Installation instruction

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1 Installation instruction Intercalated generator CIC Reference : /2008 Complete 12V or 24V system Wet or gel battery 1

2 Installation instructions - Intercalated generator Table of contents Safety instructions... 3 Delivery content... 4 Overview... 5 Electrical connectors... 6 Installation... 7 Connection of the cooling circuit... 8 Connection of the output of the cooling circuit... 9 Electrical connection Output Control system of the regulator Electric voltage selection Electrical isolation of the generator

3 Safety instructions Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, and your machinery. I Electric shock Do not operate this machinery without electrical enclosures and covers in place. Shut off electrical power before accessing electrical equipment. Use insulated mats whenever working on electrical equipment. Make sure your clothing and skin are dry, not damp when handling electrical equipment. Remove wristwatch and all jewelry when working on electrical equipment. Do not connect utility shore power to vessel s AC circuits, except through a ship-to-shore double throw transfer switch. Damage to vessel s AC generator may result if this procedure is not followed. Electrical shock results from handling a charged capacitor. Discharge capacitor by shorting terminals together. The voltage at the terminals of the generator and the regulator can reach several hundred Volts while the engine is running. Do not manipulate the terminals while the engine is running. Do not touch AC electrical connections while engine is running, or when connected to shore power. Lethal voltage is present at these connections! I Burn risks Always check the engine coolant level at the coolant recovery tank. In case of an engine overheat, allow the engine to cool before touching the engine or checking the coolant. Do not touch hot engine parts or exhaust system components. A running engine gets very hot! Steam can cause injury or death! I Fire risks Prevent flash fires. Do not smoke or permit flames or sparks to occur near the carburetor, fuel line, filter, fuel pump, or other potential sources of spilled fuel or fuel vapors. Use a suitable container to catch all fuel when removing the fuel line, carburetor, or fuel filters. Do not operate with the air cleaner/silencer removed. Do not smoke or permit flames or sparks to occur near the fuel system. Keep the compartment and the engine/ generator clean and free of debris to minimize the chances of fire. Wipe up all spilled fuel and engine oil. I Explosion risks Follow re-fueling safety instructions. Keep the vessel s hatches closed when fueling. Open and ventilate cabin after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine. All fuel vapors are highly explosive. Use extreme care when handling and storing fuels. Store fuel in a wellventilated area away from spark-producing equipment and out of the reach of children. I Accidental starting Make certain all personnel are clear of the engine before starting. Make certain all covers, guards, and hatches are reinstalled before starting the engine. I Battery explosion Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing. Never connect the negative ( ) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation of explosive gases. To avoid sparks, do not disturb the battery charger connections while the battery is being charged. Avoid contacting the terminals with tools, etc., to prevent burns or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery. Always turn the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last when servicing the battery I Battery acid When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which is destructive. If it comes in contact with your skin, wash it off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps. Battery explosion can cause injury or death! I Magnetic power Rotor has strong permanent magnetic power (50kgf) 3

4 Installation instructions - Intercalated generator Delivery content The equipment supplied by Nanni Diesel can vary depending on your order. Intercalated generator Diameter :340 mm Thickness : 125 mm Weight : 35 kg Electronic regulator Length: 470 mm Width: 126 mm Height: 106 mm Weight: 8.8 kg Cooling hoses x2 Diameter : 15 mm Length: 6 m Clamps x5 5. Connector 18 plugs & 1 shunt & 2 pods 6. Cable 24 mm 2 three-phase x3 4

5 Installation instructions - Intercalated generator Overview You have chosen a Nanni Diesel product, thanks for your confidence! The compact intercalated generator (CIC) is an electrical power generating device. It can be coupled to the entire Nanni Diesel engine range from 21 to 200 hp, between the flywheel housing and the transmission (shaft line, sail-drive or other). Its cooling system allows an intensive use of the electric generator. The system concept allows to obtain an output close to 85%, without needing preventive maintenance. The regulator also allows to adapt to the type of batteries (wet or gel) thanks to two levels of load. It can produce it s maximum amperage without battery, and can tolerate a sudden disconnection of the batteries and/or of the load without damage. The output voltage of the regulator is constant and independent of the load and batteries. If the load is too important, the temperature of the regulator will increase. At 85 C, the maximum avail - able current is reduced by half. If the temperature reaches 95 C, the power is cut off. The system restarts once that the temperature has dropped. In case of big overload, the current continue to increase, but the output voltage decreases, like power supply. I Warning: We strongly recommend to equip the onboard electrical system with an adequate set of protection for the persons and the objects Once the system is installed and correctly connected to the electrical system of the boat, the regulator begins to operate once the engine is start. It can deliver a continuous power of 4kW when the engine is running at at least 1500 rpm. Until that point, the power delivered by the regulator depends on the engine rpm, as shown in the curves below. kw kw For 24V parallel output For 12V parallel output rpm rpm I Warning: If the batteries had been used for a long time or are unloaded, do not run the engine with the regulator at less than 1500 rpm. In every case, adapt the engine rpm according to the energetic needs. 5

6 Overview Electrical connectors U V W Terminals of the generator (CIC-1) Three-phases output terminals of the generator UVW. I Warning : The voltage at the terminals of the generator can reach several hundred Volts while the engine is running. Correctly fix the carter and do not manipulate the terminals while the engine is running. CIC- 1 Input terminals of the regulator (CIC-2) Three-phases output terminals of the regulator UVW. I Warning : Like the generator, the voltage at the regulator terminals can reach several hundred Volts when the engine is running. Do not manipulate the terminals when the engine is running. U W CIC- 2 V Output terminals of the regulator (CIC-3) 4 output terminals to the batteries. Each pair is independent: 2x 12V 160A or 2x 24V 80A. This output can be coupled to generate: 12V 300A or 24V 160A. CIC- 3 6

7 Installation instructions - Intercalated generator Installation CIC- 4 1 Electronic regulator The electronic regulator (1) is corrosion protected in order to improve its resistance in saltwater environment. The protective casing and terminals are not watertight. It s recommended to place the regulator horizontally in a secure place to protect it from water, shock and vibration, as shown in picture CIC-4. Fix the regulator on a fixed and solid support using screws and washers Ø10 (not provided). Install the regulator as near as possible of the engine in order to be compliant with the recommend cables length. I Warning : If the regulator has to be mounted to a wall, it s recommended to place it vertically as shown on the picture CIC-5 (cooling connectors upward) CIC- 5 CIC- 6 7

8 Installation Connection of the cooling circuit CIC 7 2 To the water outlet Hoses Ø15 Clamps Ø15 To the engine Engine seawater pump 2. Electronic regulator 3. Generator The system is cooled by the passing of seawater in the circuit as shown on the outline above (CIC-7). This circuit is feed by the seawater pump of the engine, water goes first through the regulator then in the generator. The Internal cooling circuit of the regulator and generator are suitable for seawater and freshwater. Use only the hoses supplied by Nanni Diesel. The connectors of the cooling circuit are hexagonal, make sure to tighten the hose clamps correctly. Test the circuit for leaks. The flow of the cooling system must be 2 litres / minute minimum. After the installation of the cooling circuit, the temperature of the regulator must be control at full load. The output power may be reduce of 50% and cause a failure if the temperature is too high. 8

9 Installation Connection of the output of the cooling circuit The water of the cooling circuit must be discharged after it has passed through the generator. As the circuit is under pressure, it s recommended to fixedly connect the output hose. Preferably, use the floating stuffing box connected to the shaft to drain the water. If it s not possible, connect the hose to the waterlock as shown below. If these two options are not possible, connect the hose directly on the hull. Evacuation 1. Exhaust 2. Waterlock 3. Stuffing box CIC- 8 9

10 Installation instructions - Intercalated generator Electrical connection Instrument panel generator CIC- 9 U V W 9 8 relay Charging lamp regulator Battery Parallel output (Continuous current) The system start automatically via a relay (not provided) which is controlled by the instrument panel as indicated in the picture CIC-9. Once the electronic regulator is installed and connected to the cooling circuit, it must be electrically connected according to the following instructions Remove the protection cover (1) on the generator then connect and tighten the 3 phases cables on the terminals U, V, W on the generator (CIC-10). The copper area of each of the three cables must be at least 24 mm2 and the length of the cables must not exceed 2 meters. It s recommended to use the cables supplied by Nanni Diesel. CIC Connect and tighten the 3 phases cables coming from the terminals of the generator on the terminals of the regulator (Picture CIC -11). Fix the cables (1) mechanically in order to avoid mechanical constraints on the connections. Cover the terminals with insulation caps (2) (not provided). CIC

11 Electrical connection Output 3. Connect and tighten the cables at the terminals of the regulator on the DC output side (picture CIC-12). Protect the connections with insulation rubber caps (not provided). Minimum cables cooper area: - 12V: 24 mm2 for each output. - 24V: 12 mm2 for each output. For a parallel output, double the copper area. CIC Connect the cables to the batteries, be careful to respect the polarity. The length of the cables must be as short as possible. The connections must be tighten and protected from corrosion and from shortcuts. The picture CIC-13 is an example of a configuration with parallel output. I Warning: If the polarity is reversed at the battery terminals during the connection, the electronic regulator will be permanently damaged! This can happen at the first contact even if the unit has not been turned on. I Warning: The electrical system must be equipped with an adequate set of protection for the persons and the objects. CIC

12 Electrical connection Control system of the regulator 9 8 Connect the electric wires in the terminals 8 and 9 of the connector (see diagram CIC-9 page 8) The terminal 8 is connected to the charging lamp. The terminal 9 is connected to the positive of the battery via the relay. The relay is controlled by the terminal 15/54 of the contact key on the instrument panel (CIC-15). The signal lamp switch off once the system is on load. I Warning: Do never disconnect the terminal 9 when the engine and the generator are running, this operation must be done when the engine is stopped. CIC 14 1 Red 7 mm 2 2 Black 3 mm 2 3 Brown 7 mm 2 4 Brown 1 7 mm 2 5 White 3 mm Purple 1 mm 2 8 Gray 1 mm 2 9 Yellow / Green 1 mm 2 10 Yellow / Green 1 1 mm 2 11 Blue 1 mm 2 terminal 15/ battery 7 mm battery 3 mm 2 3 Starter 7 mm 2 4 Preheating 7 mm 2 5 Stop 3 mm D+ alternator 1 mm 2 8 Oil switch 1 mm 2 9 Water switch 1 mm 2 10 Water sender 1 mm 2 11 Revolution counter 1 mm 2 CIC 15 12

13 Electrical connection Electric voltage selection 2 The electronic regulator allow to choose the tension load. Thanks to this process, the tension load can be adjust in accordance to the type of battery. The selection for a «wet» or a «gel» battery can be done if the terminals 2 and 11 of the connector are connected. The selection is active once the system is restart. 11 CIC- 16 Battery 12V Battery 24V A constant tension will be provided at the terminals of the regulator if the shunt is made or not, like indicated : With shunt (recom gel) Output tension : 14,4V Output tension : 28,8V W/o shunt Output tension : 13,9V Output tension : 27,9V 13

14 Electrical connection Electrical isolation of the generator I Warning : This step is very important in order to detect a defect on the electrical insulation of the generator after the connection of the cables. Every generator is tested in our factory, but this check must also be done by the installer after the set up of the system. The test must be done on a generator that is already coupled on an engine and a gearbox and when the engine is stopped. Take off the protective casing on top of the generator, then control the resistance (in Ω) between the terminal U and the casing of the generator. The value must be infinite (like an open circuit). Repeat this operation for the terminals V and W. Perform this operation with a multimeter set to position «ohmmeter». If an electric resistance appears, do not start the system and contact your dealer. 14

15 15

16 Nanni Industries S.A.S. 11, Avenue Mariotte - Zone Industrielle BP La Teste France Tel : + 33 (0) Fax : +33 (0) contact@nannidiesel.com Nanni Industries SAS This document is made as an user guide for the installation of the Nanni Diesel intercalated generator. This document don t cover all the possibilities but give some recommendations and advices for the installation of this device. Pictures, schemas, texts and informations contained in this document are based on the characteristics of the product available at the publication. Nanni Diesel reserve the right to modify the document without prior notice 16

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