Carrier ASPASICCA007 User Manual
LISTED
Owner’s 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)
O
A Not Intended for use as Primary Power In place of utility or in a
“ life-support applications. “
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
INTRODUCTION
Thank you for purchasing this model of the Carrier
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generator will operate using either vapor withdrawn liquid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).
♦ READ THIS MANUAL THOROUGHLY
if any portion of this manual is not understood, contact the
nearest Carrier 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
property damage.
-------
m WARNING M
After this heading, read instructions that, if not
strictly complied with, may result in serious
personal injury or property damage.
—M CAUTION
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
A
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.
--------------
A
This symbol points out potential electrical
A
shock hazard.
The operator is responsible for proper and safe use
of the equipment. Carrier strongly recommends that the
operator read this Owner's 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 owner’s information,
including warranty, electrical diagrams, exploded views
and lists of repair parts, 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 GT990 Engine
• ASPAS1CCA015 - 13 kW NG, 15 kW LP, V-twin GT990 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.
♦ HOWTO 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 contacting a Carrier 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. See Figure 1.1 or Figure 1.2 in
Section 1.4 for decal location.
Model No. Serial No.
______________________________
_____________
__________________
Carrier
Table of Contents
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
TABLE
OF
COMIEMIS
Introduction
Read This Manual Thoroughly
Contents ..........................................................
Operation and Maintenance
.................................
Inside Front Cover
.............................
IFC
................................
IFC
IFC
How to Obtain Service .........................................IFC
Safety Rules
....................................................................
Standards index .......................................................3
Section 1 - General Information
....................................
1.1 Unpacking/lnspection.........................................4
1.2 Protection Systems
............................................
1.3 NEC Requirement for Arc Fault Circuit
Interruption Breaker for Bedrooms
.....................
1.4 The Generator ....................................................5
1.5 Specifications
......................................................
1.6 System Set LED..................................................6
1.7 Fuel Requirements and Recommendations
1.8 Fuel Consumption
...............................................
..........
1.9 Location ..............................................................7
1.10 Battery Installation
............................................
1.11 The Battery.........................................................8
Section 3 - Maintenance...............................................12
3.1 Fuses
..............................................................
12
3.2 Checking the Engine Oil Level.........................13
3.3 Changing the Engine Oil
3.4 Changing the Oil Filter
2
3.5 Changing the Engine Air Cleaner
3.6 Spark Plug(s)
..................................................
..................................
.....................................
....................
13
14
14
14
3.7 Battery Maintenance........................................15
4
4
3.8 Cooling System................................................15
3.9 Corrosion Protection
3.10 Attention After Submersion
........................................
...............................
16
16
3.11 Out of Service Procedu re.................................16
4
Section 4 - Service........................................................17
6
6
7
8
4.1 Service Schedule
Section 5 - Troubleshooting
5.1 Troubleshooting Guide......................................18
Section 6 ~ Warranty....................................................19
.............................................
........................................
17
18
Section 2 - Operation.......................................................9
2.1 Break-in Procedure....
2.2 Using the Auto/Off/Manual Switch
2.3 Automatic Transfer Operation
2.4 Sequence of Automatic Operation
2.5 Manual Transfer Operation
2.6 Setting the Exercise Timer
2.7 Protection Systems
.......................................
.....................
.........................
...................
.............................
..............................
..........................................
9
9
10
10
11
11
12
Carrier
IMPORTANT SAFETY INSTRUCTIONS
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
/M,
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. JB2L
A
WARNING:
The en|;ine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
in
I This product contains or emits chemicals
I known to the state of California to cause
I 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. Many
accidents are caused by failing to follow simple and
fundamental rules or precautions.
Carrier 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. If using a procedure,
work method or operating technique Carrier does not
specifically recommend, ensure 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 operate or maintain this
equipment.
Potentially lethal voltages are generated by
A
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.
WARNING:
DANGER
m GENERAL HAZARDS m
For safety reasons, Carrier recommends that the
Installation, initial start-up and maintenance of this
equipment is carried out by a Carrier 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 Carrier 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.
Carrier
IMPORTANT SAFETY INSTRUCTIONS
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
SAFETY RULES
A
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.
A
A FIRE HAZARDS A
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.
A
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, 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, Ml 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
__________________________
Carrier
GENERAL
INFORMATION
Section 1 — General Information
Carrier Air-cooied 7 kW, 12 kW and 15 kW Generators
DANGER
Only qualified electricians or contractors should
A
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.
I.l UNPACKINC/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.
• This UL listed standby generator set is packaged with
an automatic transfer switch with built in load center.
The combination transfer switch and load center is
pre-wired with a two foot and 30 foot conduit. Circuit
breakers for emergency circuit connections are
included.
• This UL listed, 2-pole switch is rated at 100 AC
amperes at 250 volts maximum. This transfer switch
is for indoor use only.
-------
M WARNINC Jà
If this generator is used to power eiectricai ioad
A
circuits normaiiy powered by a utiiity power
source, it is required by code to instaii 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 & 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 their 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 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 notify
personnel that one of these faults has occurred. There is
also a “System Set” LED that is lit when all of the
conditions describe in Section 1.3 are true.
1.3 NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION BREAKER FOR BEDROOMS
In 2001, the National Electric Code (NEC) introduced a
requirement for new construction. This new requirement
indicates the need for Arc Fault Circuit Interrupters to be
used to protect the complete branch circuit that feeds a
dwelling bedroom. The actual NEC requirement is
indicated below.
♦ 1.3.1 SECTION 210.12 ARC FAULT CIRCUIT
__________
1. Definition: An arc fault circuit interrupter is a device
intended to provide protection from the effects of arc
faults by recognizing characteristics unique to arcing
and by functioning to de-energize the circuit when an
arc fault is detected.
2. Dwelling Unit Bedrooms: All branch circuits that
supply 125 volt, single-phase, 15 and 20 ampere
outlets installed in dwelling unit bedrooms shall be
protected by an arc fault circuit interrupter listed to
provide protection of the entire branch circuit.
Section 210.12 requires that AFCI protection be provided
on branch circuits that supply outlets (receptacle,
lighting, etc.) in dwelling bedrooms. The requirement is
limited to 15 and 20 ampere, 125 volt circuits. There is no
prohibition against providing AFCI protection on other
circuits or in locations other than bedrooms. Because
circuits are often shared between a bedroom and other
areas such as closets and hallways, providing AFCI
protection on the complete circuit would comply with
210.12.
If during the installation of the Carrier Home Standby
system the decision is made to provide back up power to
a bedroom branch circuit, then the circuit breaker in the
Carrier Transfer Switch should be replaced with an Arc
Fault Circuit Interrupter.
It is most important that breakers only be switched like for
like. For instance, if replacing a 15A breaker, it MUST be
replaced with a 15A AFCI breaker. Likewise, a 20A
breaker MUST be replaced with a 20A AFCI.
These AFCI breakers are available at the nearest
electrical wholesaler or hardware store.
Siemens item #
Q115AF
Q120AF
INTERRUPTER PROTECTION
Description
15A Single Pole AFCI
20A Single Pole AFCI
____________
Carrier
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
1.4 THE GENERATOR
Figure 1.1-7 kW, Single Cylinder GH-410 Engine
Section 1 — General Information
GENERAL
INFORMATION
Figure 1.2 - 12 kW and 15 kW, V-twin GT-990 Engine
Carrier 5
GENERAL
INFORMATION
Section 1 — General Information
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
1.5 SPECIFICATIONS
♦ 1.5.1 GENERATOR
Model ASPAS1CCA007 ASPAS1CCA012 ASPAS1CCA015
Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP
Rated Voltage 120/240 120/240 120/240
Rated Max. Continuous Load Current (Amps)
120 Volts** 50.0 NG/58.3 LP 100.0 NG/100.0 LP 108.3 NG/125.0 LP
240 Volts 25.0 NG/29.2 LP 50.0 NG/50.0 LP 54.2 NG/62.5 LP
Main Line Circuit Breaker 30 Amp 50 Amp 65 Amp
Phase 1 1 1
Number of Rotor Poles 2 2 2
Rated AC Frequency 60 Hz 60 Hz 60 Hz
Power Factor 1 1 1
Recommended Air Filter Carrier Part # 0C8127 Carrier Part # 0C8127 Carrier Part # 0C8127
Battery Requirement Group 26 Group 26 Group 26
(At 0° F-17.8° C) 12 Volts and 12 Volts and 12 Volts and
350 Cold-cranking 525 Cold-cranking 525 Cold-cranking
Amperes Minimum Amperes Minimum Amperes Minimum
Weight 375 Pounds 470 Pounds 487 Pounds
Output Sound Level @ 23 ft (7m) at full load 68 db (A) 70.5 db (A) 71.5 db (A)
Normal Operating Range -20°F (-28,8°C) to 104°F (40°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 wii! decrease г^юи! 1 percent for each O’" C (10° F) above 16° C (60° F) ambient temperature.
Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts.
♦ 1.5.2 ENGINE
ASPAS1CCA007 ASPAS1CCA012 ASPAS1CCA015
Type of Engine GH-410 GT-990 GT-990
Number of Cylinders 1 2 2
Rated Horsepower 14.5 @ 3,600 rpm 30 @ 3,600 rpm 30 @ 3,600 rpm
Displacement 410cc 992cc 992cc
Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast
Iron Sleeve Iron Sleeve Iron Sleeve
Valve Arrangement Overhead Valves Overhead Valves Overhead Valves
Ignition System Solid-state w/Magneto Solid-state w/Maqneto Solid-state w/Magneto
Recommended Spark Plug RC14YC RC12YC RC12YC
Spark Plug Gap 0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.508 mm (0.020 inch)
Compression Ratio 8.5:1 9.5:1 9.5:1
Starter 12 Vdc 12 Vdc 12Vdc
Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.7 Ots Approx. 1.7 Ots
Recommended Oil Filter Carrier Part # 70185D Carrier Part # 70185D Carrier Part # 70185D
Recommended Air Filter Carrier Part # 0C8127 Carrier Part # 0C8127 Carrier Part # 0C8127
Operating RPM 3,600 3,600 3,600
1.6 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
f. 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 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.
0 Carrier
4. No alarms are present, for example, low oil pressure,
high temperature, etc.
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 carburetlon 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.
Loading...