Armstrong A50CU User Manual

Date: 10/01/07

OWNERS MANUAL

CUMMINS SERIES:

MODELS A50CU, A75CU, A05CU, A200CU, A300CU, A400CU,
A500CU, A600CU, A830CU, A1000CU

SAVE THESE INSTRUCTIONS

This manual contains important instructions regarding for all
Armstrong Power Systems LLC power generator Models. The
information contained here must be followed during installation
and maintenance of the generator and batteries. Keep this

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 2

SAVE THESE INSTRUCTIONS

This manual contains important instructions regarding for all Armstrong
Power Systems LLC power generator Models. The information contained
here must be followed during installation and maintenance of the genera­tor and batteries. Keep this manual with the equipment. If the equipment
is traded or sold, give the manual to the new owner.

You are now the owner of a Armstrong Power generator powered by
CUMMINS engine. All our components keep the highest standards in
quality, efficiency and durability.

Each unit pass thru a complete test and inspection to guarantee the
quality of your unit. We provide warranty on every component subject to
the warranty coverage and limitations.

To get the best results from your new generator please read carefully
this document before starting the unit and follow the instructions.

If you have any question regarding your equipment please call your
dealer or contact us. Please have the generator model, and serial num­bers when you call. Parts may be obtained directly from our distributors.

Once again thank you for your trust in Armstrong Power and welcome to
our family.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

The warranty period for the power generator begins on the date of sale and continues for a period of 2 years or 1500 hours (what ever comes first).

Responsibilities: a) As the owner, you are responsible for the performance of the required maintenance listed on your operators manual. b) Armstrong Power may

deny your warranty coverage if your engine or part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Coverage: Armstrong Power warrants that your unit shall be free from defects in materials and workmanship which cause the unit to fail. During the period mentioned

above from the date of the original sale.

Limitations: this warranty certificate shall not cover any of the following. a) Repair or replacement required because of misuse or neglect, improper maintenance,

repairs improperly performed or replacements not conforming to Armstrong Power specifications that adversely affect performan ce and/or durability, and alteration or

modifications not recommended or approved in writing by Armstrong Power. b) Replacement of parts and other services and adjustments necessary for required

maintenance at and after the first scheduled replacement point.

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WARRANTY CERTIFICATE

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1. INTRODUCTION

This manual provides general safety information for installing, operating and maintenance of Armstrong Power

equipments. The purchaser should comply with the instructions and information in this manual, and is strongly ad­vised that all personnel to be associated with the equipment supplied should be made familiar with the information
contained herein.

It is essential that the personnel engaged in the installation, commissioning and maintenance of this equipment are

both competent and experienced in these fields, and that they comply with the relevant statutory requirements and
regulations, including he provisions of the Health and Safety act 1974, and any such modifications and amendments
which may subsequently become a legal requirement.

The equipment supplied by Armstrong Power should be installed by, or under the supervision of, competent person-

nel in accordance with good engineering practice, established codes of practice, those statutory requirements appli­cable to the installation site, the IEE regulations as applicable and, where the appropriate, in accordance with any
instructions specifically advised by the company.

You are requested, in accordance with the needs of safe operation and the provisions of the act, to take such steps

as are necessary to ensure that the appropriate information on the proper use and handling of our equipment is
made available by yourself to all those concerned. Similarly, this information must be available to anyone who may
purchase, or otherwise acquire from your self, such products for use in their own premises.

2. GENERAL

The generating set is designed to be safe when used in the correct manner. The following safety precautions, if fol-

lowed will minimize the possibility of accidents. Before performing any procedure or operating technique, it is up to

the user to ensure that it‘s safe. The generating set should only be operated by personnel who are authorized and

trained.

Warning:

 Read and understand all safety precautions, and warnings before operating the generating set.
 Failure to follow the instructions, procedures and safety precautions in this manual may increase the possibility

of accidents and injuries.

 Never start the generating set unless it is safe to do so.
 Do not attempt to operate the generating set with a know unsafe condition.
 If the generating set is unsafe, fit danger notices and disconnect the battery negative (-) lead so that it cannot

be started until the condition is corrected.

 Disconnect the battery negative (-)lead prior to attempting any repairs or cleaning inside the enclosure, if

equipped.

 Appropriate firefighting equipment is to hand.
 The metal work on every part of the generating set must be connected by means of an earth continuity conduc-

tor to an effective earth point.

 Care must be taken to avoid spillage from the batteries.
 No loose items or combustible material should be left on or against any part of the generator.
 Do not risk injury by coming into contact with moving parts of the plant, or by allowing anything to be draw in

by the cooling fan or intake system.

 Install and operate this generating set only in full compliance with relevant National, local or federal codes,

standards or other requirements.

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3. FIRE AND EXPLOSION

Risk of serious injuries or death

 Don‘t touch the battery charger or the connections during the battery charging process.
 Always disconnect the negative terminal from the battery before to start any work on the unit.

 Keep the room, the floor and the generating set clean. When spills of fuel, oil, battery electrolyte or coolant occur

they should be cleaned up immediately.

 Never store flammable liquids near the engine.
 Store oily rags in covered metal containers.
 Avoid refilling the fuel tank while the engine is running.
 Do not attempt to operate the generating set with any known leaks in the fuel system.

Fuels and fumes associated with generating sets can be flammable and potentially explosive.
Proper care in handling these materials can dramatically limit the risk of fire or explosion.
However, safety dictates that fully charged BC and ABC fire extinguishers are kept on hand.
Personnel must know how to operate them.

 The acids in the battery can cause explosion.
 Avoid any contact between the tools and the terminals in the battery.
 Never use metallic objects on the neck or hands when handling the set.
 Never connect the negative terminal from the battery to the positive terminal from

the starter.

 Don‘t smoke or allow sparks, flames or other sources of ignition around the fuel or bat-

teries.

 Use adequate equipment to take fuel from the set.
 Never test the battery by touching together the terminals.
 Ensure the generating set room is properly ventilated.

4. INSTALLATION, HANDLING AND TOWING

 Make electrical connections in compliance with relevant electrical codes, standards or other requirements. This in-

cludes requirements for grounding and ground/earth faults.

 For stationary generating sets with remote fuel storage systems, make sure such systems are installed in compliance

with relevant codes, standards or other requirements.

 Engine exhaust emissions are hazardous to personnel. The exhaust for all indoor generating sets must be piped out-

doors via leak-free piping in compliance with relevant codes, standards and other requirements. Ensure hot exhaust
silencers, piping and turbochargers, if equipped, are clear of combustible material and are guarded for personnel
protection per safety requirements. Ensure that fumes from the exhaust outlet will not be hazard.

 Never lift the generating set by attaching to the engine or alternator lifting lugs. Use a sling with a ―spreader bar‖

connected to the base frame.

 Ensure the lifting rigging and supporting structure is in good condition and has capacity suitable for the load.
 Keep all personnel away from the generating set when it is suspended.
 Make sure all personnel are out of the generating set canopy or container, if equipped, before closing and latching

enclosure doors.

 When towing a mobile generating set, observe all codes, standards or other regulations and traffic laws. These in-

clude those regulations specifying required equipment and maximum and minimum speeds. Ensure brakes, if fitted,
are in good order.

 Do not permit personnel to ride in or on the mobile generating set. Do not permit personnel to stand or ride on the

drawbar or to stand or walk between the generating set and the towing vehicle.

 Do not install or use the generating set in any classification of hazardous environment unless it has been specifically

designed for that environment.

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5. MECHANICAL

The generating set is designed with guards for protection from moving parts. Care
must still be taken to protect personnel and equipment from other mechanical
hazards when working around the generating set.

 Do not attempt to operate the generating set with safety guards removed.

While the generating set is running do not attempt to reach under or
around the guards to do maintenance or for any other reason.

 Keep hands, arms, long hair, loose clothing and jewellery away from pul-

leys, belts and other moving parts.

Attention!! Some moving parts con not be seen clearly when

the set is running.

 Keep access doors on enclosures, if equipped, closed and locked when not

required to be open.

 Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces and

sharp edges and corners.

 Wear protective clotting including gloves and hat when working around the

generating set.

 Do not attempt to remove the radiator filler cap until the coolant has cooled. Then loosen the cap slowly to relive

any excess pressure before removing the cap completely.

 Ethyl ether starting aids must not be used on engines with combustion air preheating devises. These starting aids

will reduce the efficient working life of the engine.

6. CHEMICAL

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Fuels, oils coolants, lubricants and battery electrolyte used in this generating set
are typical of the industry. However they can be hazardous to personnel if not
treated properly.

 Do not swallow or have skin contact with fuel, oil, coolant, lubricants and

battery electrolyte. If swallowed, seek medical treatment immediately. Do
not induce vomiting if fuel is swallowed. For skin contact, wash with soap
and water.

 Do not wear clothe that has been contaminated by fuel or lube oil.
 Wear an acid resistant apron and face shield or goggles when servicing

the battery. If electrolyte is spilled on skin or clotting, flush immediately
with large quantities of water.

 Always keep good ventilation when the equipment is working. Carbon

Monoxide inhalation cause death. Always maintain inspection routine of
the exhaust system.

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7. NOISE

Generating sets that are not equipped with sound attenuating enclosures can produce
noise levels in excess of 105 dBA. Prolonged exposure to noise levels above 85 dBA is
hazardous to hearing.

 Ear protection must be worn when operating or working around an operating

set.

8. ELECTRICAL

Safe and efficient operation of electrical equipment can be achieved only if the equip­ment is correctly installed, operated and maintained.

 The generating set must be connected to the load only by trained and quali-

fied electricians who are authorized to do so, and in compliance with rele­vant electric codes, standards and other regulations.

 Ensure the generating set, is effectively grounded/earthed in accordance

with all relevant regulations prior operation.

 The generating sets should be shutdown with the battery negative (-) termi-

nal disconnected prior to attempting to connect or disconnect load connec­tions.

 Do not attempt to connect or disconnect load connections while standing in

water or on wet or soggy ground.

 Do not touch electrical energized parts of the generating set and/or inter-

connecting cables or conductors with any part of the body or with any non
insulated conductive object.

 Place the control panel cover as soon as connection or disconnection of the

load cables is complete. Do not operate the generating set without the
cover securely on place.

 Connect the generating set only to loads and/or electrical systems that are com-

patible with it‘s electrical characteristics and that are within it‘s rated capacity.

 Be sure all power is disconnected from the electrical equipment being serviced.
 Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut, abraded or oth-

erwise degraded. Replace terminals that are worm, discolored or corrode. Keep terminals clean and tight.

 Insulate all connections and disconnected wires.
 Use only class BC or Class ABC extinguishers on electrical fires.

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9. FIRST AID FOR ELECTRIC SHOCK

Identification / look out for:

 Unconsciousness and Burns
 Establish site of entry and exit of electric shock

What to do:

 Switch off the main switch.
 Break the contact between electrical source and patient using dry non-conductive object like wooden stick.
 Call for help.
 If breathing and heartbeat has stopped begin CPR

1. CALL
Check the victim for unresponsiveness. If there is no response, Call 911 and return to the victim. In most locations
the emergency dispatcher can assist you with CPR instructions.

2. BLOW

3. PUMP

Tilt the head back and listen for breathing. If
not breathing normally, pinch nose and cover
the mouth with yours and blow until you see
the chest rise. Give 2 breaths. Each breath
should take 1 seconds.

If the victim is still not breathing normally, coughing or moving, begin chest
compressions. Push down on the chest 11/2 to 2 inches 30 times
right between the nipples. Pump at the rate of 100/minute, faster than once
per second.
CONTINUE WITH 2 BREATHS AND 30 PUMPS UNTIL HELP ARRIVES.

In unconscious patient with intact breathing and pulse recovery position en­sures the prevention of tongue falling back and blocking the airway.

What to do:

 Place the patient on their back.
 Lift the chin to ensure the air way is open.
 Patient's arm on your side should be positioned so as to make a right angle

with his body, with elbow bent and palm facing out.

 Patient's other arm on opposite side should be placed across the chest, with

back of their hand against the cheek on your side of the patient.

 Pull up the patient's knee joint (side away from you) as it bends with the foot

flat on the ground.Roll over the patient in this position towards your side.

 By tilting the patient's head back ensure that the airway is open.
 The uppermost leg should be adjusted in such a way that the hip and knee

are at right angles.

Seek immediate medical help / ambulance.

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10. SPECIAL CONSIDERATIONS FOR BATTERY

CAUTION – The electrolyte is a dilute sulfuric acid that is harmful to the skin

and eyes. It is electrically conductive and corrosive. The following procedures are
to be observed:

1) Wear full eye protection and protective clothing,

2) Where electrolyte contacts the skin, wash it off immediately with water,

3) Where electrolyte contacts the eyes, flush thoroughly and immediately with water and
seek medical attention, and

4) Spilled electrolyte is to be washed down with an acid neutralizing agent. A common
practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon
(4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of
reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the
area dried.

CAUTION – Lead-acid batteries present a risk of fire because they generate

hydrogen gas. The following procedures are to be followed:

1) DO NOT SMOKE when near batteries,

2) DO NOT cause flame or spark in battery area, and

3) Discharge static electricity from body before touching batteries by first touching a
grounded metal surface.

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GENERATING SET
INSTALLATION

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1. LOCATION

The generating set sub base tank or frame (if it‘s the case)

is specifically designed for ease of moving the set. Improper
handling can cause serious damage to the generator and
components.
Never lift the generating set by attaching lugs to the engine
or alternator. Shackles and chains of suitable length and
lifting capacity must be used. A spreader bar is required to
prevent damaging the set.

See the drawings:

The location for a generator is dependent on applicable
codes and associated support systems for the generator
such as ventilation, wiring, fuel, and exhaust.

The following factors should be considered:

 The ideal location for any generator is away from ex-

treme ambient temperatures and where the generator
is protected from adverse weather conditions. It is
recommended that generator be as close to the load it
is supporting as possible.

 The structure where the Generator Set will be set upon

must be strong enough to support the weight of the
Gen-Set, its' auxiliary equipment, and other equipment
mounted on the structure.

 The structure must meet a 1 hour non-combustion fire

rating.

 The installation site must be clean, dry and not subject

to flooding.

 Because of excessive ambient temperatures associ-

ated with the use of stand-alone metal sheds from
exposure to sunlight, a concrete pad with a supported

roof and an outside security enclosure (fence) to pro­tect the unit from vandalism, birds, rodents, and other
small animals is recommended.

 The Gen-Set generates heat while running. Installing

the Gen-Set in a tightly enclosed building or shed is not
recommended. The site must provide for adequate
cooling and ventilation with a minimum of duct work.
Adequate ventilation for a generator is specified in
cubic feet per minute.

 The site must permit engine exhaust gases to be piped

away to an area that is uninhabited by people or ani­mals. Care must be given to ensure that exhaust gases
do not re-enter an occupied area.

 The outside site must provide access to the generator

to allow for maintenance, service, and repair. A three
foot (.914 meter) service clearance around the unit is
recommended.

 Fuel supply and ease of refueling must be taken into

consideration.

 Adequate normal and emergency lighting must be pro-

vided in any installation.

1.1. GROUND/FLOOR LOADING

The foundation for the generator must support the total
weight of the generator. This includes fuel, oil, and the
weight of any associated support systems.

Plan for 3 feet (1 Meters) of access around the generator
for maintenance, service and repair.

When calculating the floor loading, ensure the fuel weight,
cooling system fluids (where applicable), piping, pumps,
power cables/runways and supporting structures are in­cluded in the calculations.

2. MOUNTING

A concrete foundation with anchored mounting bolts, is
recommended. Steel Beams are an acceptable alternative.
Foundations help in the servicing and repair of Gen-Set's
and protect the unit from moisture that could occur from
seepage. The concrete base that the generator is mounted
to should be separate and independent from the surround­ing structure.

The following applies to concrete bases:

A Single (See Figure 1)or Double (See Figure 2) pedestal
base may be used. A height of at least 6 inches higher than
floor level is recommended.

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Figure 1- Single Pedestal Concrete Mount

Figure 2 - Double Pedestal Concrete Mount

 A double pedestal base allows easier cleaning under

most generator's.

 Double pedestals provide better access for inspecting

for oil or fuel tank leaks.

 The generator should be retained to the pedestal base

with fasteners that are recommended by the generator
set manufacturer.

 The concrete base should extend beyond the genera-

tor's "Footprint" by at least 12 Inches (305 mm) on all
sides.

 The higher the mounting base is made, the easier the

unit will be to work on when performing maintenance,
service, or repairs. Typically bases are required to be
raised at least 6 inches (153 mm) above floor level.
Placing the unit higher than 6 inches sometimes has
the advantage of making it easier to change the unit's
oil.

 Passing fuel lines and electrical conduit for a "stub-up"

through the concrete base is a standard practice of
gen-set installers.

 Concrete foundations are typically mixed by volume.

The typical ratio of cement, sand, and aggregate is
1:2:3 with a maximum 4 inch (102 mm) slump and 28
day compressive strength of 2500 psi (173 kPa).

 A generator can typically be mounted to a combustible

floor or roof, dependent upon code, however, the sur­face beneath the engine and beyond the engine to a
minimum distance of 12 inches (305 mm) must be

covered with a non combustible insulation and a mini­mum of 24 gage sheet metal between the insulation
and the generator. See Figure 3.

Figure 3. Combustible Floor and Roof

 Optional vibration isolators beyond those already built

in the generator also help reduce transmitted noise,
however, it is recommended that one verify that the
generator manufacturer recommends the use of an
isolator.

 Insulation must be a non-combustible material, typi-

cally a Fiberglas mat.

3. VENTILATION

3.1. OUTDOOR INSTALLATIONS - AIR COOLED UNITS

If your generator is expected to be in temperatures lower
than -20oF(-29oC) a cold weather package may be required.

The following general rules apply:

 Where strong prevailing winds are anticipated, face the

engine end away from the wind.

 Plan the installation carefully to prevent the cooling air

vents on the generator from becoming clogged by
leaves, grass, snow, etc.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL