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Serial Number
QT
2.4L
45kW
Model: 005261-0
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.
Cover043 Rev. 0 02/06 Part No. 0G0201
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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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Stationary Emergency Generator Important Safety Instructions INTRODUCTION This symbol points out potential fire hazard. Thank you for purchasing this model of the Stationary Emergency 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
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Stationary Emergency Generator 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 con
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Stationary Emergency Generator Important Safety Instructions � Before performing any maintenance on the gen- � Stationary Emergency Generators installed with erator, disconnect its battery cables to prevent an automatic transfer switch will crank and start accidental start-up. Disconnect the cable from the automatically when normal (utility) source volt- battery post indicated by a NEGATIVE, NEG or (–) age is removed or is below an acceptable preset first. Reconnect that cable last. level. To
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Stationary Emergency Generator 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- Stationary Emergency Generator Model and erator’s lower connection
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Stationary Emergency Generator Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol rent Stationary Emergency Generator. It is powered base anti-freeze and deionized water. Cooling system by a gaseous fueled engine operating at 1800 rpm for capacity is listed in the specifications. Use only deion- 4-pole direct drive units, 3600 rpm for 2-pole direct ized water and only low s
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Stationary Emergency Generator Engine Protective Devices OVERCRANK SHUTDOWN ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required After a prespecified duration of cranking, this func- to operate for long periods of time without an opera- tion ends the cranking if the engine has failed to tor on hand to monitor such engine conditions as start. The overcrank LED will turn ON. Turn OFF the coolant temperature, oil pressure or rpm. For that AUTO/OFF/MANUAL switch, then t
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Stationary Emergency Generator Fuel Systems P ROPANE 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 Stationary Emergency Generator may be equipped expansion from the liquid to the vapor state. The with one of the following fuel systems: vapor withdrawal system is generally best suited for � Natural gas fuel system
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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 45 240 1 Ø
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Stationary Emergency Generator General Information ALTERNATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING See “Voltage Codes”. This Stationary Emergency CONNECTIONS Generator may be rated at any one of three voltages, either single-phase or three-phase. The electrical 3-PHASE ALTERNATORS wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the The Stationary Emergency Generator is designed voltage/phase required for the application. If
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Stationary Emergency Generator 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 Stationary Emergency Generator has been properly properly serviced with the recommended types installed,
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Stationary Emergency Generator Installation � Battery charger connection to 120 VAC. � Insert the fuse into the control panel. � Move the AUTO/OFF/MANUAL switch to the MAN- � Communication wires connected between transfer UAL position. The engine should now crank and switch and generator (HTS only). start. � Unit secured to pad. � Check voltage at the generator terminals. � For 3-phase units, check phase rotation at the START-UP CHECKLIST transfer switch terminals. The generator phase rotati
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Stationary Emergency Generator Operation STATIONARY EMERGENCY 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
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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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Stationary Emergency Generator Service Schedule SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW 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,
