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Beta Marine BetaGen 10, Installation Manual, Page: 2 / 116

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Beta Marine BetaGen 10 Installation Manual Download Page 2

Typical Heat Exchanger Cooling System

Typical Keel Cooling System

Images Are For Illustration Purposes 
& Not Necessarily Representative

Summary of Contents for BetaGen 10

Page 1: ...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 Heat Exchanger Keel Radiator Cooled BetaSe...

Page 2: ...Typical Heat Exchanger Cooling System Typical Keel Cooling System Images Are For Illustration Purposes Not Necessarily Representative...

Page 3: ...s we ask you to always provide the WOC Works Order Card number and or the engine serial number Please refer to page 4 Generating Set Type Power kVA Power kW Hz Frequency BETA WOC NO K Engine Type Alte...

Page 4: ...ine Lubrication 51 Bleeding the Fuel System 52 Control Modules Overview 54 Control Modules Installation 57 SECTION 2 INITIAL GENERATING SET ENGINE START UP 59 Initial Start Up 59 Normal Starting and S...

Page 5: ...n and recommendations given in this publication are based on the latest information available at the time of publication and are subject to alteration at any time The information given is subject to t...

Page 6: ...IIA 49T IIIA On the crankcase behind the fuel filter on the starboard side of the engine when viewed from the AC end BetaSet BetaGen 4 2 6 2 11 2 On the crank case below the fuel injection pump on the...

Page 7: ...SE DEATH IF THE GENERATING SET IS NOT CORRECTLY INSTALLED MAINTAINED AND USED IMPORTANT The decision to connect to the AC electrical output terminals of the generating set is the responsibility of a q...

Page 8: ...run at high speed and can cause injury if personnel or clothing come in contact with the belts or pulleys when the engine is running If not originally purchased with the generating set forward end al...

Page 9: ...installer must ensure that when connections are made they are clean and free of leaks G Oil The Beta Marine generating set is supplied with a dipstick for the engine Ensure the dipstick is returned a...

Page 10: ...little to influence the waveform because it depends upon the cyclic irregularity of the generating set inherent in the design of the engine and inertia of the set and the construction of the generator...

Page 11: ...ld be a heater element resistive load A system incorporating a larger electric motor could have a running power factor nearer to 0 8 Beta Marine Ltd sell equipment producing POWER and the units of pow...

Page 12: ...marine applications This means they are suitable for use on seagoing recreational and inland waterways craft Stage IIIA engines are only suitable for craft on European Inland Waterways if the vessel i...

Page 13: ...11...

Page 14: ...HP rpm HP rpm 9 6 1500 11 4 1800 Engine Prime Output kW rpm kW rpm 7 2 1500 8 5 1800 Starting Aid Glow Plug Firing Order 1 2 3 Valve Tip Clearance Cold mm in 0 145 0 185 0 0057 0 0072 Direction of Ro...

Page 15: ...800 17 8 1500 21 4 1800 20 6 1500 24 3 1800 10 1 1500 12 1 1800 13 3 1500 16 0 1800 15 4 1500 18 1 1800 12 3 1500 14 7 1800 16 2 1500 19 5 1800 18 7 1500 22 1 1800 9 2 1500 11 0 1800 12 1 1500 14 6 18...

Page 16: ...3 Phase 1500 rpm 0 8PF kVA 6 0 Typical Maximum Load In Amps Per Phase 415v Based On kW Electrical Load 7 0 Approxomate Fuel Consumption Prime Power 2 2 4 Pole 1800rpm 60Hz 120v 1 Phase NPE32 B 4 Maxim...

Page 17: ...3 6 3 6 NPE32 B 4 NPE32 D 4 NPE32 D 4 10 1 13 0 14 5 9 2 11 8 13 2 10 0 13 0 15 0 2 9 3 7 3 7 NPE32 D 4 NPE32 E 4 NPE32 E 4 9 7 15 5 17 6 8 8 14 1 16 0 64 6 94 0 107 0 3 1 4 3 4 6 NPE32 B 4 NPE32 D 4...

Page 18: ...500 29 5 1800 Engine Prime Output kW rpm kW rpm 18 8 1500 22 0 1800 Starting Aid Glow Plug Firing Order 1 3 4 2 Valve Tip Clearance Cold mm in 0 18 0 22 0 0071 0 0087 Direction of Rotation Counter Clo...

Page 19: ...3 1800 53 6 1500 62 8 1800 31 2 1500 38 2 1800 31 2 1500 38 2 1800 40 0 1500 46 9 1800 38 0 1500 46 6 1800 38 0 1500 46 6 1800 48 8 1500 57 2 1800 28 4 1500 34 8 1800 28 4 1500 34 8 1800 36 4 1500 42...

Page 20: ...hase 1500 rpm 0 8PF kVA 18 2 Typical Maximum Load In Amps Per Phase 415v Based On kW Electrical Load 20 2 Approxomate Fuel Consumption Prime Power 4 8 4 Pole 1800rpm 60Hz 120v 1 Phase ECP32 2S 4 Maxim...

Page 21: ...8 5 ECP32 3S 4 ECP32 3S 4 ECP32 3S 4 26 2 33 5 39 6 23 8 30 5 36 0 27 0 34 0 40 0 6 3 7 9 8 5 ECP32 1M 4 ECP32 2M 4 ECP32 2M 4 29 7 39 6 42 9 27 0 36 0 39 0 180 0 240 0 260 0 7 3 9 7 9 2 ECP28 2S 4 E...

Page 22: ...m 52 2 1500 61 5 1800 Engine Prime Output kW rpm kW rpm 39 0 1500 45 9 1800 Starting Aid Intake Air Heater When Required Firing Order 1 3 4 2 Valve Tip Clearance Cold mm in 0 23 0 27 0 0091 0 0106 Dir...

Page 23: ...769 230 0 3769 230 0 53 6 1500 62 8 1800 57 5 1500 67 6 1800 40 0 1500 46 9 1800 42 9 1500 50 5 1800 48 8 1500 57 2 1800 52 2 1500 61 5 1800 36 4 1500 42 7 1800 39 0 1500 45 9 1800 Intake Air Heater W...

Page 24: ...Phase 1500 rpm 0 8PF kVA 38 2 Typical Maximum Load In Amps Per Phase 415v Based On kW Electrical Load 43 0 Approxomate Fuel Consumption Prime Power 9 2 4 Pole 1800rpm 60Hz 120v 1 Phase ECP32 2M 4 Maxi...

Page 25: ...5 0 38 6 40 9 134 0 142 0 9 2 10 4 ECP32 2M 4 ECP32 2M 4 45 0 48 0 40 9 43 6 47 0 49 0 9 2 10 3 ECP32 3L 4 ECP32 3L 4 49 5 52 8 45 0 48 0 300 0 320 0 10 5 11 8 ECP32 2M 4 ECP32 2M 4 53 4 58 0 50 0 52...

Page 26: ...pm 10 0 3000 11 8 3600 Engine Prime Output kW rpm kW rpm 7 5 3000 8 8 3600 Starting Aid Glow Plug Firing Order 1 2 Valve Tip Clearance Cold mm in 0 145 0 185 0 0057 0 0072 Direction of Rotation Counte...

Page 27: ...6 3600 34 8 3000 36 2 3600 8 2 3000 9 7 3600 12 3 3000 14 6 3600 26 0 3000 27 3 3600 10 0 3000 11 8 3600 15 0 3000 17 8 3600 31 8 3000 32 9 3600 7 5 3000 8 8 3600 11 2 3000 13 3 3600 23 7 3000 24 5 36...

Page 28: ...0 8PF kVA Typical Maximum Load In Amps Per Phase 415v Based On kW Electrical Load Approxomate Fuel Consumption Prime Power 2 Pole 3600rpm 60Hz 120v 1 Phase S16F 180 Maximum AC Output 60Hz 1 Phase 3600...

Page 29: ...0 39 0 52 0 2 3 3 5 4 5 ECP28 M 2 ECP28 2L 2 13 7 23 1 12 5 21 0 14 0 23 0 3 6 5 9 S16F 180 ECP28 M 2 ECP28 2L 2 7 7 14 0 17 0 7 0 12 7 15 4 58 0 85 0 103 0 2 9 4 2 4 8 ECP28 M 2 ECP28 2L 2 15 0 24 0...

Page 30: ...9 3600 Engine Prime Output kW rpm kW rpm 23 7 3000 24 5 3600 Starting Aid Glow Plug Firing Order 1 3 4 2 Valve Tip Clearance Cold mm in 0 145 0 185 0 0057 0 0072 Direction of Rotation Counter Clockwis...

Page 31: ...e 3000 rpm 0 8PF kVA 25 5 Typical Maximum Load In Amps Per Phase 415v Based On kW Electrical Load 28 0 Approxomate Fuel Consumption Prime Power 7 1 2 Pole 3600rpm 60Hz 120v 1 Phase ECP28 VL 2 Maximum...

Page 32: ...ng or hot parts of the engine that could cause personal injury should be effectively shielded Engine parts and accessories that require frequent inspection and or servicing must be readily accessible...

Page 33: ...C electrical alternator and an air outlet with an electric powered extraction fan which should be located as high as possible in the engine compartment room maximising ventilation and reducing ambient...

Page 34: ...image 12a depending on installation requirements the anti vibration mounts may be positioned either between the generating set feet and base frame or between the vessels seating and base frame should...

Page 35: ...against the rising piston with the consequences possibly being a bent con rod s an emulsified engine oil and or a damaged fuel pump Seawater syphoning past worn impellers in the seawater pump flooding...

Page 36: ...se injection bends that may add either 15 cms or 20 cms to the height If it is still not enough then an antisyphon vacuum valve must be fitted 50 cms above the loaded water line sea level Please refer...

Page 37: ...ractically possible so that all the water can drain down into it The waterlock should have sufficient capacity to hold an exhaust system full of water draining into it Always create a gooseneck with t...

Page 38: ...eawater raw water to cool the closed circuit system via the heat exchanger 1 It is very important that the seawater inlet should have a strainer system either A built into the sea cock or B a high lev...

Page 39: ...ling This is very dangerous as the exhaust will eventually fill and sea raw water will back up into the engine through the exhaust valve Catastrophic failure will result as soon as the engine is resta...

Page 40: ...have a surface area that is exposed to the canal river or sea water of 0 25 x the hp of the engine the square feet of cooling tank area required for steel hulls KEEL COOLING SKIN TANKS BetaSet BetaGen...

Page 41: ...Supply Return Pipe 28mm 28mm 28mm 28mm 28mm 32mm 32mm 32mm 32mm Baffle Gap Minimum 30mm 30mm 30mm 30mm 30mm 30mm 30mm 30mm 30mm Baffle Gap Maximum 40mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm 40mm BetaSet...

Page 42: ...en water is allowed to enter the combustion chamber via the exhaust and hydraulics against the rising piston with the consequences possible being a bent con rod s an emulsified engine oil and or a dam...

Page 43: ...RE Exhaust back pressure should be as low as possible it is increased by long exhaust length and sharp bends Keep exhaust systems to a minimum length and have gradual bends avoid tight angled elbows B...

Page 44: ...you experience an outbreak of bacterial growth you can either empty and clean out your fuel pipes and tank or use biocide additives and filtering Low sulphur diesel fuel regulations changed recently r...

Page 45: ...ne must be secured separated and protected from any source of significant heat The filling storage venting fuel supply arrangements and installation must be designed and installed so as to minimise th...

Page 46: ...hen run the engine off load for 10 minutes Allow to cool to a safe temperature then re check the level and top up as necessary Check the calorifier feed pipe to see if it is starting to warm Run the e...

Page 47: ...rating set the kit is supplied loose but the required 3 8 BSPT is pre installed ready for connection If a kit is retrospectively being fitted the engine thermostat housing will require drilling and ta...

Page 48: ...lant overflow pipe WARNING New engines are supplied with the engine coolant drained off ENGINE COOLANT The coolant solution must be a mixture of 70 50 fresh water and 30 50 anti freeze This requiremen...

Page 49: ...to fully cool down before removing the pressure cap and topping up the engine coolant to 25 mm 1 below the filler neck Subject to installation it maybe possble to place a drip tray or container to cat...

Page 50: ...ctically possible The reason for this is to ensure that the maximum voltage from the battery is available to the starter motor The longer the cable run the more the voltage drop will be due to resista...

Page 51: ...Cranking Amp Cable Volt drop Max length both cables added together 7 10 12 4 2 6 2 11 2 22 2 25 2 100 0 00017V 4 7m 14 21 120 0 00017V 3 9m 35mm2 2 AWG Cable BetaSet BetaGen Cranking Amp Cable Volt dr...

Page 52: ...of oil or SAE rating Do not use lubricant additives and or fully synthetic lubricating oil WARNING New engines are supplied with the engine lube oil drained off AC ELECTRICAL INSTALLATION WARNING ELEC...

Page 53: ...vel is too low add new oil to the engine to the specified level please refer to image 39 When using an oil of a different make or viscosity from the previous one drain out the old oil Never mix two di...

Page 54: ...cause an explosion Fuel must be removed from skin to prevent infection 41 Fuel filter bleed bolt The fuel filter will be located HEAT EXCHANGER BetaSet BetaGen 7 10 12 Forward end starboard side when...

Page 55: ...with no bubbles come out of the fuel filter bleed bolt please refer to image 43 8 Shut tighten the fuel filter bleed bolt please refer to image 40 or 41 The hand priming lever or button will be locat...

Page 56: ...LPM Remote Control Module EPM72 KEY SWITCH START STOP PROTECTION MODULE STANDARD FOR THE BETASET BETAGEN 26 THROUGH TO 49 Standard for generating sets specified with electrical insulated return engine...

Page 57: ...e not included but are available at additional cost Separate Hours Run Meter Beta Marine Generating Set RSM72 Local Control Module LPM72 Remote Control Module 99mm 80mm 80mm 68mm DSE3110 MANUAL AUTO S...

Page 58: ...C functionality and dual mutual standby to reduce engine wear The module can be easily configured using the DSE Configuration Suite PC software Selected front panel editing is also available The DSE73...

Page 59: ...oots back over themselves and then push the 2 plug sockets together check all pins are fully engaged then use a cable tie to lock them together A Pack the protective plastic boots with petroleum jelly...

Page 60: ...RSM720 Local Module Connection The RSM720 local module has 3 connection blocks all of which are sculpted One connection block has 10 pins a second has 9 pins and the third has 8 pins the module conne...

Page 61: ...dules will allow 3 attempts to start before engine shut down on fault protection engages INITIAL ENGINE START UP POINTS If the engine has not started after 3 attempts there is a possibility that air i...

Page 62: ...ed for 10 seconds the module will shut down on overcrank fault protection and the warning light will illuminate 3 Once the engine has run up to operating speed the engine protection hold off timer wil...

Page 63: ...nce done all engine fault protection circuits become live All lights except DC on should stop illuminating In the event of a engine protection fault the appropriate light will illuminate and the engin...

Page 64: ...ction circuit on start up for 18 seconds after initial firing Both fail to start lights will not illuminate Both running lights will not illuminate Both charge fail lights will not illuminate for up t...

Page 65: ...Temperature AC alternator over speed Engine Fault Warning The generating set will not automatically shut down for the following engine fault warning DC Alternator charge fail NB Please note that both...

Page 66: ...Change engine lubricating oil Change oil filter Check for leaks on header tank tubestack Tighten end cap bolts if required Drain off any water in fuel water separator AFTER 150 HOURS If shallow sump...

Page 67: ...nd fastenings Check condition of all coolant fuel oil pipes and clamps Lubricate keyswitch on control panel with petroleum jelly WD40 or equivalent if applicable Check sacrificial anode replace if nec...

Page 68: ...the most common cause for electrical faults check on a regular basis please refer to Electrical Fault Finding within trouble shooting 45 BETAGEN ACOUSTIC ENCLOSURE BetaGen acoustic enclosures should b...

Page 69: ...tities of engine oil required please refer to pages 12 to 29 1 Run the engine for 10 minutes to warm up the oil then stop it and open the oil filler cap 2 Your engine is provided with a sump drain pum...

Page 70: ...from the AC alternator end BetaSet BetaGen 26 33 40 49 40T IIIA 49T IIIA Aft engine starboard side when viewed from the AC alternator end BetaSet BetaGen 4 2 6 2 11 2 22 2 25 2 Forward End port side...

Page 71: ...tarboard side when viewed from the AC alternator end BetaSet BetaGen 14 21 Under air filter starboard side when viewed from the AC alternator end BetaSet BetaGen 26 33 40 49 40T IIIA 49T IIIA Aft engi...

Page 72: ...the same direction as they were before the impeller was removed NB If any pieces of rubber impeller are missing then they must be located as they are most likely to be trapped in the entrance to or wi...

Page 73: ...semble using new O rings The tube stack can be fitted either way around but must be aligned correctly with the horizontal line and rubber seal between the alignment marks at the exhaust end of the hea...

Page 74: ...then tighten link bolt 4 Check that the depression of the belt at position shown is approximately 1 2 or 12 mm when pushed down firmly by thumb Tighten support bolts Please refer to image 61 5 Belt t...

Page 75: ...tilation Air flow in Air flow out 66 SF16 Ventilation Air flow out Air flow in 64 NPE Ventilation Air flow out Air flow in 67 BetaGen Ventilation Air flow out Air flow in IMPORTANT Do not attempt this...

Page 76: ...and trickle charge as appropriate f Fuel tanks should be kept full during the lay up period to eliminate water condensation in the tank Water entering the fuel injection system can cause considerable...

Page 77: ...Check wiring to the plugs and replace plugs if they have burnt out Stop solenoid stuck in off position Check solenoid is free to return to the run position Problem Starter motor will not turn or turn...

Page 78: ...is too low this must be 850 min Increase engine tick over speed Faulty stop solenoid Disconnect wiring to solenoid If running improves check for a wiring fault Broken fuel injection pump spring Replac...

Page 79: ...ubricating oil heat exchanger cooled Possible Cause Solution Oil goes milky due to seawater entering Check installation has an anti syphon valve been fitted exhaust manifold Change engine oil and run...

Page 80: ...mum output is required For further information please visit www betamarine co uk Problem Engine overheats heat exchanger cooled The most common cause of overheating is insufficient seawater flow due t...

Page 81: ...gn engine modify bed Injectors blocked through excess carbon Remove and check injector nozzles replace if required caused by water in the fuel Problem Battery quickly discharges Possible Cause Solutio...

Page 82: ...ally supplied with the generating set and follow the instructions for Check of residual voltage and Alternator does not excite These processes are known as field flashing For all other AC alternator f...

Page 83: ...ng illuminates PSM720 only screw on the pre heat timer at the rear of the module and adjust to approximately 6 seconds maximum NB Although the EPM72 RSM72 LSM72 do not have a pre heat warning light al...

Page 84: ...rrect replace fuel solenoid with new Insulated Return Relay Panels will be mounted in the following areas The generating set engine does not start but starter is No fuel check the fuel tank level and...

Page 85: ...rating set engine pre heat is not operating Time the duration of the programmed pre heat engine not cranking period is correct 6 seconds maximum Check connections on the engine harness to preheat rela...

Page 86: ...ystem Heat Exchanger Header Tank or Radiator pressure cap check that it is not loose or faulty replace cap should it be required High exhaust back pressure must not exceed the stated back pressure by...

Page 87: ...f the impeller has a vane missing it will be lodged either in the pipe leading to the heat exchanger or within it this must be located and removed The tube stack within the heat exchanger may be block...

Page 88: ...s these connections are harder to distinguish between in poorly lit areas Whilst doing this check integrity of each connection to ensure terminals have not become damaged Once checked re fit cable tie...

Page 89: ...26 33 Grounded Earth Wiring Page 93 9 BetaSet BetaGen 7 12 14 21 26 33 40 40T IIIA 6 2 11 2 22 2 25 2 Insulated Return Wiring Page 94 10 BetaSet BetaGen 49 49T IIIA Insulated Return Wiring Page 95 11...

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Page 104: ...are preapproved in accordance with Stage IIIA of the Directive except where mentioned For detailed list please contact Beta Marine Ltd or refer to our website The person empowered to sign on behalf of...

Page 105: ...tial to cause skin cancer In the case of contact immediately rinse skin with plenty of water for several minutes and then wash contact area with soap and water Keep out of reach of children The rules...

Page 106: ...104 Notes...

Page 107: ...105 Notes...

Page 108: ...rificial Anode 209 61840 Heat Exchanger O Rings 2 x 212 07273 Heat Exchanger Seawater Pump Impellor Kit Inc O Ring Belt Drive Pump 207 02132 KIT Heat Exchanger Seawater Pump Impellor Kit Inc O Ring Ge...

Page 109: ...80110 207 09041 KIT 207 09041 KIT 207 02132 KIT 7 7 207 09042 KIT 214 00292 214 00292 600 01361 214 63090 Q 214 63090 Q 214 96830 PNA PNA PNA PNA PNA PNA BetaSet Gen 26 BetaSet Gen 33 BetaSet Gen 40...

Page 110: ...n Earth Starter Battery Alternator V Drive Belt PNA Heat Exchanger Seawater Pump V Drive Belt PNA 2 Pole Generating Set Model BetaSet Gen 25 2 Heat Exchanger Fuel Filter 211 60210 SET or 211 02817 GEN...

Page 111: ...Set Gen 11 2 BetaSet Gen 22 2 211 60210 211 60210 211 60210 SET or 211 02817 GEN 211 60210 211 60210 211 60210 SET or 211 02817 GEN 211 63760 211 63760 211 60390 211 08132 211 08132 211 08132 209 6184...

Page 112: ...Record Service Date Responsible 1 Commissioned 2 First 25 hours 3 First 50 hours 4 Every 150 hours with shallow sump 5 Every Year Every 250 hours if sooner 6 7 8 9 Every Year Every 750 hours if sooner...

Page 113: ...111 Service Date Responsible 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32...

Page 114: ...112 Service Date Responsible 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48...

Page 115: ...Service Date Responsible 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64...

Page 116: ...Beta Marine Limited Davy Way Waterwells Quedgeley Gloucester GL2 2AD UK Tel 44 0 1452 723492 Fax 44 0 1452 883742 Email sales betamarine co uk Website www betamarine co uk Ref OM 221 20033 REV 13 0220...

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