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Serial Number
QT
2.5L
25kW
Model: 005212-0
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.
Cover018 Rev. 0 09/05 Part No. 0F7922
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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 .........................................................................2090 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 186 CONNECTION CIRCUIT BREAKER 178 WIRES TO 183 BOX Out 178 GENERATOR CONNECTION Battery Charger BOX Input GROUND TO GENERATOR 120 Volt + Neutral CONNECTION BOX Grd To Generator Control Panel FRAME RAIL CIRCUIT BREAKER SIZE KW VOLTS / AMPS LUG SIZE 25 240 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 EXHAUST MANIFOLD PROCEDURE 1. If necessary, clean gasket surfaces on exhaust AUTHORIZED SERVICE FACILITIES manifold and cylinder head. 2. Install exhaust manifold and exhaust manifold gasket. Before working on the generator, ensure the fol- 3. Install fasteners. lowing: NOTE: � The AUTO/OFF/MANUAL switch is in the OFF Exhaust manifold fasteners must be tightened in position. two stages. � The 15A fuse has been removed from the
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Standby Generator Sets Maintenance Figure 10.2 — Cylinder Head Installation CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level (Figure 10.3) at least every 20 hours of operation, or prior to use. � Remove oil dipstick and wipe dry with a clean, lint- free cloth. � Install oil dipstick, then remove again. � Oil should be between FULL and ADD marks. � If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL
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Standby Generator Sets Maintenance MAI NTENANCE OWNER/ DANGER OPERATOR CAN PERFORM Do not attempt to adjust the governor. Only qualified service facilities should adjust the CHECK ENGINE OIL LEVEL governor. Excessively high operating speeds Refer to “Checking Fluid Levels”. are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not CHECK BATTERY available and may shorten engine life. Correct � See “Checking
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Standby Generator Sets Maintenance Finally, have the insulation resistance of stator and SPARK PLUGS rotor windings checked. If insulation resistances are Reset the spark plug gap or replace the spark plugs excessively low, the generator may require drying. as necessary (Figure 10.4). 1. Clean the area around the base of the spark plugs BATTERY to keep dirt and debris out of the engine. Clean All lead-acid storage batteries discharge when not in by scraping or washing using a wire brush a
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Standby Generator Sets Maintenance BATTERY REPLACEMENT Battery electrolyte fluid is an extremely corro- When replacing batteries, use the same number and sive sulfuric acid solution that can cause severe the type of battery that follows: burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective BCI Group No. CCA goggles, protective clothing and gloves when 26 525 @ 0 deg. F handling a battery. If fluid is spilled, flush the affected area imme
