battery before performing service or
Maintenance must be performed on a regular basis to ensure

the generator set performs properly and to extend the life of
the generator set.
Generator set routine maintenance will depend on the
installed location environment and application for which the
generator set is used. Consider these factors when planning
the maintenance schedule.
Stand-by generator sets installed in a clean and dry location
will require at least a visual inspection once a month.
Stand-by generator sets installed in a dusty, damp or humid
locations will require inspections and maintenance more
frequently.
Refer to the engine manufacturers manual for the
scheduled maintenance on the engine.
Refer to the alternator manufacturers manual for the
scheduled maintenance on the alternator.
Standby generator set must be exercised at least once per
month at a minimum of 70% load for one hour.
^ WARNING
Electrical shock can cause injury or death.

maintaining or working near this equipment are
fully aware of the emergency procedures in case
of accidents.

55
9.2 Periodic Maintenance

O=Check X= Replace
System
= Contact your authorized Yanmar dealer or distributor
Check Item
Check and refill engine

coolant
Cooling
System
Daily
Every 50 Every 250 Every 500

Hours
Hours
Hours
Electrical
Equipment
Check and clean

radiator fins
Check and adjust
cooling fan V-belt
O 1st
time
O 2nd and
after
X or every
year
whichever
comes first
Adjust intake / exhaust

valve clearance
Lap intake / exhaust

valve seats
Check indicators
Check engine oil level
O
O
O
Drain and fill engine oil
X 1st
time
Replace engine oil filter
Engine
Speed
Control
Emission
Control
Warranty
Check and adjust

governor lever and
engine speed control
Inspect turbocharger (if

equipped) (blower wash
as necessary)
Inspect crankcase
breather system
Drain fuel tank
Drain fuel / water

separator
Fuel
Hoses
X 2nd and
after
Inspect, clean and test

fuel injectors
Check and refill fuel tank
Check fuel / water

separator
O
O
Clean fuel / water

separator
Replace fuel filter
Replace fuel system and

cooling system hoses
Intake and
Exhaust
Clean or replace air

cleaner element
Complete
Engine
Overall visual inspection

daily
Every 2000
Hours
Check battery
Engine Oil
Every
1500
Hours
Drain, flush and refill

cooling system with new
coolant
Cylinder
Head
Every
1000
Hours
or every 2
years
O
56
10. Alternator
10.1 Generator Designation
HC(K) 534C2 (eg)
HC - Standard range Generators

HCK - Dedicated range (HC5 only)
I - Applications, M = Marine I = Industrial,
5 - Frame size, 4, 5, or 6
3 - Separate excitation, PMG
or
4 - Self Excited
4 - Number of poles, 4 or 6
C - Core Size
2 - Number of bearings, 1 or 2
10.4 Lifting
^ WARNING
The generator lifting points are designed to lift the
generator only.

Do not lift the complete generating set by the
generator lifting points.
When lifting the generator use a spreader bar to ensure
that the angle on the lifting chains are vertical to the lifting
position on the generator.
The product is an AVR controlled, separately excited (by a

shaft driven pilot exciter) synchronous ac generator or a self
excited (shunt arrangement). Designed for incorporation into
a generating-set. (A generating-set is defined as machinery
in European directives).
10.2 Serial Number Location
Each generator has a unique serial number stamped into the

upper section of the drive end of the frame.
The serial number is also shown on the nameplate.
Two other labels are located inside the terminal box, both
fixed inside of the terminal box, one on the sheet metal-work
and the other on the main frame of the generator. Neither of
these two labels is considered to be permanently fixed.
10.3 Rating Plate
The generator has been supplied with a self-adhesive rating

plate label to enable fitting after final assembly and painting.
Stick the nameplate to the outside of the non-drive end of
the terminal box. The surface in the area where a label is
to be stuck must be flat, clean, and any paint finish must be
fully dry before attempting to attach label. Recommended
method for attaching label is peel and fold back sufficient of
the backing paper to expose some 20 mm of label adhesive
along the edge which is to be located against the sheet
metal protrusions. Once this first section of label has been
carefully located and stuck into position progressively peel
off the backing paper and smooth down with a clean cloth.
The adhesive will achieve a permanent bond in 24 hours.
A factory fitted metal nameplate is available for some
applications.
57
10. Alternator
10.5 Automatic Voltage Regulators
To make AVR selections and adjustments remove the AVR

cover and refer to the appropriate section depending upon
type of AVR fitted. Reference to the generator nameplate will
indicate AVR type.
Most of the AVR adjustments are factory set in positions which
will give satisfactory performance during initial running tests.
Subsequent adjustment may be required to achieve optimum
performance of the set under operating conditions.
10.5.1 Type AS440
1 - 8& Z2 linked for normal remove for auxiliary winding

2 - Output Voltage adjustment
3 - Hand trimmer link when not used
4 - Low voltage selection (110v)
5 - Droop adjustment
6 - To optimize analogue input sensitivity
7 - Excitement trip cut off adjustment
8 - Stability control
9 - UFRO adjustment
10 - Stability section
11 - Frequency section
Stability Selection
No.
Power range
Response
B-D
A-C
B-C
A-B
Slow
Fast
Fast
Fast
< 100kW
< 100kW
100-550kW
> 550kW
Initial Start Up
On completion of generating set assembly and before
starting the generating set, ensure that all of the engine
manufacturers pre-running procedures have been
completed, and that adjustment of the engine governor is
such that the generator will not be subjected to speeds in
excess of 125% of the rated speed.
Over-speeding the generator during initial setting of the
speed governor can result in damage to the generator
rotating components.
Voltage Set Up
The voltage is factory set as per the rating plate. If necessary
adjust the voltage to the no load level as required.
To adjust the voltage remove the AVR access cover plate,
use the insulated tool supplied.
Stability Set Up
The STABILITY control potentiometer is pre-set and should
not normally require adjustment. If adjustment is necessary
proceed as follows:
-
Run the generating set on no-load and check that
speed is correct and stable.
-
Turn the STABILITY control potentiometer clockwise,
and then turn slowly anti-clockwise until the generator
voltage starts to become unstable. The correct setting is
slightly clockwise from this position (i.e. where the machine
volts are stable but close to the unstable region).
58
10. Alternator
10.5.2 Type MX341
The following jumper connections must be in the correct
position for the correct number of poles and the operating
frequency of the generator.
Frequency selection terminals
4 pole 50Hz LINK 2-3
4 pole 60Hz LINK 1-3
Stability selection terminals
LINK A-B
Excitation Interruption Link
K1-K2
Initial Start Up
Over-speeding the generator during initial setting of the
speed governor can result in damage to the generator
rotating components.
Voltage Set Up
adjust the voltage to the no load level as required.
To adjust the voltage remove the AVR access cover plate,
use the insulated tool supplied.
Stability Set Up
proceed as follows:
- Run the generating set on no-load and check that speed is
correct and stable.
- Turn the STABILITY control potentiometer clockwise, and
then turn slowly anti-clockwise until the generator voltage
starts to become unstable. The correct setting is slightly
clockwise from this position (i.e. where the machine volts
are stable but close to the unstable region).
1 - Volts
2 - Indicator led
3 - UFRO
4 - Frequency
5 - Dip
6 - Stability
7 - Excitation trip
8 - Stability section
9 - Droop
10 - Trim
11 - Link (over 550kW)
12 - Isolation link
13 - 2 x pin 2 use either
14 - Std. sensing links
59
10. Alternator
10.5.4 Type MX321
The following jumper connections on the AVR should be

checked to ensure they are correctly set for the generating
set application.
MX321 jumper connections
Frequency selection terminals
4 pole 50Hz operation - Link 2-3
4 pole 60Hz operation - Link 1-3
Stability selection terminals UC22 - Link A-B
Stability selection terminals UC27 - Link B-C
Excitation Interruption Link - K1-K2
1 - Volts
2 - Indicator led
3 - I/limit
4 - UFRO
5 - Frequency selector
6 - Dip
7 - rms
8 - Dwell
9 - Stability
10 - Over/v
11 - Exc trip
12 - Stability selector
13 - Droop
14 - Trim
15 - Link (over 550kW)
Voltage Set Up
adjust the voltage to the no load level as required. To adjust
the voltage remove the AVR access cover plate, use the
insulated tool supplied.
Stability Set Up
proceed as follows:
Run the generating set on no-load and check that speed is
correct and stable. Turn the STABILITY control potentiometer
clockwise, then turn slowly anti-clockwise until the generator
voltage starts to become unstable.
Note: The correct setting is slightly clockwise from this
position (i.e. where the machine volts are stable but close to
the unstable region).
10.6 Electrical Protection
It is the responsibility of the end user and contractors/subcontractors to ensure that the overall system protection
meets the needs of any inspector, local electricity authority
or safety rules, pertaining to the site location.
^ WARNING
Incorrect installation and/or protective systems
can result in injury and/or equipment damage.

Installers must be qualified to perform electrical
installation work.
Adequate electrical protection must be provided so that there
will be no danger to personnel, danger of fire or damage to
the generator under fault conditions.
Initial Start Up
Overspeeding the generator during initial setting of the speed
governor can result in damage to the generator rotating
components.
60
10. Alternator
10.7 Fault Finding
^ WARNING
Important: Before commencing any fault finding procedure
examine all wiring for broken or loose connections.
3. Check residual voltage. Refer to subsection 7.4.7.

4. Follow Separate Excitation Test Procedure to check
generator and AVR. Refer to subsection 7.5.
Unstable voltage either on no-load or with load.
1. Check speed stability.
2. Check stability setting. Refer to subsection 4.6.
High voltage either on no-load or with load.
1. Check speed.
2. Check that generator load is not capacitive (leading power
factor).
Low voltage no load.
1. Check speed.
2. Check link 1-2 or external hand trimmer leads for
continuity.
Four types of excitation control system, involving four types

of AVR, can be fitted to the range of generators covered by
this manual. The systems can be identified by a combination
of AVR type, where applicable, and the last digit of the
generator frame size designation. Refer to the generator
nameplate then proceed to the appropriate subsection.
Low voltage on load.

1. Check speed.
2. Check UFRO setting.
3. Follow Separate Excitation Procedure to check generator
and AVR.
10.7.1 SX460 AVR
No voltage build-up when starting set.

1. Check speed
2. Check residual voltage.
generator and AVR.
No voltage build-up when starting set.

1. Check circuit breaker ON.
2. Check speed.
3. Check residual voltage. Refer to subsection 7.4.7.
generator and AVR.

2. Check stability setting.

2. Check stability setting.

1. Check speed.
factor).

1. Check speed.
2. Check link 1-2 or external hand trimmers leads for
continuity. Check continuity of leads 7-8 and P3-P2 for
continuity.
factor).
Low voltage, no load.

1. Check speed.
continuity.
1. Check speed.
2. Check UFRO setting.
and AVR.
10.7.2 SX440 AVR
No voltage build up when starting set.

1. Check link K1-K2 on auxiliary terminals.
2. Check speed
10.7.3 SX421 AVR
Low voltage no load.

1. Check speed.
continuity.
1. Check speed.
2. Check UFRO setting. Refer to subsection 4.7.1.1.
and AVR.
Excessive voltage/speed dip on load switching.
1. Check governor response.
61
8. Alternator
10.8 Alternator Maintenance
^ WARNING
As part of routine maintenance procedures, periodic attention
to winding condition (particularly when generators have been
idle for a long period) and bearings is recommended.
When generators are fitted with air filters regular inspection
and filter maintenance is required.
10.8.1 Winding Condition
Warning: Service and fault finding procedures present

hazards which can result in l injury or death. Only personnel
qualified to perform electrical and mechanical service should
carry out these procedures. Ensure engine starting circuits
are disabled before commencing service or maintenance
procedures. Isolate any anti-condensation heater supply.
10.8.2 Guidance Of Typical Insulation

Resistance [IR] Values
The following is offered as general information about IR

values and is aimed at providing guidance about the typical
IR values for generators from new through to the point of
refurbishment.
Generators In Service
It is known that a generator will give reliable service with
an IR value of just 1.0 M. For a relatively new generator
to be so low it must have been subjected to inappropriate
operating or storage conditions.
10.8.3 Winding Condition Assessment

The AVR should be disconnected and the Resistance
Temperature Detector (R.T.D.) leads grounded during this
test.
NOTICE
The AVR must be disconnected and the resistance
Temperature Detector (R.T.D.) leads grounded
during this test.
The condition of the windings can be assessed by
measurement of insulation resistance [IR] between phase to
phase, and phase to earth.
Measurement of winding insulation should be carried out:
1. As part of a periodic maintenance plan.
2. After prolonged periods of shutdown.
3. When low insulation is suspected, e.g. damp or wet
windings.
Care should be taken when dealing with windings that are
suspected of being excessively damp or dirty. The initial
measurement of the [IR] Insulation Resistance should
be established using a low voltage (500V) megger type
instrument. If manually powered the handle should initially be
turned slowly so that the full test voltage will not be applied,
and only applied for long enough to very quickly assess
the situation if low values are suspected or immediately
indicated.
Full megger tests or any other form of high voltage test
should not be applied until the windings have been dried out
and if necessary cleaned.
10.9 Replacement Parts
Contact your Himoinsa Power System dealer or distributor

to order parts. Have your genset serial and model number
when ordering parts.
Any temporarily reduction in IR values can be restored

to expected values by following one of the drying out
procedures.
62
11. Specifications
11.1 Generator Set Models
Generator Set Model
Voltage
Engine Model Alternator Model
HYW 9 M6
120/240V 1 Ph - 60HZ
3TNV76
PI044F
HYW 14 M6
120/240V 1 Ph - 60 Hz
3TNV88
PI144F
HYW 20 M6
120/240V 1 Ph - 60 Hz
4TNV88
PI144E
HYW 25 M6
120/240V 1 Ph - 60 Hz
4TNV84T
PI144H
HYW 35 M6
120/240V 1 Ph - 60 Hz
4TNV98
UCI 244 C
HYW 45 M6
120/240V 1 Ph - 60 Hz
4TNV98T
UCI 224 E
HYW 9 T6
120/480 3 Ph - 60 Hz
3TNV76
PI044E
HYW 14 T6
120/480 3 Ph - 60 Hz
3TNV88
PI044F
HYW 20 T6
120/480 3 Ph - 60 Hz
4TNV88
PI044H
HYW 25 T6
120/480 3 Ph - 60 Hz
4TNV84T
PI144E
HYW 35 T6
120/480 3 Ph - 60 Hz
4TNV98
PI144H
HYW 45 T6
120/480 3 Ph - 60 Hz
4TNV98T
PI144K
63
11. Specifications
11.2 Engine Models
11.2.1 3TNV76
Engine Type
In-line 3 Cylinder Diesel Engine
Bore & Stroke
3.0 in. (76 mm) x 3.2 in. (82 mm)
Displacement
68 cu. in. (1.12 L)
Compression Ratio
23.5 : 1
Combustion System
Spherical Swirl Chamber System (IDI)
Cooling System
Liquid Cooled
Aspiration
Natural
Rated Horsepower Hp (kW)
15 (11)
Rated Speed rpm
1800
Dimensions, Open Skid
57.1 x 24.4 x 50.4 in. (1450 x 620 x 1280 mm)
Dimensions, Sound Attenuated
58.1 x 29.5 x 43.7 in. (1475 x 750 x 1110 mm)
Weight, Open Skid With Radiator
723 lb (328 kg)
Weight, Sound Attenuated
1347 lb (611 kg)
1.2.2 3TNV88
Engine Type
Bore & Stroke
3.46 in. (88 mm) x 3.54 in. (90 mm)
Displacement
100 cu. in. (1.64 L)
Compression Ratio
19.1 : 1
Combustion System
Direct Injection
Cooling System
Liquid Cooled
Aspiration
Natural
Rated Horsepower Hp (kW)
22.7 (16.9)
Rated Speed rpm
1800
57.1 x 24.4 x 50.4 in. (1450 x 620 x 1280 mm)
58.1 x 29.5 x 43.7 in. (1475 x 750 x 1110 mm)
853 lb (387 kg)
1468 lb (666 kg)
64
11. Specifications
11.2.3 4TNV84T
Engine Type
Bore & Stroke
3.31 in. (84 mm) x 3.54 in. (90 mm)
Displacement
122 cu. in. (2.0 L)
Compression Ratio
18.9 : 1
Combustion System
Direct Injection
Cooling System
Liquid Cooled
Aspiration
Turbocharged
Rated Horsepower Bhp (kWm)
37.1 (27.7)
Rated Speed rpm
1800
66.9 x 24.4 x 50.4 in. (1700 x 620 x 1280 mm)
88.6 x 43.3 x 52.8 in. (2250 x 1100 x 1340 mm)
917 lb (416 kg)
2315 lb (1050 kg)
11.2.4 4TNV88
Engine Type
Bore & Stroke
3.46 in. (88 mm) x 3.54 in. (90 mm)
Displacement
134 cu. in. (2.19 L)
Compression Ratio
19.1 : 1
Combustion System
Direct Injection
Cooling System
Liquid Cooled
Aspiration
Natural
30.2 (22.5)
Rated Speed rpm
1800
57.1 x 24.4 x 50.4 in. (1450 x 620 x 1280 mm)
88.6 x 43.3 x 52.8 in. (2250 x 1100 x 1340 mm)
1003 lb (455 kg)
975 lb (2150 kg)
65
11. Specifications
11.2.5 4TNV98
Engine Type
Bore & Stroke
3.31 in. (84 mm) x 3.54 in. (90 mm)
Displacement
203 cu. in. (3.32 L)
Compression Ratio
18.5 : 1
Combustion System
Direct Injection
Cooling System
Liquid Cooled
Aspiration
Natural
55.8 (41.6)
Rated Speed rpm
1800
76.8 x 30.7 x 50.4 in. (1950 x 620 x 1340 mm)
88.6 x 43.3 x 52.8 in. (2250 x 1100 x 1340 mm)
1332 lb (604 kg)
2315 lb (1050 kg)
11.2.6 4TNV98T
Engine Type
Bore & Stroke
3.86 in. (98 mm) x 4.33 in. (110 mm)
Displacement
203 cu. in. (3.32 L)
Compression Ratio
18.1 : 1
Combustion System
Direct Injection
Cooling System
Liquid Cooled
Aspiration
Turbocharged
68.4 (51.0)
Rated Speed rpm
1800
76.8 x 30.7 x 50.4 in. (1950 x 780 x 1280 mm)
88.6 x 43.3 x 52.8 in. (2250 x 1100 x 1340 mm)
1584 lb (702 kg)
2513 lb (1140 kg)
66

HIPOWER Yanmar Generators Manual

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Generating Sets

Industrial Generator Sets

5. CEM7 Control Panel............................................................................ 20

5.2 Control Panel............................................................................................... 21

5.4 Data LEDs................................................................................................... 23

HIMOINSA POWER SYSTEMS

5.5 Starting And Stopping Genset................................................................... 24

Interruption Of Function Mode.................................................................. 24

5.10 Engine Alarms........................................................................................... 27

6.3 Engine Alarms............................................................................................. 33

DSE3000 Series Control Panel......................................................... 34

7.3 Graphical Display.......................................................................................... 34

7.6 Manual Operation.......................................................................................... 36

HIMOINSA POWER SYSTEMS

7.10 Fault Icons................................................................................................... 38

8. DSE5310 Series Control Panel........................................................... 39

8.6 Viewing The Instruments.............................................................................. 49

8.7 User Configurable Indicators....................................................................... 51

HIMOINSA POWER SYSTEMS

Serial Number Location............................................................................ 57

10.6 Electrical Protection................................................................................. 60

10.8 Alternator Maintenance............................................................................ 62

10.9 Replacement Parts.................................................................................... 62

Illustrations and technical detail provided courtesy of Cummins Generator Technologies.

HIMOINSA POWER SYSTEMS

This manual provides information and procedures to safely

The safety information in this manual is denoted by the

The level of risk is indicated by the following signal words:

Do not operate generator without an Operators Manual.

Use properly rated lifting equipment to lift heavy objects.

All personnel that will be operating, maintaining and working

Clean up spilt fluids and dispose of fluids, contaminated

If you have any safety concerns or questions that are not

^ California Proposition 65 Warning

Extinguish all smoking material when adding fuel or working

Disconnect negative (-) battery cable before performing

Do not operate generator set with safety guard(s) removed.

Battery posts, terminals and related accessories contain

HIMOINSA POWER SYSTEMS

1.3 Operational Hazards

^You must adhere to local codes and regulations where

HIMOINSA POWER SYSTEMS

Do not smoke while refueling. Do not refuel near sparks

^ Clean up fluid spills and contaminated material in

accordance with local regulations.

1.4 Maintenance Hazards

Service and maintenance procedures must be carried

All electrical equipment can be dangerous if not

^ California Proposition 65 Warning

HIMOINSA POWER SYSTEMS

Open Skid Model HYW 45 T6

HIMOINSA POWER SYSTEMS

HIMOINSA POWER SYSTEMS

3.2 Control Of Material

When the genset is delivered, check that the received material

Safety rules for diesel gensets

3.3 Outdoor Installations

The generator set can be temporarily placed on a firm level

3.4 Indoor Installations

For the correct installation of a genset in closed premises,

HIMOINSA POWER SYSTEMS

Open Skid Set

The recommended room dimensions are displayed in the

The foundation must be designed by an engineer experienced