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Parts, Adjustment and
Maintenance Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
C US
ASPAS1CCA007 (6 kW NG, 7 kW LP)
ASPAS1CCA012 (12 kW NG, 12 kW LP)
LISTED
ASPAS1CCA015 (13 kW NG, 15 kW LP)
R
GENERAC
POWER SYSTEMS, INC.
R
Not intended for use as Primary Power in place of utility
!
!
or in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
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The operator is responsible for proper and safe use INTRODUCTION of the equipment. Carrier strongly recommends that the This Carrier model is a compact, high performance, dealer read this Parts, Adjustment and Maintenance air-cooled, engine-driven generator designed to Manual and thoroughly understand all instructions before automatically supply electrical power to operate critical using this equipment. Carrier also strongly recommends loads during a utility power failure. instructing other use
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Table of Contents Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Introduction ........................Inside Front Cover Section 2 – Troubleshooting ........................10 Read This Manual Thoroughly ..............................IFC 2.1 Troubleshooting Guide ......................................10 Contents ................................................................IFC Operation and Maintenance ..................................IFC How to Obtain Service ...........................
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SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to ! ! all operators and potential operators of this equipment. ! ! ! ! GENERAL HAZARDS WARNING: The engine exhaust from this product • For safety reasons, Carrier recommends that this contains chemicals known to the state equipment be installed, serviced and repaired by a Carrier of California to cause cancer, birth defects or
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ELECTRICAL HAZARDS FIRE HAZARDS • All generators covered by this manual produce • Keep a fire extinguisher near the generator at all times. dangerous electrical voltages and can cause fatal Do NOT use any carbon tetra-chloride type extinguisher. electrical shock. Utility power delivers extremely high and Its fumes are toxic, and the liquid can deteriorate wiring dangerous voltages to the transfer switch as well as the insulation. Keep the extinguisher properly charged and standby generator. Avoi
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Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 5. Use an accurate AC voltmeter to check utility power 1.1 BEFORE INITIAL START-UP source voltage across transfer switch terminals N1 Before starting, complete the following: and N2. Nominal line-to-line voltage should be 240 1. Set the generator’s main circuit breaker to its OFF (or volts AC. open) position. 6. Check utility power source voltage across terminals 2. Set the generator's AUTO
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Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 1.4 GENERATOR TESTS UNDER LOAD 1.5 CHECKING AUTOMATIC To test the generator set with electrical loads applied, OPERATION proceed as follows: To check the system for proper automatic operation, 1. Set generator’s main circuit breaker to its OFF (or proceed as follows: OPEN) position. 1. Set generator’s main circuit breaker to its OFF (or 2. Turn OFF all loads connected to the transfer switc
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Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 3. Turn on appliances, lights, pumps, etc., that are on 7. Turn utility power to the main distribution panel back the emergency circuits in an attempt to fully load the on. This can be done by switching the service main generator. Be cautious not to overload the generator. breaker to the on or closed position. Allow the Use the following chart as a guide: generator to shut down. Unit 120 Vo
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Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 9. Reverse procedure steps 1-5 to reinstall demand 14. It may be necessary to make minor adjustments to regulator. the preset adjustment screw settings to achieve maximum power, particularly at higher altitudes. If 10. Reverse the procedure to convert back to natural experiencing problems with the unit producing gas. maximum power, follow the procedure in Section 1.6 1.7.2 12KW AND 15KW, V-
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Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 6. When frequency is correct at no load, check the AC 7. Restart the unit. voltage reading. If voltage is incorrect, the voltage 8. Slowly turn the idle adjust screw to adjust the no-load regulator may require adjustment. idle frequency to 63-63.5 Hz (with top open). 9. The governor is now set. 1.8.2 12 KW AND 15 KW UNITS ◆ 1. Loosen governor clamp bolt (See Figure 1.6). 1.9 VOLTAGE REGULAT
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Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators • Remove the four screws attaching the valve cover with NOTES: a #2 or #3 phillips screwdriver. • Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine. While w
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Section 2 — Troubleshooting Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 2.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 1. Fuse blown. 1. Replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary. 3. Defective starter contactor. (7 kW) 3. * 4. Defective starter motor. 4. * 5. Dead Battery. 5. Charge or replace battery. The engine cranks but 1. Out of fuel. 1. Replenish fuel. will
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Section 3 — Maintenance Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators 3.1 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Carrier Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly if Repair is Needed. FUEL Fuel lines and connections*XM LUBRICATION Oil level XM Oil X AFTER BREAK-IN, AND Y Oil filter X AFTER BREAK-IN, AND Y COOLING Enclos
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240VAC UTILITY INPUT 12Vdc TRANSFER RELAY COIL NEUTRAL CONNECTION HOT HOT Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram — Single Cylinder — Drawing No. 0E9014 CONTROL PANEL BOX ENGINE WIRING ENGINE WIRING 225 224A 224 225A 33 224A CLOSEST TO BEARING 22 BATTERY BATTERY DIAGRAM KEY DIAGRAM KEY 11 225A BA CCHARGER HARGER ((UTILITY) UTILITY) 4 TX BCR BBA - BRUSH ASSEMBLY A - BRUSH ASSEMBLY 22 0 CB2 1144 BCR - BATTERY CHARGE RELAY BCR - BATTERY CHARG
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240VAC UTILITY INPUT 240VAC UTILITY INPUT 112Vdc TRANSFER 2Vdc TRANSFER RRELAY COIL ELAY COIL NEUTRAL CONNECTION NEUTRAL CONNECTION HHOT OT HOT HOT Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram — Single Cylinder — Drawing No. 0E9014 CONTROL PANEL BOX CONTROL PANEL BOX ENGINE WIRING 225 225 2224A 24A 2224 24 225A 225A 3 224A 224A CCLOSEST TO BEARING LOSEST TO BEARING 2 BATTERY DIAGRAM KEY 1 2225A 25A BBAA CHARGER (UTILITY) 44 TX TX BCR BCR BA - BR
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Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic — Single Cylinder — Drawing No. 0E9015 11 11 11 11 11 11 C2-6 22 22 22 22 22 22 C2-5 TX 240VAC 225A 225A 225A N2 N1 00 33 2225A 25A UTILITY 56VA 22 N2 N2 INPUT 2224A 24A 11 2224A 24A 224A BATTERY BATTERY 225B 225B N1 12Vdc 225 225 225 23 CHARGER CHARGER TRANSFER 224B 224B 1133 1VA RELAY 194 11 11 2222 00 1133 COIL 22 2225A 25A 2224 24 224 N1 11 99 99 77 77 BCR BCR F2 F1 22 11 66 33 44 + 15B 15 15
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Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic — Single Cylinder — Drawing No. 0E9015 11 11 11 11 1111 C2-6 C2-6 22 22 2222 22 22 CC2-5 2-5 TTXX 240VAC 240VAC 225A 225A 225A NN22 NN11 0 3 225A UTILITY UTILITY 556VA 6VA 2 N2 N2 N2 N2 IINPUT NPUT 224A 1 224A 2224A 24A BATTERY 225B NN11 112Vdc 2Vdc 225 2225 25 23 23 CHARGER TRANSFER TRANSFER 224B 13 1VA 1VA RRELAY ELAY 1194 94 11 22 0 13 COIL COIL 2 225A 224 2224 24 N1 N1 1 9977 BCR F2 F2 FF11 2
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240VAC UTILITY INPUT 12Vdc TRANSFER RELAY COIL NEUTRAL CONNECTION HOT HOT Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram — V-Twin — Drawing No. 0E9016 CONTROL PANEL BOX EENGINE WIRING NGINE WIRING 225 224A 224 225A 33 22 DDIAGRAM KEY IAGRAM KEY BBATTERY ATTERY 11 224A 225A CCHARGER HARGER BA - BRUSH ASSEMBLY BA - BRUSH ASSEMBLY CLOSEST TO BEARING BCR - BATTERY CHARGE RELAY BCR - BATTERY CHARGE RELAY TX 22 CCB1 - MAIN OUTPUT BREAKER B1 - MAIN OUTP
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2240VAC UTILITY INPUT 40VAC UTILITY INPUT 12Vdc TRANSFER 12Vdc TRANSFER RRELAY COIL ELAY COIL NEUTRAL CONNECTION NEUTRAL CONNECTION HOT HOT HHOT OT Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram — V-Twin — Drawing No. 0E9016 CCONTROL PANEL BOX ONTROL PANEL BOX ENGINE WIRING 225 225 224A 224A 2224 24 225A 225A 3 2 DIAGRAM KEY BATTERY 1 CHARGER 2224A 24A 2225A 25A BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CCLOSEST TO BEARING LOSEST TO BEARING T
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Section 4 - Electrical Data Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic — V-Twin — Drawing No. 0E9017 11 11 1111 11 C2-6 22 22 22 22 22 TX C2-5 225A 225A 225A N2 N1 240VAC 33 225A 225A UTILITY 56VA 22 224A 224A N2 N2 INPUT 11 2224A 24A 224A BBATTERY ATTERY 2225B 25B N1 12Vdc 225 225 225 CCHARGER HARGER 23 2224B 24B 13 13 1VA RELAY 13 13 194 22 COIL 224 224 224 N1 11 77 77 99 99 BCR BCR 11 66 33 44 1133 11 11 00 + - 1133 00 0 12VDC ACCESSORY SOCKET CUSTOMER CONNECTION
