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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
-4-
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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GB
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 sacricial 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 identication (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
-6-
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 inuence 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 modications 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 specications,
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 identication plate shown here
is afxed di-rectly to the appliance.
A) Manufacturer identication
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 qualications
to carry out installation and testing of the
appliance.
Ordinary maintenance: series of
operations necessary to keep the
appliance in a state of proper efciency
and operation. These operations are
normally planned by the Manufacturer,
who sets down the qualications required
to carry them out and the intervention
method.
Special maintenance: series of operations
necessary to keep the appliance in a
state of proper efciency 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 qualications, 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 identication plate, the approximate
number of working hours and the type of
problem encountered.
User Manual
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GB
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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GB
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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GB
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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GB
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
sufciently 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 afxed 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 signicant 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 specic technical qualications,
abilities and experience that has been
acquired in and is recognised by the
specic 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 sufcient
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
sufcient 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
specic 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 dening 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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GB
- 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
efciency, 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 specic technical knowledge
or special abilities must only be carried
out by qualied technicians, who have
esperience in the specic 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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GB
Each organisation has the job of applying
certain procedures to identify, evaluate and
control the inuence that its own activities
(products, services, etc.) have on the
environment.
The procedures to be followed to identify
signicant 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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GB
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 dening
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
Important
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
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)
/