Bryant ASPAX1BBA015 User Manual
C
U
S
Installation and
Owner’s Manual
Air-cooled Automatic
Standby Generators
Model: ASPAX1BBA015
(13 kW NG, 15 kW LP)
LISTE
D
GENERAC
POWER SYSTEMS, INC.
*This manual should remain with the unit.*
Not intended for use as Primary Power in place of utility
or in life-support applications.
R
R
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
INTRODUCTION
Thank you for purchasing this model of the Bryant
product line. This model is a compact, high performance, air-cooled, engine-driven generator designed
to automatically supply electrical power to operate
critical loads during a utility power failure.
This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either
vapor withdrawn liquid propane (LP) or natural gas
(NG).
This unit meets the 1998 and later California
emissions regulations. To ensure that the engine
continues to meet these regulations, refer to the
following information and instructions in this
owner’s manual.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood,
contact the nearest dealer for starting, operating and
servicing procedures.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death, in addition to severe
property damage.
After this heading, read instructions that, if not
strictly complied with, may result in serious personal injury or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict
compliance with the special instructions while
performing the service are essential to preventing
accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates follows:
This symbol points out important safety infor-
mation that, if not followed, could endanger
personal safety and/or property of others.
This symbol points out potential explosion haz-
ard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly recommends instructing other users to properly
start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
CONTENTS
This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts, for model:
• Model ASPAX1BBA015 – 13 kW NG, 15 kW LP, Vtwin GT-990 Engine
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a dealer. Normal
maintenance service and replacement of parts are the
responsibility of the owner/operator and, as such, are
not considered defects in materials or workmanship
within the terms of the warranty. Individual operating
habits and usage contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See a dealer for service aids
and accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact a dealer for assistance. Service technicians are factory-trained and are capable of handling
all service needs.
When contacting a dealer about parts and service,
always supply the complete model number and serial
number of the unit as given on its data decal, which
is located on the generator.
The Bryant Dealer is:
Dealer Name
Address
City State Zip
Model No.______________ Serial No._______________
Table of Contents
15 kW Generator
Introduction ........................Inside Front Cover
Read This Manual Thoroughly ........................ IFC
Contents .......................................................... IFC
Operation and Maintenance ............................ IFC
How to Obtain Service ..................................... IFC
Safety Rules ........................................................2
Standards Index ..................................................3
Section 1 – General Information ...................4
1.1 Unpacking/Inspection .................................... 4
1.2 Location ........................................................ 4
1.3 Protection Systems ........................................4
1.4 System Set LED ............................................4
1.5 The Generator ...............................................5
1.6 Specifications ................................................ 6
1.6.1 Generator ........................................... 6
1.6.2 Engine ................................................ 6
1.7 Fuel Requirements and Recommendations ...6
1.8 Fuel Consumption ......................................... 6
1.9 Reconfiguring the Fuel System ......................7
1.9.1 15 kW, 990cc Engines ........................7
1.10 Location ........................................................ 7
1.10.1 Generator ........................................... 7
1.10.2 Transfer Switch .................................. 8
1.11 Battery Installation ........................................ 8
1.12 The Battery ................................................... 8
Section 2 – Post Installation Start-up
and Adjustments .........................9
2.1 Before Initial Start-up ....................................9
2.2 Check Transfer Switch Operation .................9
2.3 Electrical Checks ..........................................9
2.4 Generator Tests Under Load ....................... 10
2.5 Checking Automatic Operation .................... 10
2.6 Adjusting the Regulator (Natural Gas Only) .. 11
2.7 Engine Governor Adjustment ...................... 12
2.7.1 15 kW Units ..................................... 12
2.8 Voltage Regulator Adjustment ...................... 12
Section 3 – Operation ....................................12
3.1 Break-in Procedure .....................................12
3.2 Using the Auto/Off/Manual Switch ............... 13
3.2.1 “Auto” Position ..................................13
3.2.2 “Off” Position....................................13
3.2.3 “Manual” Position ............................. 13
3.3 Automatic Transfer Operation ..................... 13
3.3.1 12 VDC Accessory Outlet .................13
3.3.2 120 VAC GFCI Outlet ....................... 14
3.4 Sequence of Automatic Operation ...............14
3.5 Manual Transfer Operation .........................14
3.5.1 Transfer to Generator
Power Source .....................................14
3.5.2 Transfer Back to Utility
Power Source .....................................15
3.6 Setting the Exercise Timer .......................... 15
3.7 Protection Systems ......................................15
3.7.1 Low Oil Pressure Switch .................. 15
3.7.2 High Temperature Switch .................15
3.7.3 Overcrank ........................................16
3.7.4 Overspeed ........................................ 16
Section 4 – Maintenance ...............................16
4.1 Fuses ...........................................................16
4.2 Checking the Engine Oil Level ..................... 16
4.3 Changing the Engine Oil .............................. 16
4.3.1 Engine Oil Recommendations .......... 16
4.3.2 Oil Change Procedure .......................17
4.4 Changing the Oil Filter ................................ 17
4.5 Changing the Engine Air Cleaner ................. 17
4.5.1 15 kW Generators ............................ 17
4.6 Spark Plug(s) .............................................. 17
4.7 Battery Maintenance ....................................18
4.8 Adjusting Valve Clearance ........................... 18
4.9 Cooling System ...........................................19
4.10 Attention After Submersion .........................19
4.11 Corrosion Protection ................................... 19
4.11.1 Additional Corrosion Protection .......19
4.12 Out of Service Procedure ............................. 20
4.12.1 Removal From Service......................20
4.12.2 Return to Service ............................. 20
4.13 Service Schedule ......................................... 21
Section 5 – Troubleshooting ........................ 22
5.1 Troubleshooting Guide ................................ 22
Section 6 – Mounting Dimensions ............. 23
Section 7 – Electrical Data ........................... 24
Section 8 – Exploded Views and
Parts Lists ................................... 28
Section 9 – Warranty ..................................... 40
1
IMPORTANT SAFETY INSTRUCTIONS
15 kW Generator
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, service and repair technicians for this equipment.
The engine exhaust from this product
contains chemicals known to the state
defects or other reproductive harm.
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before
installing,operating or servicing this equipment.
Become familiar with this Owner’s Manual and with
the unit. The generator can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to
the unit are, therefore, not all-inclusive. Any personal
injury or property damage resulting from the use of a
procedure, work method or operating technique not
specifically recommended by the manufacturer, shall
be the sole responsibility of the operator. Operators
who deviate from manufacturer recommended safety
procedures and operating techniques, or fail to take
the necessary precautions, do so at their own risk.
WARNING:
of California to cause cancer, birth
WARNING:
DANGER
Despite the safe design of this generator, oper-
ating this equipment imprudently, neglecting its
maintenance or being careless can cause possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
2
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and maintenance of this equipment is carried out by a dealer.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict compliance with applicable codes and standards.
Following installation, do nothing that might render the system unsafe or in noncompliance with
such codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The
generator MUST be installed outdoors.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and contact the
nearest dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent
accidental start up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
ELECTRICAL HAZARDS
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as does the standby generator when it is in operation. Avoid contact with bare wires, terminals,
connections, etc., while the unit is running. Ensure
all appropriate covers, guards and barriers are in
place before operating the generator. If work must
be done around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical system.
• After installing this home standby electrical system, the generator may crank and start at any time
without warning. When this occurs, load circuits
are transferred to the STANDBY (GENERATOR)
power source. To prevent possible injury if such a
start and transfer occur, always set the generator’s
AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the 7.5A
and 15A fuses from the generator control panel.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.
FIRE HAZARDS
• For fire safety, the generator must be installed
and maintained properly. Installation always must
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher near the generator at all
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for
use on the standby electric system. Keep the extinguisher properly charged and be familiar with its
use. Consult the local fire department with any
questions pertaining to fire extinguishers.
IMPORTANT SAFETY INSTRUCTIONS
15 kW Generator
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install
the fuel supply system according to applicable
fuel-gas codes. Before placing the home standby
electric system into service, fuel system lines must
be properly purged and leak tested according to
applicable code. After installation, inspect the fuel
system periodically for leaks. No leakage is permitted.
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and laws, the published information listed
below may be used as installation guide for this
equipment.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, avail-
able from the Food and Energy Council, 909
University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND
MAINTENANCE OF FARM STANDBY ELECTRICAL
SYSTEMS, available from the American Society
of Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
3
Section 1 — General Information
15 kW Generator
DANGER
Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for
damage.
• This standby generator set has been factory supplied with a weather protective enclosure that is
intended for outdoor installation only.
If this generator is used to power electrical load
circuits normally powered by a utility power
source, it is required by code to install a transfer switch. The transfer switch must effectively
isolate the electrical system from the utility
distribution system when the generator is operating (NEC 700, 701 and 702). Failure to isolate
an electrical system by such means will result in
damage to the generator and also may result in
injury or death to utility power workers due to
backfeed of electrical energy.
If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage on
the freight bill or affix his or her signature under the
consignor's memo of loss or damage.
If a loss or damage is noted after delivery, separate
the damaged materials and contact the carrier for
claim procedures.
“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later.
1.2 LOCATION
To lift the generator, insert pipe having sufficient
strength and diameter through the lifting holes which
are located near the unit’s base (see Figure 1.1). The
unit may also be lifted by using a hook and hoist
method provided a spreader bar is used to ensure
the lifting lines clear the roof panel.
DANGER
When lifting or hoisting equipment is used, be
careful not to contact overhead power lines.
The generator’s weight of more than 300
pounds requires proper tools, equipment and
qualified personnel to be used in all phases of
handling and unpacking.
1.3 PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have
to run for long periods of time with no operator present to monitor engine conditions. For that reason, the
engine is equipped with the following systems that
protect it against potentially damaging conditions:
1. Low Oil Pressure Sensor 3. Overcrank
2. High Temperature Sensor 4. Overspeed
There are LED readouts on the control panel to indi-
cate that one of these faults has occurred. There is
also a “System Set” LED that is described below.
1.4 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
1. The AUTO/OFF/MANUAL switch is set to the
AUTO position.
2. The utility voltage being supplied to the unit is
being sensed by the Control PCB. If the utility
sense voltage is not connected to the unit or if it
is below 168 volts AC, then the system set light
will flash rapidly. This indicates that if the AUTO/
OFF/MANUAL switch is placed in the Auto position , the generator will start.
3. The “Not In Auto” dip switch is set to the OFF
position on the control board.
4. No alarms are present, for example, low oil pressure, high temperature, etc.
4
1.5 THE GENERATOR
Figure 1.1 – 15 kW, V-twin GT-990
Dipstick
Oil
Section 1 — General Information
15 kW Generator
Control
Panel
Data
Decal
Exhaust
Enclosure
Lifting Holes
Oil Filter
Battery
Compartment
GFCI
Outlet
Fuel
Regulator
Fuel
Inlet
Composite Base
5
Section 1 — General Information
15 kW Generator
1.6 SPECIFICATIONS
1.6.1 GENERATOR
Rated Max. Cont. Power Capacity (Watts*) ..... 13,000 NG/
15,000 LP†
Rated Voltage....................................................... 120/240
Rated Max. Continuous Load Current (Amps)
120 Volts + ......................................108.3 NG/125.0 LP
240 Volts .............................................. 54.2 NG/62.5 LP
Main Line Circuit Breaker ....................................65 Amp
Phase ............................................................................. 1
Number of Rotor Poles ................................................... 2
Rated AC Frequency ................................................60 Hz
Power Factor ..................................................................1
Recommended Air Filter ...........................Part # 0C8127
Battery Requirement at
-17.8° C (0° F) ....................... Group 26/26R 12 Volts and
525 Cold-cranking Amperes Minimum
Weight ........................................................... 487 Pounds
Output Sound Level @ 23 ft (7m)
at full load ................................................... 71.5 db (A)
Normal Operating Range ........................... -20°F (-28.8°C)
* Maximum wattage and current are subject to and limited by such factors
as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power decreases about 3.5 percent for each 1,000
feet above sea level; and also will decrease about 1 percent for each 6° C
(10° F) above 16° C (60° F).
+ Total current in two separate circuits. Current in each circuit must not
exceed the value stated for 240V.
1.6.2 ENGINE
Type of Engine ......................................................GT-990
Number of Cylinders ...................................................... 2
Rated Horsepower .................................. 30 @ 3,600 rpm
Displacement ..........................................................992cc
Cylinder Block .....................Aluminum w/Cast Iron Sleeve
Valve Arrangement ..................................Overhead Valves
Ignition System ..............................Solid-state w/Magneto
Recommended Spark Plug .................................. RC12YC
Spark Plug Gap ............................0.508 mm (0.020 inch)
Compression Ratio ................................................... 9.5:1
Starter .................................................................... 12Vdc
Oil Capacity Including Filter.................... Approx. 1.7 Qts
Recommended Oil Filter ........................... Part # 070185
Recommended Air Filter ...........................Part # 0C8127
Operating RPM ........................................................ 3,600
to 104°F (40°C)
1.7 FUEL REQUIREMENTS
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed
above the liquid fuel in the storage tank.
The engine has been fitted with a fuel carburetion
system that meets the specifications of the 1997
California Air Resources Board for tamper-proof
dual fuel systems. The unit will run on natural gas or
LP gas, but it has been factory set to run on natural
gas. Should the primary fuel need to be changed to
LP gas, the fuel system needs to be reconfigured. See
instructions in the “Reconfiguring the Fuel System”
section.
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 5 inches
to 7 inches water column (0.18 to 0.25 psi); and
for liquid propane, 11 inches to 14 inches of water
column (0.4 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below 4 inches
water column for natural gas or 10 inches water
column for liquid propane for all load ranges.
1.8 FUEL CONSUMPTION
Model # Nat. Gas (*) LP Vapor (**)
1/2 Load Full Load 1/2 Load Full Load
05207 156 220 1.58/58 2.40/88
* Natural gas is in cubic feet per hour.
** LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
DANGER
Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause
an explosion. No leakage of fuel is permitted.
Natural gas, which is lighter than air, tends to
collect in high areas. LP gas is heavier than air
and tends to settle in low areas.
6
G
T
T
U
T
G
OSE
S
L
T
OR
OUSING PORT
JUSTER
SC
S
OU
S
Section 1 — General Information
15 kW Generator
1.9 RECONFIGURING THE
FUEL SYSTEM
1.9.1 15KW, 990CC ENGINES
To reconfigure the fuel system from NG to LP, follow
these steps:
NOTE:
The primary regulator for the propane supply is
NOT INCLUDED with the generator. A fuel pressure of 11 to 14 inches of water column (0.4 to
0.5 psi) to the fuel inlet of the generator MUST
BE SUPPLIED.
1. Turn off the gas supply. (if connected)
2. Open the roof and remove the door.
3. Remove the battery. (if installed)
4. Remove the engine air in baffle located on the left-
hand side of the battery compartment. Two M6
screws are located on top of the baffle and two
M6 screws are located on the inside of the baffle
towards the back.
5. Remove the small hose clamp and hose from the
fuel regulator. It may be necessary to pry the hose
off of the brass fitting using a screwdriver to gently lift up the hose edge.
6. Remove the small brass hose fitting from the
regulator casting.
7. Place the small fuel jet, thread side first, into the
threaded hole originally occupied by the brass
hose fitting (Figure 1.2).
8. Using a short No. 2 Phillips screw driver, thread
the small fuel jet into the regulator casting. Do
not over tighten.
9. Apply thread sealant to the threads of the hose
fitting and replace it into the regulator body.
10. Re-attach the small hose and hose clamp and
tighten as necessary.
11. Replace the engine air in baffle using the four M6
screws.
12. Identify both brass adjustment screws on the
regulator.
NOTE:
One adjustment screw can be accessed from the
front of the unit and the second can be accessed
from the back of the unit enclosure by removing
the plastic hole plug. The screw can be turned
with a long flat blade screwdriver.
13. To adjust the system to run on LP fuel, turn
BOTH adjuster screws 1/2 TURN CLOCKWISE.
The system should now be set for maximum
power and best performance. DO NOT, UNDER
ANY CIRCUMSTANCES, REMOVE THE SET
PINS FROM THE REGULATOR HOUSING.
THIS WILL VOID THE WARRANTY.
Figure 1.2 - Demand Regulator
TLET PORT
FUEL H
BRASS HOSE
FITTIN
IDLE CIRCUI
POR
1/8 NP
BRASS HOSE
FITTIN
AD
REW
REGULAT
H
MAL
FUEL JE
14. It may be necessary to make minor adjustments
to the preset adjustment screw settings to achieve
maximum power, particularly at higher altitudes.
If experiencing problems with the unit producing
maximum power, follow the procedure in Section
2.6 (Adjusting the Fuel Regulator).
1.10 LOCATION
1.10.1 GENERATOR
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
• Install the unit where air inlet and outlet open-
ings will not become obstructed by leaves, grass,
snow, etc. If prevailing winds will cause blowing or
drifting, consider using a windbreak to protect the
unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator
for maintenance and servicing. A good rule is to
allow three feet of space on all sides.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings to
the prevailing winds.
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping.
• Install the generator as close as possible to
the transfer switch. HOWEVER, REMEMBER
THAT LAWS OR CODES MAY REGULATE THE
DISTANCE.
• The genset must be installed on a level surface.
The base frame must be level within two (2) inches
all around.
7
Section 1 — General Information
15 kW Generator
1.10.2 TRANSFER SWITCH
1.10.2.1 15 kW Units
Transfer switches for use with this generator are sold
separately and can be purchased from dealers.
• Install any transfer switch in accordance with the
instructions supplied with the transfer switch.
• Failure to utilize a the manufacturer’s transfer
switch with this generator will void the warranty.
1.11 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if
necessary and have the battery fully charged before
installing it.
Before installing and connecting the battery, complete
the following steps:
1. Set the generator's AUTO/OFF/MANUAL switch to
OFF.
2. Turn off utility power supply to the transfer
switch.
3. Remove the 7.5 amp and 15 amp fuses from the
generator control panel.
Battery cables were factory connected at the generator (Figure 1.3). Connect cables to battery posts as
follows:
4. Connect the red battery cable (from starter con-
tactor) to the battery post indicated by a positive,
POS or (+).
5. Connect the black battery cable (from frame
ground) to the battery post indicated by a negative, NEG or (—).
6. Replace the 7.5 amp and 15 amp fuses in the
generator control panel.
NOTE:
Damage will result if battery connections are made
in reverse.
Figure 1.3 – Battery Cable Connections
NOTE:
The generator is equipped with a battery trickle
charger that is active when the unit is set up for
automatic operation. With the battery installed
and utility power source voltage available to the
transfer switch, the battery receives a trickle
charge while the engine is not running, to prevent
self-discharge. The trickle charger is designed to
help extend the life of the battery by maintaining the battery when the unit is not running. The
trickle charge feature cannot be used to recharge
a discharged battery.
1.12 THE BATTERY
Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
When replacing the battery, use the following type of
battery: Group 26/26R 12-volt battery with a rating
of 525 cold-cranking amps minimum for 15 kW at
-17.8º C (0º F) minimum. When using a maintenancefree battery, it is not necessary to check the specific
gravity or electrolyte level. Have these procedures
performed at the intervals specified in the “Service
Schedule.” A negative ground system is used. Battery
connections are shown on the wiring diagrams. Make
sure the battery is correctly connected and terminals
are tight. Observe battery polarity when connecting
the battery to the generator set.
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following precautions are to be observed when working on
batteries:
• Remove the 7.5A and 15A fuses from the generator control panel;
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
8
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive.
Section 2 — Post Installation Start-up and Adjustments
15 kW Generator
The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, immediately
flush thoroughly with water and seek medical
attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or 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.
Lead-acid batteries present a risk of fire because
they generate hydrogen gas. The
following procedures are to be followed:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from body before touching the battery by first touching a grounded metal
surface.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as the
battery cables are connected.
Be sure the utility power supply is turned off, or
sparking may occur at the battery posts as the
cables are attached and cause an explosion.
2.1 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Set the generator’s main circuit breaker to its
OFF (or open) position.
2. Set the generator's AUTO/OFF/MANUAL switch to
the OFF position.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as the
utility main line circuit breaker).
4. Check the engine crankcase oil level and, if neces-
sary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark.
5. Check the fuel supply. Gaseous fuel lines must
have been properly purged and leak tested in
accordance with applicable fuel-gas codes. All
fuel shutoff valves in the fuel supply lines must
be open.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
2.2 CHECK TRANSFER SWITCH
OPERATION
Refer to Section 3.5, of the owner’s manual for manual operation procedures.
DANGER
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
2.3 ELECTRICAL CHECKS
Complete electrical checks as follows:
1. Set the generator’s main circuit breaker to its
OFF (or open) position.
2. Set the generator's AUTO/OFF/MANUAL switch to
the OFF position.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as the
utility main line circuit breaker).
4. Turn on the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
DANGER
The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extremely
hazardous and possibly fatal electrical shock.
Proceed with caution.
5. Use an accurate AC voltmeter to check utility
power source voltage across terminals N1 and
N2. Nominal line-to-line voltage should be 240
volts AC.
6. Check utility power source voltage across termi-
nals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-toneutral voltage should be 120 volts AC.
7. When certain that utility supply voltage is compat-
ible with transfer switch and load circuit ratings,
turn OFF the utility power supply to the transfer
switch.
8. Set the generator's main circuit breaker to its
OFF (or open) position. Initial tests will be conducted at no-load condition.
9. On the generator panel, set the AUTO/OFF/
MANUAL switch to MANUAL. The engine should
crank and start.
10. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set
the generator’s main circuit breaker to its ON (or
closed) position.
9
Section 2 — Post Installation Start-up and Adjustments
15 kW Generator
DANGER
Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in dangerous and possibly fatal electrical shock.
11. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal
lugs E1 and E2. Voltage should be 242-252 volts;
frequency should read about 61-63 Hertz.
12. Connect the AC voltmeter test leads across terminal lug E1 and neutral; then across E2 and
neutral. In both cases, voltage reading should be
121-126 volts AC.
13. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at noload for a few minutes to stabilize internal engine
generator temperatures.
14. Set the generator's AUTO/OFF/MANUAL switch to
OFF. The engine should shut down.
NOTE:
It is important not to proceed until certain that
generator AC voltage and frequency are correct
and within the stated limits. Generally, if both AC
frequency and voltage are high or low, the engine
governor requires adjustment. If frequency is correct, but voltage is high or low, the generator’s
voltage regulator requires adjustment.
2.4 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied,
proceed as follows:
1. Set generator’s main circuit breaker to its OFF
(or open) position.
2. Set the generator's AUTO/OFF/MANUAL
switch to OFF.
3. Turn OFF the utility power supply to the transfer
switch, using the means provided (such as a utility main line circuit breaker).
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
4. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's E1/E2 terminals. The transfer switch
operating lever should be down.
5. Set the generator's AUTO/OFF/MANUAL switch
to MANUAL. The engine should crank and start
immediately.
6. Let the engine stabilize and warm up for a few
minutes.
7. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.
8. Turn ON electrical loads. Apply an electrical load
equal to the full rated wattage/amperage capacity
of the installed generator.
9. Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage
should be greater than 230 volts; frequency
should be greater than 58 Hertz.
10. Let the generator run at full rated load for 20-30
minutes. Listen for unusual noises, vibration or
other indications of abnormal operation. Check
for oil leaks, evidence of overheating, etc.
11. When testing under load is complete, turn OFF
electrical loads.
12. Set the generator's main circuit breakers to their
OFF (or open) positions.
13. Let the engine run at no-load for a few minutes.
14. Set the AUTO/OFF/MANUAL switch to OFF. The
engine should shut down.
2.5 CHECKING AUTOMATIC
OPERATION
To check the system for proper automatic operation,
proceed as follows:
1. Set the generator’s main circuit breaker to it’s
OFF (or open) position.
2. Check that the AUTO/OFF/MANUAL switch is set
to OFF.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
4. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the utility power source side.
5. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a utility main line circuit breaker).
6. Set the AUTO/OFF/MANUAL switch to AUTO.
Then set the generator’s main circuit breaker to
its ON (or closed) position. The system is now
ready for automatic operation.
7. Turn OFF the utility power supply to the transfer
switch.
With the AUTO/OFF/MANUAL switch at AUTO, the
engine should crank and start when the utility source
power is turned OFF. After starting, the transfer
switch should connect load circuits to the standby
side. Let the system go through its entire automatic
sequence of operation.
10
Section 2 — Post Installation Start-up and Adjustments
15 kW Generator
With the generator running and loads powered by
generator AC output, turn ON the utility power supply
to the transfer switch. The following should occur:
• After about six seconds, the switch should transfer
loads back to the utility power source.
• About one minute after retransfer, the engine
should shut down.
2.6 ADJUSTING THE REGULATOR
(NATURAL GAS ONLY)
Although the generator has been factory set to provide maximum power, it may be necessary in some
areas to adjust this setting. Because natural gas has
different BTU or power content across the country
the engine may not perform as designed.
If experiencing engine problems at high or full load
conditions follow these steps. It will require a frequency meter to perform this procedure.
1. Turn off utility power to the main distribution
panel in the house. This can be done by switching
the service main breaker to the off or open position.
2. Allow the generator to start before loading the
generator. Confirm the no-load frequency with
the roof open and door off is set at 63-63.5 Hz.
Transfer load to emergency circuits.
3. Turn on appliances, lights, pumps, etc., that are
on the emergency circuits in an attempt to fully
load the generator. Be cautious not to overload
the generator. Use the following chart as a guide:
Unit 120 Volts 240 Volts
15 kW 108.3 amps 54.2 amps
Figure 2.1 — Dual Fuel Regulators
V-twin
Adjustment
Screw
(Both Sides)
Set Pin
(Both Sides)
Adjustment
Screw
(One Side
Only)
6. When the highest frequency is reached maximum
power has been set. Then turn both adjustment
screws 1/4 turn counterclockwise. Regulator is
now set.
410
Set
Pin
Figure 2.2 — Placement of Regulator
Adjustment Screw
4. When full load has been achieved. Connect a frequency meter to the output lugs of the generator’s
main line circuit breaker.
5. The fuel regulator is fitted with two adjustment
screws. While watching the frequency meter,
slowly turn the adjustment screw clockwise or
counterclockwise one at a time until highest frequency is read on the meter. Only limited adjustment is available between the set pins. Under no
circumstances should any of the pins be removed
(Figures 2.1 and 2.2).
7. Turn utility power to the main distribution panel
back on. This can be done by switching the service main breaker to the on or closed position.
Allow the generator to shut down.
Do not make any unnecessary adjustments.
Factory settings are correct for most applications. However, when making adjustments, be
careful to avoid overspeeding the engine.
If this procedure or equipment are not available,
locate the nearest Dealer and they can perform the
adjustments.
NOTE:
A service fee may be charged for this adjustment.
11
Section 3 — Operation
15 kW Generator
2.7 ENGINE GOVERNOR ADJUSTMENT
If both AC frequency and voltage are correspondingly
high or low, adjust the engine governor as follows:
2.7.1 15 KW UNITS
1. Loosen governor clamp bolt (See Figure 2.3).
Figure 2.3 — V-twin Engine Governor
Adjustment
Idle Spring
Governor
Shaft
(Rotate
Clockwise)
Governor Clamp Bolt
2. Completely remove the idle spring.
3. With governor arm at wide open throttle position,
rotate governor shaft fully clockwise. Tighten
clamp bolt to 84 inch-pounds.
4. Start unit and apply full load. Use full load speed
adjust screw (Figure 2.4) to adjust frequency to
58 Hz.
5. Remove load, stop engine, loosen the idle adjust
screw and reconnect the idle spring.
6. Push the governor arm to the closed throttle position. Make sure the idle spring does not stretch at
all.
7. Restart the unit.
8. Slowly turn the idle adjust screw to adjust the noload idle frequency to 63-63.5 Hz.
9. The governor is now set.
Figure 2.4 — V-twin Full Load Speed Adjust
12
No Load Idle
Adjustment Screw
Screw
Full Load Speed Adjust Screw
2.8 VOLTAGE REGULATOR
ADJUSTMENT
With the frequency between 62-63.5 Hertz, slowly
turn the slotted potentiometer (Figure 2.5) until line
voltage reads 244-252 volts.
NOTE:
Remove the access panel on top of the control
panel to adjust the voltage regulator.
Figure 2.5 – Voltage Adjustment Potentiometer
NOTE:
The voltage regulator is housed above the generator's
control panel. The regulator maintains a voltage in
direct proportion to frequency. For example, at 62
Hertz, line-to-neutral voltage will be 124 volts.
3.1 BREAK-IN PROCEDURE
Once the unit has been installed and all electrical
checks have been made, it is strongly recommended
that the following “Break-in Procedure” be completed
to ensure correct generator operation in the future.
1. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
2. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
3. The unit will start, and the transfer switch will
transfer to standby.
4. Using the transfer switch’s built-in emergency
load center, turn on circuits to load the generator
to approximately 25% rated load and run the unit
for one hour.
5. Run the unit for one hour at 50% rated load.
6. Run the unit for one hour at 75% rated load.
7. Run the unit for one hour at 100% rated load.
8. Turn ON the utility power supply to the transfer
switch, which will allow the transfer switch to
transfer back to utility power. The unit will continue to run for one minute and then shut down.
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