Dometic BLUTEC40D Kasutusjuhend

BLUTEC40D

Marine generator

Installation and Operating Manual

Marinegenerator

Montage- und Bedienungsanleitung

Générateur marin

Instructions de montage

et de service

Generador marino

Instrucciones de montaje y de uso

Gerador marítimo

Instruções de montagem e manual de

instruções

Generatore marino

Istruzioni di montaggio e d’uso

Nautische generator

Montagehandleiding en

gebruiksaanwijzing

Marinegenerator

Monterings- og betjeningsvejledning

Maringenerator

Monterings- och bruksanvisning

Båtgenerator

Monterings- og bruksanvisning

Laivageneraattori

Asennus- ja käyttöohje

EN

DE

FR

ES

PT

IT

NL

DA

SV

NO

FI

ENERGY & LIGHTING

TEC

User Manual

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GB

GUARANTEE CLAUSES

The equipment is guaranteed according to the contents of Directive 1999/44EC.

The Manufacturer’s guarantee is expressly excluded in the case that the breakdown and/

or irregular functioning of the equipment is caused by or depends on incorrect set-up.

The equipment is guaranteed for two years or 1000 operating hours against breakdown or

malfunction. The guarantee shall be invalid once the indicated duration has been exceeded

or if the recommended maintenance programme has not been followed.

User Manual

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CONTENTS

TABLE OF CONTENTS

GENERAL INFORMATION............................ 6

TECHNICAL INFORMATION......................... 8

SAFETY INFORMATION ............................. 11

INFORMATION ON MOVEMENT AND

INSTALLATION ........................................... 15

INFORMATION ON ADJUSTMENTS........... 25

INFORMATION ON USE ............................. 25

MAINTENANCE INFORMATION ................ 27

TROUBLESHOOTING INFORMATION ...... 31

INFORMATION ON SPARE PARTS............ 33

WIRING DIAGRAM...................................... 35

CONNECTION TO THE EXTERNAL POWER

SUPPLY........................................................ 35

A

Adjustment method

(25)

C

Changing engine oil

(29)

Changing the fuel lter (30)

Changing the sacricial anode (30)

Changing the water pump rotor (33)

Check oil level (28)

Connecting the battery (21)

Connecting the battery charger (21)

Connecting the fuel indicator (21)

Connection to the exhaust (22)

Connection to the external power supply (36)

Connection to the power supply (20)

Cooling water connection (24)

D

Decommissioning the unit

(34)

Description of controls (25)

E

Electrical connection to the external network

(21)

F

Finding malfunctions

(31)

Fuel connection (22)

Fuel circuit (23)

G

General description of the appliance

(8)

General rules (11)

Glossary and terms (7)

I

Improper use

(10)

Installing the unit (16)

L

Loading and transport

(15)

M

Main components

(8)

Manufacturer and appliance identication (6)

Movement and lifting (16)

P

Packing and unpacking

(15)

Prolonged inactivity of the unit (26)

R

Recommendations for maintenance

(27)

Recommendations for movement and installation (15)

Recommendations for use and operation (25)

Recommendations when changing parts (33)

Recommended lubricants (28)

Requesting assistance (7)

Rules for adjustment and maintenance (12)

Rules for movement and installation (11)

Rules for operation and use (12)

Rules for safety from environmental impact (13)

S

Safety and information signs

(14)

Safety devices (10)

Safety for the disposal of Waste from Electrical and

Electronic Equipment (WEEE Directive 2002/96)

(13)

Scope of the manual (6)

Starting and stopping the unit (26)

Storage (16)

T

Table of alarm signals

(32)

Table of maintenance operations (27)

Technical data (9)

Testing the unit (24)

Tank-Generator distance (22)

W

Wiring diagram

(35)

User Manual

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GB

This manual, which is an integral part of

the equipment, has been drawn up by the

manufacturer to provide the information

required by those trained and authorised

to work on and with it during its working

life.

This information is supplied by the

Manufacturer in the original language

(Italian) and

may be translated into other languages

to satisfy legal and/or commercial

requirements.

Those to whom this information is

addressed must not only use the

appliance in a proper manner, but must

read the information carefully and apply all

instructions strictly.

Spending a short time reading this

information will allow you to avoid risks

that might result in a health or safety

hazard and in economic damage.

Should this manual contain information

that is additional to the actual set-up of the

appliance, this additional information will

have no inuence on the rest.

Keep this manual in a safe, known and

easily accessible place for the entire

working life of the appliance, so that it is

always to hand when required.

The manufacturer reserves the right to

makeall modications it may deem t,

without undertaking to give any prior

notice.To highlight certain sections of

text that are particularly important or to

indicate certain important specications,

various symbols have been used. These

are described below.

GENERAL INFORMATION

SCOPE OF THE MANUAL

MANUFACTURER AND APPLIANCE IDENTIFICATION

Danger - Attention

Warning - Caution

Indicates states of severe danger that,

if ignored, may seriously endanger the

health and safety of persons.

Indicates that it is necessary to take

suita-ble precautions in order to avoid

endan-gering the health and safety

of persons and causing economic

damage.

Important

Indicates technical information of

particular importance that must not be

ignored.

The identication plate shown here

is afxed di-rectly to the appliance.

A) Manufacturer identication

B) Conformity markings

C) Model/Serial number

D) Year of manufacture

E) Technical data

A

B

C

D

E

User Manual

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Certain terms that are used frequently in

the manual are described, so as to give

the fullest possible view of their meaning.

Installation technician: a technician

selected and authorised by the

Manufacturer or his agent, from among

those with the necessary qualications

to carry out installation and testing of the

appliance.

Ordinary maintenance: series of

operations necessary to keep the

appliance in a state of proper efciency

and operation. These operations are

normally planned by the Manufacturer,

who sets down the qualications required

to carry them out and the intervention

method.

Special maintenance: series of operations

necessary to keep the appliance in a

state of proper efciency and operation.

These operations are not planned by the

Manufacturer and must be carried out by

the maintenance technician.

Senior maintenance technician: a

technician selected and authorised by

the Manufacturer from among those with

the necessary qualications, experience

and information to carry out special

maintenance and repairs on the appliance.

GLOSSARY AND TERMS

REQUESTING ASSISTANCE

For any assistance, please contact the

Manufacturer’s Service Department.

When requesting technical assistance,

please indicate the information provided

on the identication plate, the approximate

number of working hours and the type of

problem encountered.

User Manual

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TECHNICAL INFORMATION

GENERAL DESCRIPTION OF THE APPLIANCE

MAIN COMPONENTS

heat exchanger (C)

The generator unit for vessels “BLUTEC

40 D”, is an appliance designed and built to

be installed on board vessels of all types.

It is used in the professional and civil

shipping sector to generate current on

sea-going vessels.

The appliance is tted with a control panel,

from which it is possible to controll all

working functions.

- Endothermic motor (A): to power all

the main components.

- Alternator (B): transofms the

mechanical energy of the motor into

alternat current electrical energy.

- Heat exchanger (C): cools the air

inside the unit through heat exchange

with the sea water.

- Water pump (D): feeds the sea water

cooling circuit

- Inverter (E): converts the supply

voltage into a perfectly stable, high

quality voltage of 230V/50Hz.

- Control panel (F): comprises the

devices used to operate and control all

functions.

control panel (F)

inverter (E)

alternator (B)

water pump (D)

endothermic motor (A)

User Manual

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TECHNICAL DATA

Appliance model Unit of

measurement

BLUTEC 40D

Dimensions

A mm 570

B mm 406

C mm 528

Weight kg 85

Motor technical data

Model YANMAR L 70 N / 320cc

Maximum power HP 6,1

maximum running speed Rev/min 3300

Fuel consumption lt 1,3

Oil sump capacity lt 1,1

Max inclination ± 20°

Generator technical data

Maximum output (continuous) W 3500

Output voltage V 230±10%

Frequency Hz 50

Insulation Class H

User Manual

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SAFETY DEVICES

IMPROPER USE

The illustration shows the position of the

devices.

- Fixed guard (A): prevents access to

moving parts of the unit. It can only be

opened by a voluntary action and with

the aid of a tool.

- Mobile guard (B): prevents access to

the interior of the unit.

- Temperature probe (C): disables the

unit if the exhaust gas reaches an ex-

cessively high temperature.

xed guard (A)

sensor (C)

xed guard (A)

mobile guard (B)

Any form of use other than that authorised

is to be considered IMPROPER USE.

Under no circumstances must this unit

be used in explosive environments or

when exposed to the elements.

User Manual

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GENERAL RULES

RULES FOR MOVEMENT AND INSTALLATION

SAFETY INFORMATION

- When designing and building this unit, the

manufacturer has paid particular attention

to all aspects that might result in a risk to

the health and safety of those working with

the unit itself. As well as complying with

current legal requirements, all “rules of

good manufacturing practice” have been

followed. The aim of this information is to

notify users of the need to pay particular

attention, in order to prevent any type of

risk.The need for prudence can never be

sufciently stressed. Safety also depends

on the operators working with the unit.

- Please read the instructions provided

in this manual carefully, and also read

the instructions afxed directly to the

unit, in particular those relating to safety.

Dedicating a short time to reading this

information will help avoid unnecessary

accidents; it is always too late to remember

what you should have done when you

have already done it.

- Pay particular attention to the meaning of

the symbols on the unit; their shape and

colour are signicant for the purposes of

safety. Make sure they remain legible, and

follow the instructions given.

- Do not tamper with, elude, eliminate or

bypass the safety devices tted. Failure to

comply with this requirement may result in

severe risks for the health and safety of

persons.

- Staff carrying out any type of operation on

the unit throughout its working life must

have specic technical qualications,

abilities and experience that has been

acquired in and is recognised by the

specic sector. If these requirements are

lacking, damage to the health and safety

of persons may result.

- When working, only use the clothing and/

or personal protection devices indicated

in the instructions for use supplied by the

manufacturer, or those foreseen by local

laws on safety in the workplace.

- During normal use or for whatever

operation, always ensure there is sufcient

access space to use the comands in

conditions that are not liable to result in a

risk for the health and safety of persons.

- Every operation, unless expressly

indicated, must be carried out with

the motor turned off and after allowing

sufcient time for it to cool down, so as to

avoid the risk of scalding.

- Lift and move the unit as described by

the manufacturer and indicated on the

packaging, on the unit itself and in the user

manual.

- The staff loading, unloading and moving

the unit, must have experience and abilities

gaiend and recognised in the sector in

question, and must be familiar with the

lifting equipment to be used.

- Loading and transport must be carried

out using means of adequate capacity,

anchoring the unit at the points foreseen

by the manufacturer. Those authorised

to carry out these operations must have

specic experience and abilities, so as

to safeguard themselves and any other

persons involved.

- All phases of installation must be

considered, from the time the general

plan was drawn up. Before starting these

phases, as well as dening the installation

area, the person authorised to carry out

these operations must, if necessary,

implement a “safety plan” to safeguard

the persons directly involved from harm,

and must scrupulously follow all laws, with

particular reference to those regarding

mobile work sites.

User Manual

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- It is necessary to ensure that the installation

area has been provided with all the suction,

power supply and drainage connections

required.

- During installation, respect the perimeter

areas indicated by the manufacturer, also

bearing in mind all the other operations in

the surrounding areas. This requirement

must be implemented in such a way as to

comply with current laws on safety at work.

- Installation and connection must be carried

out according to the manufacturer’s

instructions. The person in charge

must also take into account all legal

requirements and rules, and must carry out

all installation and connection operations in

a workmanlike manner. When installation

has been completed, before use, he must

carry out a general check to ensure these

requirements have been met.

- As well as being suitably trained and

informed regarding use of the unit, the

operator must have the abilities and

knowledge required for the type of work

to be carried out.

- Even after adequate documentation,

simulate a few test operations on rst

use, if necessary, so as to identify the

various controla and their main functions,

in particular those relating to start-up and

stoppage.

- Only use the unit for the purposes

foreseen by the manufacturer. Improper

use of the unit may result in risks for

the health and safety of persons, and in

damage to property.

- The appliance has been designed and

built to satisfy all the working conditions

indicated by the manufacturer. Tampering

with any of the devices in order to achieve

performance levels other than the ones

foreseen may result in risks for the health

and safety of persons, and in damage to

property.

- Do not use the unit if the safety devices

are not properly installed and operating

correctly. Failure to comply with this

requirement may result in severe risks for

the health and safety of persons.

- Keep the appliance in a state of maximum

efciency, by carrying out the planned

maintenance operations foreseen by

the manufacturer. If these are properly

carried out, they will ensure the appliance

provides optimum performance, a longer

working life and constant compliance with

the safety requirements.

- Before carrying out any maintenance

or adjustments, activate all the safety

devices provided and evaluate the need

to inform the persons working on the

machine and any persons in the vicinity. In

particular, make sure that the surrounding

areas are adequately marked and prevent

access to any of the devices that might, if

active, result in unexpected dangers and

risks to the health and safety of persons.

- Maintenance and adjustment operations

must only be carried out by persons

authorised to do so, who must ensure that

all the necessary safety precautions are

taken and that the procedures indicated

here are complied with.

- All maintenance operations that

require specic technical knowledge

or special abilities must only be carried

out by qualied technicians, who have

esperience in the specic sector of

operation.

- To carry out maintenance operations in

areas that are not easily accessible or

dangerouse, ensure that suitable safety

precautions are taken for yourselves and

others, in full compliance with current

laws on safety at work.

RULES FOR OPERATION AND USE

RULES FOR ADJUSTMENT AND MAINTENANCE

User Manual

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Each organisation has the job of applying

certain procedures to identify, evaluate and

control the inuence that its own activities

(products, services, etc.) have on the

environment.

The procedures to be followed to identify

signicant impacts on the environment must

take the following factors into account:

- Emissions into the atmosphere

- Discharge of liquids

- Waste management

- Contamination of the ground

- Use of raw materials and natural

resources

- Local problems relating to environmental

impact

In order to minimise environmental impact,

the manufacturer provides, below, a series of

indications that should be taken into account

by all those who, for whatever reason,

work with the appliance during its expected

working life.

- All packaging components must be

disposed of according to current laws in

force in the country in which said disposal

takes place.

- During installation, ensure that the

location is suitably ventilated, so as to

avoid any concentration of air that might

be unhealthy for operators.

- During use and maintenance, do not

disperse pollutants into the environment

(oils, greases, etc.) and make sure they

are disposed of separately according to

the composition of the various materials

and in compliance with current laws in

that regard. Electrical and electronic

components should be disposed of as

special waste.

- Keep noise levels down to reduce noise

pollution.

- When decommissioning, select all the

components according to their chemical

characteristics and dispose of them

according to type.

RULES FOR SAFETY FROM ENVIRONMENTAL IMPACT

SAFETY FOR THE DISPOSAL OF WASTE FROM ELECTRICAL

AND ELECTRONIC EQUIPMENT (WEEE DIRECTIVE 2002/96)

- Replace worn components with original

spare parts. Use the oils and greases in-

dicated in the manual. All this will ensure

that the machine retains the functions and

safety levels foreseen.

- Do not discard pollutants into the environ

-

ment. They must be disposed of accord-

ing to current laws.

- Waste from Electrical and Electronic

Equipment may contain dangerous

substances that are potentially harmful

for the environment and for public

health. They must always be disposed

of properly.

- When decommissioning, select all the

components according to their chemical

characteristics and dispose of them

according to type, in compliance with

current laws.

- With reference to the WEEE

directive (Waste from Electrical and

Electronic Equipment), the user, when

decommissioning, must separate the

electrical and electronic components and

dispose of them in special authorised

collection centres, or return them, still

installed, to the dealer on making a new

purchase.

- All the components that must be

removed and disposed of separately are

marked by a special indication.

- Unlawful disposal of Waste from

Electronic and Electrical Equipment

(WEEE) is punishable under the laws

in force in the country in which any

infringement is found.

User Manual

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- For example, to implement European

directives (2002/95/CE, 2002/96/CE,

2003/108/ CE) within Italy, a Decree

Law (No. 151 of 25 July 2005) has been

issued, foreseeing a  ne of 2000÷5000

€.

SAFETY AND INFORMATION SIGNS

The illustration indicates the position of the

signs af xed to the appliance.

Read the user manual: the

operator must read and fully

understand the whole contents

of the document to understand

the commands and functions

of the machine. Keep the

document within easy access.

Danger of electrocution:

never access areas that contain

live elements.

Danger of scalding: beware of

hot surfaces.

BA

User Manual

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PACKING AND UNPACKING

LOADING AND TRANSPORT

RECOMMENDATIONS FOR MOVEMENT AND INSTALLATION

INFORMATION ON MOVEMENT AND INSTALLATION

When moving and installing the appliance,

follow the indications provided by

the manufacturer and marked on the

packaging and in the instructions for

use. Those authorised to carry out these

operations must, if necessary, organise

a “safety plan” to safeguard the persons

directly involved.

The packaging, to reduce

working dimensions, may

vary according to the type

of transport being used.

To facilitate transport,

the appliance may be

shipped with some of its

components dismantled

and suitably protected

and wrapped.

Certain parts, particularly

electrical components, are protected with

damp-proof nylon.

All the information required to carry out

loading and unloading is indicated on the

packaging.

During unloading, check that the

components are undamaged and that all

the components are present.

The packing materials must be disposed of

in compliance with current laws.

The packaging may be:

A) on a pallet in a cardboard box

B) in a crate (for overland or air cargo

shipping)

Loading and transport, according to

the place of destination, may take

place using different means.

The following diagram illustrates the

most common solutions.

During transport, in order to avoid

sudden movements, make sure the

load is adequately fastened to the

vehicle.

means of transport

lifting

equipment

User Manual

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MOVEMENT AND LIFTING

STORAGE

INSTALLING THE UNIT

The unit can be moved using a fork lift

truck or hoist of suitable capacity.

To lift and move the unit with an overhead

hoist, use the U-bolts provided.

Before lifting, check that the load

is properly centred. Move the load

with care, so as to avoid sudden and

dangerous swinging.

In the event of prolonged inactivity, check

the conditions of the storage area, the type

of packaging and check that the conditions

are such as to ensure proper maintenance

of the unit.

Avoid storing in environments that are

damp or exposed to the weather.

All phases of installation must be

considered, from the time the general

plan was drawn up. Before starting

these phases, as well as dening

the installation area, the installation

technicial who will be carrying out

these operations must, if necessary,

implement a “safety plan” to safeguard

the persons directly involved from

harm, and must scrupulously follow all

laws, with particular reference to those

regarding mobile work sites.

Important

WITHOUT PACKING

MATERIALS

PACKING WITH

CARDBOARD BOX

PACKING IN A CRATE

max

2000

max length pipe 1000

no siphon

muffler at 30 cm down

the generator plane

max 1000

sea water inlet - generator plate

max

2000

max length pipe 1000

no siphon

max 1000

sea water inlet - generator plate

muffler at 30 cm down

the generator plane

User Manual

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The installation area must have suitable

environmental conditions (light, ventilation,

etc.).

The  oor, as well as having a load capacity

capable of bearing the weight and vibration

of the unit, must be stable and level to

guarantee proper support.

The installation area must have all the

supply and drainage connections required.

The applicance can be installed in a

number of ways (see  gure)

– installation above the water line

– installation below the water line

exhaust pipe

sea water  lter

cock

silencer

water line

sea water intake

silencer

anti-siphon valve

water line

exhaust pipe

sea water  lter

cock

sea water intake

INSTALLATION ABOVE THE WATER LINE

INSTALLATION BELOW THE WATER LINE

User Manual

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If the anti-siphon valve has to be  tted,

install it as shown in the  gure.

If the generator is too high on the water line it’s useful introduce after the cock

one-way valve to advantage the pump priming.

anti-siphon valve

Take care that water does

not stagnate in the drainage

pipe.

Important

User Manual

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Proceed as indicated.

1. -Identify the exact

position using the

boring template (A),

supplied in the pack,

and drill the holes.

2. -Insert the plugs (B)

provided.

3. -Position the unit in

the set area.

4. -Fix the unit to

the oor using

appropriate screws

(B).

5. -Identify the exact

position and, if

necessary, trace the

coordinates so as to

position the control

panel properly (C)

(see gure).

6. -Fix the control

panel (C) using the

screws (D) provided.

drilling

template (A)

block (B)

control panel (C)

screw (C)

screw (D)

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CONNECTION TO THE POWER SUPPLY

The connection must be carried out by

a quali ed, authorised technician, in

compliance with current laws and using

appropriate, prescribed materials.

Before carrying out any operation, turn

the main power supply off.

Only connect the battery after having

made all the electrical connections.

Important Important

Warning - Caution

230V (POWER

CABLES)

12V

(BATTERY

CHARGER)

LENGTH UP TO 6

M (BATTERY

CONNECTION)

LENGTH OVER 6 M

(BATTERY

CONNECTION)

4 mm

2

2.5 mm

2

16 mm

2

25 mm

2

Table of Cable Sections

Proceed as indicated.

1 -Open the door (E).

2 -Unfasten the screws to

dismantle the casing (F).

3 -Use cables of the correct

diameter (see “Table of

Cable Sections”).

4 -Connect the cable to

terminals (G) (230V

live and earth) on the

panelboard.

5 -Connect cable (H)

powering the control

panel to the socket (L).

6 -Connect the battery as

indicated in the following

paragraphs.

7 -Replace the casing (F)

and fasten the screws.

8 -Close the door (E) when

the operation has been

completed.

casing (F)

door (E)

cable (H)

terminals (G)

intake (L)

+ battery

fuel reserve indicator

battery charger

- battery

terminals

(G)

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