Carrier ASPAS1CCA012, ASPAS1CCA015 User Manual

Parts, Adjustment and

Maintenance Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models: ASPAS1CCA007 (6 kW NG, 7 kW LP) ASPAS1CCA012 (12 kW NG, 12 kW LP) ASPAS1CCA015 (13 kW NG, 15 kW LP)

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

Not intended for use as Primary Power in place of utility

or in life-support applications.

LISTE

GENERAC

POWER SYSTEMS, INC.

DANGER

Carrier

INTRODUCTION

This Carrier 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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

READ THIS MANUAL THOROUGHLY

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:

After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death, in addition to 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 information that, if not followed, could endanger personal safety and/or property of others.

This symbol points out potential explosion hazard.

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. Carrier strongly recommends that the dealer read this Parts, Adjustment and Maintenance Manual and thoroughly understand all instructions before using this equipment. Carrier 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 information for three different Carrier models:

•

ASPAS1CCA007 – 6 kW NG, 7 kW LP, single-cylinder

GH-410 Engine

•

ASPAS1CCA012 – 12 kW NG, 12 kW LP, V-twin GT-

990 Engine

•

ASPAS1CCA015

– 13 kW NG, 15 kW LP, V-twin 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 Carrier 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 Carrier Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact a Carrier Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

When inquiring about parts or 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. See Figure 1.1 or Figure 1.2 in Section 1.4 of the Owner’s Manual for decal location.

Model No. ____________ Serial No. ____________



DANGER

Table of Contents

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

Carrier 1

Introduction ........................Inside Front Cover

Read This Manual Thoroughly ..............................IFC

Contents ................................................................IFC

Operation and Maintenance ..................................IFC

How to Obtain Service ..........................................IFC

Important Safety Instructions ........................2

Standards Index ........................................................3

Section 1 – Post Installation Start-up and

Adjustments ..............................................4

1.1 Before Initial Start Up ..........................................4

1.2 Check Transfer Switch Operation........................4

1.3 Electrical Checks ................................................4

1.4 Generator Tests Under Load ..............................5

1.5 Checking Automatic Operation............................5

1.6 Adjusting The Regulator (Natural Gas Only) ......5

1.7 Reconfiguring The Fuel System ..........................6

1.7.1 7kW, 410cc Engine ....................................6

1.7.2 12kW and 15kW, V-Twin Engines..............7

1.8 Engine Governor Adjustment ..............................7

1.8.1 7kW Units ..................................................7

1.8.2 12kW and 15kW Units................................8

1.9 Voltage Regulator Adjustment ............................8

1.10 Adjusting GH-410/GT-990 Valve Clearance........8

1.11 The Battery ..........................................................8

Section 2 – Troubleshooting ........................10

2.1 Troubleshooting Guide ......................................10

Section 3 – Maintenance ..............................11

3.1 Service Schedule ..............................................11

Section 4 – Electrical Data ............................12

Section 5 – Exploded Views and

Parts Lists....................................26

Section 6 – Unit Dimensions ........................47

Section 7 – Notes ............................................48

2 Carrier

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Parts, Adjustment and Maintenance Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Carrier cannot possibly anticipate every possible circumstance that might involve a hazard. The warning in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique that Carrier does not specifically recommend, satisfy yourself that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the generator unsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, 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.

GENER

AL HAZARDS

• For safety reasons, Carrier recommends that this equipment be installed, serviced and repaired by a Carrier Dealer.

• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. 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 Carrier Dealer for parts needing repair or replacement.

• Before performing any maintenance on the generator, disconnect its battery 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.

!!!

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:

DANGER

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 well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable. 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.

• If people must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.

• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. Never disconnect the ground wire. 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

• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department for any questions pertaining to fire extinguishers.

EXPLOSION HA

ZARDS

• 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.

• Fuels such as natural gas and 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, available 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.

◆

Carrier 3

4 Carrier

Section 1 — Post Installation Start-up and Adjustments

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

1.1 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. Turn OFF all loads connected to the transfer switch terminals T1 and T2.

5. Check the engine crankcase oil level and, if necessary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark.

6. 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.

1.2 CHECK TRANSFER SWITCH

OPERATION

Refer to Section 3.5, of the owner’s manual for manual operation procedures.

Do not attempt manual transfer switch operation 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.

1.3 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 all loads connected to the transfer switch terminals T1 and T2.

4. Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker).

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 transfer switch terminals N1 and N2. Nominal line-to-line voltage should be 240 volts AC.

6. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-to-neutral voltage should be 120 volts AC.

7. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer switch.

8. On the generator panel, set the AUTO/OFF/ MANUAL switch to MANUAL. The engine should crank and start.

9. 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.

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.

10. 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.

11. 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.

12. Set the generator’s main circuit breaker to its OFF (or open) position. Let the engine run at no-load for a few minutes to stabilize internal engine generator temperatures.

13. 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.

DANGER

1.4 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. Turn OFF all loads connected to the transfer switch terminals T1 and T2.

3. Set the generator's AUTO/OFF/MANUAL switch to OFF.

4. Turn OFF the utility power supply to the transfer switch, using the means provided (such as a utility main line circuit breaker).

5. 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.

6. Set the generator's AUTO/OFF/MANUAL switch to MANUAL. The engine should crank and start immediately.

7. Let the engine stabilize and warm up for a few minutes.

8. Set the generator’s main circuit breaker to its ON (or closed) position. Loads are now powered by the standby generator.

9. Turn ON electrical loads connected to transfer switch T1 and T2. Apply an electrical load equal to the full rated wattage/amperage capacity of the installed generator.

10. 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.

11. 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.

12. When testing under load is complete, turn OFF electrical loads.

13. Set the generator's main circuit breaker to its OFF (or OPEN) position.

14. Let the engine run at no-load for a few minutes.

15. Set the AUTO/OFF/MANUAL switch to OFF. The engine should shut down.

1.5 CHECKING AUTOMATIC OPERATION

To check the system for proper automatic operation, proceed as follows:

1. Set generator’s main circuit breaker to its 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 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. 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.

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.

1.6 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 that the No Load Frequency, with the top open and front panel off, is set to 63-63.5 Hz. Transfer load to emergency circuits.

Section 1 — Post Installation Start-up and Adjustments

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

Carrier 5

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:

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 one (7 kW), or two (12 & 15 kW) adjustment screws. While watching the frequency meter, slowly turn the adjustment screws clockwise or counterclockwise one at a time until the highest frequency is read on the meter. Only limited adjustment is available because of the set pin. Under no circumstances should any of the pins be removed (Figures 1.1 and 1.2).

Figure 1.1 — Dual Fuel Regulators

6. When the highest frequency is reached maximum power has been set. From this point turn both adjustment screws 1/4 turn counterclockwise. The regulator is now set.

Figure 1.2 — Placement of Regulator

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.

1.7 RECONFIGURING THE

FUEL SYSTEM

1.7.1 7 KW, 410CC ENGINE

To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.3):

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 main gas supply (if connected).

2. Open the top and remove the front panel.

3. Remove the battery (if installed).

4. Disconnect wire #0 and wire #14 from the gas solenoid on top of the demand regulator.

5. Remove the carburetor fuel hose from the outlet port of the demand regulator.

6. Remove the demand regulator by removing the fastener that retains the regulator mounting bracket.

7. Remove the square headed steel pipe plug from outlet port #1 and the brass hose barb fitting from outlet port #2.

8. Refit the brass hose barb fitting to outlet port #1 and the square headed steel pipe plug to outlet port #2.

Figure 1.3 – Demand Regulator

◆

OSE

JUS

SCREW

Section 1 — Post Installation Start-up and Adjustments

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

Unit 120 Volts 240 Volts

7 kW 50.0 amps 25.0 amps 12 kW 100.0 amps 50.0 amps 13 kW 108.3 amps 54.1 amps

6 Carrier

V-twin

Adjustment

Screw

(Both Sides)

Adjustment

Screw

(One Side Only)

Set Pin

(Both Sides)

410

Set

HOSE & PL

WITCHED SIDE

FUEL H

BRASS HOSE

FITTIN

TMEN

FUEL H

BRASS HOSE

FITTIN

TLE

POR

FUEL JE

Adjustment Screw

NG FUEL SYSTE

LP FUEL SYSTE

9. Reverse procedure steps 1-5 to reinstall demand regulator.

10. Reverse the procedure to convert back to natural gas.

1.7.2 12KW AND 15KW, V-TWIN ENGINES

To reconfigure the fuel system from NG to LP, follow these steps:

NOTE:

1. Turn off the gas supply. (if connected)

2. Open the top and remove the front panel.

3. Remove the battery. (if installed)

4. Remove the engine air in baffle located on the lefthand 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 1.4).

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.

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 1.6 (Adjusting the Fuel Regulator).

Figure 1.4 - Demand Regulator

1.8 ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly high or low, adjust the engine governor as follows:

1.8.1 7 KW UNITS

1. Loosen the governor clamp bolt (Figures 1.5).

2. Hold the governor lever at its wide open throttle position, and rotate the governor shaft clockwise as far as it will go. Then, tighten the governor lever clamp bolt to 70 inch-pounds (8 N-m).

3. Start the generator; let it stabilize and warm up at noload.

4. Connect a frequency meter (or high quality multimeter set to the frequency mode) across the generators AC output leads.

5. Turn the speed adjust nut to obtain a frequency reading of 63 Hertz.

Figure 1.5 — Engine Governor Adjustment

Single Cylinder Engines

◆

OSE

OUSING PORT

JUSTER

Section 1 — Post Installation Start-up and Adjustments

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

Carrier 7

TLET PORT

FUEL H

BRASS HOSE FITTIN

IDLE CIRCUI

POR

1/8 NP

BRASS HOSE

FITTIN

REW

REGULAT H

MAL

FUEL JE

GOVERNOR

SHAFT

GOVERNOR

CLAMP

BOLT

ADJUST SCREW

6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment.

1.8.2 12 KW AND 15 KW UNITS

1. Loosen governor clamp bolt (See Figure 1.6).

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position (rotated fully clockwise), 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 1.7) 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.

Figure 1.6 — Engine Governor Adjustment

V-twin Engines

Figure 1.7 — Full Load Speed Adjust Screw

V-Twin Engines

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the no-load idle frequency to 63-63.5 Hz (with top open).

9. The governor is now set.

1.9 VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 62-63 Hertz, slowly turn the slotted potentiometer (Figure 1.8) until line voltage reads 247-252 volts.

Figure 1.8 – Voltage Adjustment Potentiometer

NOTE:

The access panel on top of the control panel must be removed to adjust the voltage regulator.

NOTE:

The voltage regulator is housed above the generator's control panel. The regulator maintains a voltage in direct proportion to frequency at a 2-to-1 ratio. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

1.10 ADJUSTING GH-410/GT-990

VALVE CLEARANCE

After the first 6 months of operation, adjust the valve clearance in the engine.

Important: If feeling uncomfortable about doing this

procedure or the proper tools are not available, please contact a Carrier dealer for service assistance. This step necessary to insure the longest life for the engine.

To adjust valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed from the

spark plug and out of the way.

◆

Section 1 — Post Installation Start-up and Adjustments

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

8 Carrier

Idle Spring

Governor Shaft

(Rotate Clockwise)

Governor Clamp Bolt

No Load Idle Adjustment Screw

Full Load Speed Adjust Screw

• Remove the four screws attaching the valve cover with a #2 or #3 phillips screwdriver.

• Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is up as high as it can go.

• Loosen the rocker jam nut. Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is 0.002-0.004 inch (0.05-0.1 mm).

NOTE:

Hold the rocker arm jam nut in place as the pivot ball stud is turned.

When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change.

Figure 1.9 - Valve Clearance Adjustment

• Install new valve cover gasket.

• Re-attach the valve cover.

NOTE:

Start all four screws before tightening or it will not be possible to get all the screws in place. Make sure the valve cover gasket is in place.

• Re-attach the spark plug wire to the spark plug.

• On GT-990, Repeat the process for the other cylinder.

NOTES:

Carrier 9

Section 1 — Post Installation Start-up and Adjustments

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

Rocker

Arm

Valve

Stem

Jam Nut

Pivot Ball

Stud

Section 2 — Troubleshooting

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

2.1 TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

The engine will not crank. 1. Fuse blown. 1. Replace 15A fuse in generator

control panel.

2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary.

3. Defective starter contactor. (7 kW) 3. *

4. Defective starter motor. 4. *

5. Dead Battery. 5. Charge or replace battery.

The engine cranks but 1. Out of fuel. 1. Replenish fuel. will not start. 2. Defective fuel solenoid (FS). 2. *

3. Open #14 wire from 3. * engine control board.

4. Defective spark plug(s). 4. Clean, re-gap or replace plug(s).

5. Valve lash out of adjustment. 5. *

The engine starts hard 1. Air cleaner plugged 1. Check, replace air cleaner. and runs rough. or damaged.

2. Defective spark plug(s). 2. Clean, re-gap or replace plug(s).

3. Fuel Regulator not set. 3. Set Fuel Regulator.

4. Fuel Pressure incorrect. 4. Confirm fuel pressure to regulator

is 11-14” water column (0.4-0.5 psi) for LP, and 5-7” water column (0.18-

0.25 psi) for natural gas.

The Auto/Off/Manual switch 1. Defective switch. 1. * is set to OFF, but the engine 2. Auto/Off/Manual switch 2. *

continues to run. wired incorrectly.

3. Defective control board. 3. *

There is no AC output from 1. Main line circuit breaker open. 1. Reset circuit breaker the generator. to ON (or closed).

2. Generator internal failure. 2. *

There is no transfer to 1. Defective transfer switch coil. 1. * standby after utility 2. Defective transfer relay. 2. * source failure. 3. Transfer relay circuit open. 3. *

4. Defective control logic board. 4. *

Unit consumes large Break-in procedure * amounts of oil. not followed (see Section 3.1).

*Contact the nearest Carrier Dealer for assistance.

10 Carrier

Carrier 11

Section 3 — Maintenance

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

3.1 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by the nearest Carrier Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* XM

LUBRICATION

Oil level XM

Oil X AFTER BREAK-IN,

AND Y

Oil filter X AFTER BREAK-IN,

AND Y

COOLING

Enclosure louvers XXW

BATTERY

Remove corrosion, XXM ensure dryness

Clean and tighten

XXM

battery terminals

Check charge state X R EVERY 6 M

Electrolyte level X R EVERY 6 M (unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner XR Y

Spark plug(s) XR Y

GENERAL CONDITION

Vibration, Noise, Leakage, XM Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY A Y

CARRIER DEALER

CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION

BLACK

CUSTOMER SUPPLIED

BATTERY

12V

LOP

HTO

CB1 - MAIN OUTPUT BREAKER

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY

D - DIODE

SC - STARTER CONTACTOR

ICT - INTERCONNECTION TERMINALS

IC - INLINE CONNECTOR

HTO - HIGH OIL TEMPERATURE SWITCH

GRD - CONTROL PANEL GROUND

FS - FUEL SOLENOID

SW1 - AUTO / OFF / MANUAL SWITCH

LOP - LOW OIL PRESSURE SWITCH

IM - IGNITION MODULE

F2 - FUSE 7.5 AMP

F1 - FUSE 15 AMP

SP - SPARK PLUG

TB - INSULATED TERMINAL BLOCK

SM - STARTER MOTOR

SW2 - SET EXERCISE SWITCH

DSW - PCB MOUNTED DIP SWITCH

DIAGRAM KEY

PRINTED CIRCUIT BOARD

DSW

CONTROL

4 - SPARE

ON - INDICATES

2 - Remote Not Auto

3 - 50 Hz Operation

1 - 20 Vac Sense Transformer

L.E.D - ALARM INDICATORS

RED

16 17

7 8 9

224

225

66A

239

15A

194

351

ENGINE WIRING

224B

BATTERY

(UTILITY)

CHARGER

225B

224B

66A

15A

239

194

66A

224

225

351

224

225

225B

224B

225

224

N2N1

2 1

12 Carrier

Section 4 - Electrical Data

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram — Single Cylinder — Drawing No. 0E9014

ENGINE WIRING

DIAGRAM KEY

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL D - DIODE DSW - PCB MOUNTED DIP SWITCH FS - FUEL SOLENOID F1 - FUSE 15 AMP F2 - FUSE 7.5 AMP GRD - CONTROL PANEL GROUND HTO - HIGH OIL TEMPERATURE SWITCH IC - INLINE CONNECTOR ICT - INTERCONNECTION TERMINALS IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TB - INSULATED TERMINAL BLOCK TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

HTO

LOP

BLACK

CUSTOMER SUPPLIED

12V

BATTERY

3 2

BATTERY

CHARGER (UTILITY)

RED

0056

L.E.D - ALARM INDICATORS

13130

868656

858518

CONTROL

PRINTED CIRCUIT BOARD

DSW 2

ON - INDICATES

1 - 20 Vac Sense Transformer

2 - Remote Not Auto

3 - 50 Hz Operation

4 - SPARE

1122554

351

2 1

225B

224B

194

66A

239

15A

225

224

15 16 17

225B

224B

351

Carrier 13

Section 4 - Electrical Data

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators

Wiring Diagram — Single Cylinder — Drawing No. 0E9014

CLOSEST TO BEARING

OUTPUT TO TRANSFER

240V GENERATOR

SWITCH CONTACTOR

66A

15A

239

194

66A

12VDC ACCESSORY SOCKET

15B

239

15A

224

225

351

224

225

VOLTAGE

REGULATOR

66A

162

SW2

351

MANUAL

SW1

15A

239

AUTO

CONNECTION

CUSTOMER

LINE

HOT

OUTLET

LOAD

HOT

WHITE

EXTERNAL

GFCI

CB3

351

194

GRD

162

66A

225B

CONTROL PANEL BOX

224A

225B

224B

225

224

224A

224B

225A

BCR

225A

CB2

162

194

RELAY COIL

NEUTRAL CONNECTION

CB1

240VAC UTILITY INPUT

12Vdc TRANSFER

66A

STATOR

225

224

225

225B

224B

224

351

194

66A 239

15A

66A

224A

225A

224B

162

VOLTAGE

REGULATOR

66A

12VDC ACCESSORY SOCKET

15B

224A

BCR

331

664

997

BBA

15A

239

CONTROL PANEL BOX

225A

225B

162

194

351

15A

CLOSEST TO BEARING

CB2

STATOR

162

66A

0055

66A

GRD

N2 N1

SW1

000

239

AUTO

MANUAL

351

SW2

CUSTOMER

CONNECTION

CB3

EXTERNAL

GFCI

OUTLET

HOT

LOAD

WHITE

HOT

LINE

WHITE

66A

240V GENERATOR

OUTPUT TO TRANSFER

SWITCH CONTACTOR

CB1

4444NN222233

222233

NEUTRAL CONNECTION

194

RELAY COIL

240VAC UTILITY INPUT

12Vdc TRANSFER

14 Carrier

CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL

(STATOR)

CB1 - CIRCUIT BREAKER, MAIN OUTPUT

HTO - HIGH OIL TEMPERATURE SWITCH

SW1 - AUTO / OFF / MANUAL SWITCH

CB2 - CIRCUIT BREAKER, ALT. EXCITATION

)TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

DPE WINDING

BCR - BATTERY CHARGE RELAY

BA - BRUSH ASSEMBLY

F1 - FUSE 15 AMP F2 - FUSE 7.5 AMP

SP - SPARK PLUG

FS - FUEL SOLENOID

IM - IGNITION MODULE

HM - HOUR RUN METER

SC - STARTER CONTACTOR

SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR

LOP - LOW OIL PRESSURE SWITCH

D - DIODE

DIAGRAM KEY

REGULATOR

ELECTRONIC

VOLTAGE

CB2

C2-8

162

C2-10

351

CONTROL

PRINTED CIRCUIT

BOARD

C2-7

FIELD

C2-9

C2-11

C2-4

C2-3

ENGINE RUN

(STATOR)

WINDING

66A

C2-2

HTO

C1-4

15A

225

224

194

66A

6 7

194

239

66A

SW2

C1-3

LOP

225

224

239

66A

194

225B

BATTERY CHARGE

WINDING

BATTERY

CHARGER

C2-1

2 1

224A

224B

225A

BCR

225A

224A

225A

224A

225

224

15A

17 15

239

1715A

194

225A

1VA

56VA

12VDC ACCESSORY

SOCKET

225

224

224A

Section 4 - Electrical Data

Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic — Single Cylinder — Drawing No. 0E9015

DPE WINDING

(STATOR)

C2-1

FIELD

C2-7

111122220

ELECTRONIC

VOLTAGE

REGULATOR

C2-10

162

CB2

C2-8

BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB2 - CIRCUIT BREAKER, ALT. EXCITATION CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL D - DIODE FS - FUEL SOLENOID F1 - FUSE 15 AMP F2 - FUSE 7.5 AMP HTO - HIGH OIL TEMPERATURE SWITCH HM - HOUR RUN METER

DIAGRAM KEY

IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

BATTERY

CHARGER

BATTERY CHARGE

C2-11

2 1

WINDING

C2-4

C2-9

225B

224B

ENGINE RUN

WINDING

(STATOR)

225A

9999777

224A

C2-2

C1-4

C2-3

66A

PRINTED CIRCUIT

661

HTO

351

11332

CONTROL

BOARD

SW2

445

225A

BCR

224A

66A

11 12 13

14 15 16

1 2

3 4 5 6 7 8

C1-3

66A

239

194

15A

225

LOP

224

194

225

224

225A

224A

225

224

194

239

66A

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