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Serial Number
2.4L
35kW
Model: 005259-0
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
This manual should remain with the unit.
Cover040 Rev. 0 02/06 Part No. 0G0238
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Standby Generator Sets Table of Contents OPERATION ...........................................................9-1 SECTION PAGE Generator Control and Operation ................................9-1 SAFETY RULES ................................................ 1-1 Operating Unit with Manual Transfer Switch ...............9-1 INTRODUCTION .....................................................1-3 Engine Start-up and Transfer ...................................9-1 Read this Manual Thoroughly .........
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Standby Generator Sets Important Safety Instructions SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. GENERAL HAZARDS WARNING: � For safety reasons, the manufacturer recommends The engine exhaust from this product that this equipment be installed, serviced and contains ch
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Standby Generator Sets Important Safety Instructions � Before performing any maintenance on the gen- � Generators installed with an automatic transfer erator, disconnect its battery cables to prevent switch will crank and start automatically when accidental start-up. Disconnect the cable from the normal (utility) source voltage is removed or is battery post indicated by a NEGATIVE, NEG or (–) below an acceptable preset level. To prevent such first. Reconnect that cable last. automatic start-
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Standby Generator Sets Important Safety Instructions INTRODUCTION This symbol points out potential fire hazard. Thank you for purchasing this model of the standby generator set product line. This symbol points out potential electrical shock hazard. Every effort was expended to make sure that the information and instructions in this manual were The operator is responsible for proper and safe use both accurate and current at the time the manual was of the equipment. The manufacturer st
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Standby Generator Sets General Information NOTE: IDENTIFICATION RECORD For actual information related to this particular DATA LABEL model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data Every generator set has a DATA LABEL that contains label affixed to the unit. important information pertinent to the generator. The data label, which can be found attached to the gen- Generator Model and Serial Number erator’s lower connection box, lists the un
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Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol rent generator set. It is powered by a gaseous fueled base anti-freeze and deionized water. Cooling system engine operating at 1800 rpm for 4-pole direct drive capacity is listed in the specifications. Use only deion- units, 3600 rpm for 2-pole direct drive units and ized water and only low silicate a
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Standby Generator Sets Engine Protective Devices OVERCRANK SHUTDOWN ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for After a prespecified duration of cranking, this func- long periods of time without an operator on hand to tion ends the cranking if the engine has failed to monitor such engine conditions as coolant tempera- start. The overcrank LED will turn ON. Turn OFF the ture, oil pressure or rpm. For that reason, the engine AUTO/OFF/MANUAL switch, then tur
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Standby Generator Sets Fuel Systems PROPANE VAPOR WITHDRAWAL FUEL SYSTEM FUEL SYSTEM This type of system utilizes the vapors formed above FUEL REQUIREMENTS the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel The standby generator may be equipped with one of expansion from the liquid to the vapor state. The the following fuel systems: vapor withdrawal system is generally best suited for � Natural gas fuel system smaller engines that r
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Standby Generator Sets Specifications COOLING SYSTEM SPECIFICATIONS Type ...................................................Pressurized Closed Recovery GENERATOR Water Pump .................................................................... Belt Driven Type ............................................................................. Synchronous Fan Speed .........................................................................2150 rpm Rotor Insulation ........................................
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Standby Generator Sets Specifications Figure 1 — Interconnections Utility In Transfer Switch CONTROL PANEL NEUTRAL TO ALTERNATOR Gen N1 NEUTRAL N1 N2 N2 23 23 194 GENERATOR 194 Load 4- # 14 GA CONNECTION 186 CIRCUIT BREAKER WIRES TO 178 183 BOX Out 178 GENERATOR CONNECTION Battery BOX Charger Input GROUND TO GENERATOR 120 Volt + CONNECTION BOX Neutral Grd To Generator Control Panel FRAME RAIL CIRCUIT BREAKER SIZE KW VOLTS / AMPS LUG SIZE 35 240 1 Ø
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Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING See “Voltage Codes”. This generator may be rated CONNECTIONS at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC con- 3-PHASE ALTERNATORS nection (lower) panel should be installed according to the number of leads and the voltage/phase required The generator is designed to supply 3-phase electri- for the application. If there are any questions
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Standby Generator Sets Installation PRIOR TO INITIAL START-UP INSTALLATION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. Prior to initially starting the generator, it must PREPARATION BEFORE START-UP be properly prepared for use. Any attempt to The instructions in this section assume that the crank or start the engine before it has been standby generator has been properly installed, ser- properly serviced with the recommended types viced, tested, a
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Standby Generator Sets Installation � Check voltage at the generator terminals. START-UP CHECKLIST � For 3-phase units, check phase rotation at the transfer switch terminals. The generator phase rotation must match the utility phase rotation. Before working on the generator, ensure the fol- � Check for coolant, fuel, oil, and exhaust leaks. lowing: � Close the generators main line circuit breaker. � The AUTO/OFF/MANUAL switch is in the OFF � Turn the generator set off. position. � Connect
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Standby Generator Sets Operation GENERATOR CONTROL AND OPERATION Do not crank the engine continuously for longer Refer to the appropriate control panel operator’s than 30 seconds, or the heat may manual for this unit. damage the starter motor. � Let engine stabilize and warm up. OPERATING UNIT WITH MANUAL � Check all applicable instrument and gauge read- ings. When certain that all readings are correct, TRANSFER SWITCH move the transfer switch manual handle to its If the generator was
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Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY COOLING SYSTEM Air intake and outlet openings in the generator com- AUTHORIZED SERVICE FACILITIES partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions as high grass, weeds, brush, leaves and snow. Before working on the generator, ensure the fol- Without sufficient cooling and ventilating air flow, the lowing: engine/generator quickly overheats, which causes it � The AUTO/OFF/M
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Standby Generator Sets Maintenance Figure 10.1 - Oil Dipstick and Oil Fill Cap EXERCISE SYSTEM Start the generator engine at least once every seven Oil Fill Cap days and let it run at least 20 minutes. See “Weekly Exercise Cycle”. INSPECT COOLING SYSTEM � Inspect engine cooling system. See “Maintenance Oil Schedule”. Dipstick � Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found. � Check hose clamps for tightness. CHECK ENGINE COOLANT LEVEL See “Checking Flu
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Standby Generator Sets Maintenance Figure 10.3 – Engine Air Cleaner CHANGING ENGINE OIL Refer to maintenance performed by authorized service Air Cleaner facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning. This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container. 3. When a
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Standby Generator Sets Maintenance BATTERY MAINTENANCE MISCELLANEOUS MAINTENANCE The battery should be inspected per Section 4.7, CLEANING THE GENERATOR Scheduled Maintenance. The following procedure should be followed for inspection: Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- 1. Inspect the battery posts and cables for tightness erator windings have an adverse effect on insulation and corrosion. Tighten and clean as necessary.
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Standby Generator Sets Service Schedule SERVICE SCHEDULE 30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use calendar time, from the
