Gillette Generators SPP-180 User Manual

OPERATION AND
INSTALLATION
GUIDE
FOR MODELS:
SPS-120 & SPP-180
GILLETTE GENERATORS
AUTOMATIC POWER SYSTEMS
Page
Introduction, General Cautions, Warnings, & Danger Points ------------------ 3-6
TABLE OF CONTENTS
Un-packing and Inspection of your Generator Set ------------------------------ 6-7
Pre-installation and Plot Planning of your Generator Set ----------------------- 7-9
Know your Gillette Generator Set---------------------------------------------------- 10
Know your Gillette Automatic Control System ------------------------------------ 11
Gaseous Dry Fuel System : Natural Gas (NG) ------------------------------------- 12-13
Gaseous Dry Fuel System : Liquid Propane Gas (LPG) ------------------------- 14-15
Prepare for Generator Operation: --------------------------------------------------- 15-18
Access to Interior, Battery Selection & Installation, Electricians Wiring Installation, & Final Preparations before Start-up
Additional Hi-Lights of (8) Point Diagnostic Panel ------------------------------- 18
Changing Fuel from NG to LPG at Job-Site ---------------------------------------- 19-20
Initial Start-Up ---------------------------------------------------------------------------- 20-21
General Service Tips ------------------------------------------------------------------- 21-23
Dimensional Print: Models SPS-120 ------------------------------------------------- 24-25
Dimensional Print: Model SPP-180--------------------------------------------------- 26-27
Electrical Connection Prints ---------------------------------------------------------- 28-29
Service Schedule ------------------------------------------------------------------------ 30
Maintenance Record -------------------------------------------------------------------- 31
PAGE 2
SAVE THESE INSTRUCTIONS
THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS THAT MUST BE FOLLOWED DURING INSTALLATION, OPERATION, AND MAINTENANCE OF THIS GENERATOR SET AND ALL ASSOCIATED EQUIPMENT.
Thoroughly read this operators manual before installing, operating, or servicing your generator set. Safe operation and best performance can be achieved only when this generator is operated and maintained properly.
INTRODUCTION
Thank you for your purchase of this SENTRY-PRO automatic start/stop home standby generator set by GILLETTE GENERATORS, INC. This generator set is intended for use as an alternative source of electric power to operate normally required household electric loads, during a utility power failure.
This generator set has an all weather protected metal enclosure, MADE EXCLUSIVELY FOR OUTDOOR INSTALLATION, and will operate on either vapor withdrawal liquid propane gas (LPG) or natural gas (NG). CAUTION: This generator does not comply with emergency power as defined in NFPA 70 of National Electric Code.
GILLETTE GENERATORS has made every effort to present a modern, safe generator set that will give you a safe, clean supply of an alternative source. However, because each installation is different, it is impossible for this manual and GILLETTE to know and advise against all possible hazards. The listings, warnings, and cautions in this manual and on tags and decals affixed to the generator set, are therefore, NOT ALL INCLUSIVE. If a certain procedure, work method, test method, or operating procedure is used, and is not recommended by GILLETTE, the person or company responsible for the generator modification, must assume all responsibility for safety and correct operation for the operator, service technician, and all others within generator area.
READ YOUR GENERATOR SET MANUAL, PLUS SEPARATE ENGINE OPERATORS MANUAL AND AUTOMATIC TRANSFER SWITCH MANUAL CAREFULLY. KNOW YOUR EQUIPMENT BEFORE YOU USE IT. CONSIDER ANY POSSIBLE, POTENTIAL HAZARDS, BEFORE OPERATING YOUR GENERATOR SET.
CAUTION: Only current licensed electrical and
plumbing contractors should install your home standby generator. All phase of installation must comply with all applicable local and national codes,
industry standards, and regulations.
THE GILLETTE WARRANTY IS AUTOMATICALLY NULL AND VOID WITHOUT THE USE OF LICENSED ELECTRICIANS AND PLUMBERS, AND SO NOTED ON THE REGISTRATION FORM THAT IS TO BE RETURNED TO GILLETTE GENERATORS, INC.
IMPORTANT SAFETY RULES
The safety alert symbol is used as a signal for possible danger, caution warning, or general hazard.
DANGER:
will result in death or serious injury.
WARNING:
avoided, could result in a death or serious injury.
CAUTION:
might result in minor or moderate injury.
NOTICE:
could result in general damage.
Read and understand the above listed safety alert symbols, plus the following symbols that are used through out this manual.
Indicating a hazard that, if not avoided,
Indicating a hazard that, if not
Indicating a hazard that, if not avoided,
Indicating a hazard that, if not avoided,
A LIST OF HAZARD SYMBOLS
AND THEIR MEANINGS
Explosion
Toxic Fumes
Fire
Rotating Parts Hot Surface
Electrical Shock
Chemical Burn Explosive Pressure
PAGE 3
WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.
NOTICE
For all safety reasons to the equipment, GILLETTE recommends installation, start-up and service be performed by experienced personnel.
Sufficient, un-obstructed flow of cooling air is critical for correct generator operation.
The generator must be installed outdoors, away from an over-hang roof where ice and snow could avalanche onto generator and away from sprinklers that could throw water up into cooling vents of generator.
Electric load applied to generator should be no more that 75% of generator maximum rating to avoid constant maximum generator load use.
Generator should not be exposed to excessive and constant moisture, dust, dirt, or corrosive environments.
If connected loads cause over heating or excessive vibration, an overload condition exists. Remove loads until condition stabilizes.
Do not sit, step, or load heavy items on generator roof. Added stress can cause breakage.
Do not start generator with air cleaner, air cleaner cover, or oil dipstick removed, nor with oil drain hose in open drain position.
Keep a fire extinguisher rated “ABC” close by your generator and be familiar on how to use it. Consult your local fire department, for additional fire prevention ideas.
Be sure that a positive manual fuel valve be installed in fuel line feeding generator.
Do not tamper with engine controls, generator is factory adjusted to supply rated voltage and speed.
Never operate generator when ambient temperature is over 105º F, as electrical insulation system may fail.
WARNING
STARTING BATTERY
PRECAUTIONS
Starting batteries are not furnished with your generator set, but they are available through your installing contractor. The home standby generator requires a Group 36, 12 VDC fully charged battery with minimum 390 cold cranking amps.
Released battery electrolyte can burn your skin and eyes and is toxic.
When electrolyte touches skin, wash it off immediately with water and seek medical attention. When electrolyte contacts eyes, flush thoroughly with water and seek medical attention.
Spilled electrolyte must be washed away with an acid neutral agent. Use a solution of one pound bicarbonate of soda to one gallon of water, and wash down acid effected areas until evidence of acid foaming reaction has ended.
A battery provides risk of electric shock. Remove watches, rings, or other metal items when working with batteries. Use tools with insulated handles.
When disconnecting battery cables, always disconnect the battery charger first, the positive battery cable second, and negative battery cable last. When reconnecting cables, always reconnect the positive battery cable first, then negative cable, and reconnect battery charger last, to reduce possible arching.
Discharge body static electricity by touching a grounded metal surface on generator before touching battery.
Do not dispose of batteries in a fire and do not open or mutilate a battery, as the battery is capable of exploding.
Lead acid batteries present a risk of fire or explosion because they generate hydrogen gas, within. Do not smoke, nor have flame or spark in a battery area.
PAGE 4
DANGER
ELECTRICAL HAZARDS
A generator produces dangerous electric
voltages and can cause a fatal electric shock and will cause sudden illness, dizziness, and incoherent actions.
Despite the safe design of this GILLETTE generator, operating it carelessly, neglecting its normal maintenance, or being ill informed of proper operations can cause possible serious injury or death.
Avoid contact with bare wires, connection points, etc., while generator is running.
Do not touch any kind of electrical circuit while standing in water, while barefooted, or while hands or feet are wet or moist.
Never wear any type of jewelry while working on a generator. Jewelry will conduct electricity, causing electric shock.
If generator must be serviced while it is running, stand on a dry, insulated surface from ground to reduce shock hazard. Never service a generator in the rain or snow.
Do not allow unqualified or ill-experienced persons to operate or service generator.
Remain alert at all times. Never work on a generator when you are physically or mentally fatigued.
This generator is equipped with a ground terminal. Always complete the grounding path from generator to an external grounding source to prevent possible electric shock.
In case of electric shock, shut the generator down at once. If this cannot be done, free the victim from source of live electric power. AVOID ANY DIRECT
CONTACT WITH VICTIM OR THE LIVE ELECTRIC POWER. Use a dry piece of wood, a dry
rope, or any other such non-conductive item, to free the victim from source of power. If victim is semi or totally unconscious, apply CPR (cardio-pulmonary resuscitation) and call for medical help immediately.
DANGER
Breathing carbon monoxide will cause fatigue, headache, dizziness, vomiting, fainting, and in prolong conditions, even death.
Operate generator only outdoors, where adequate ventilation is available. Avoid generator installations under decks, inside garages or carports, in basement, along side home exterior within five feet of home vent, roof overhang vent, a window that can be opened, or other such home invasion points. Use same precautions when installing generator at property line, close to a neighbor’s home, or any buildings that house animals.
WARNING
POTENTIAL BURN OR FIRE
CONDITIONS
Contact with exhaust muffler and exhaust pipe can result in serious burns.
Exhaust heat may ignite combustibles such as leaves or other such debris that is allowed to accumulate around base of generator where exhaust exits.
Do not touch hot exhaust or engine parts, and avoid hot exhaust gases.
Keep at least a three foot clearance on all sides of generator.
Do not install generator any closer than five feet from any combustibles or buildings with walls having less than one hour, fire rating.
Code of Federal Regulation (CFR), Title 36, states that generators must have a spark arrestor attached to muffler outlet pipe, to eliminate sparks from engine operation. USDA Forest Service standard #5100-C requires spark arrestor protection when generator is operated within federal parks and forests.
Generator installation must always comply with local codes, standards, laws, and regulations. Check with your local fire department to learn of these precautions. Keep a fire extinguisher (rated “ABC” by NFPA as appropriate use on generator fires) nearby, at all times. Keep the extinguisher properly charged and become familiar with its use.
CARBON MONOXIDE POISON
A running engine produces a poisonous gas from its muffler exhaust pipe. This is an odorless, invisible, and colorless poison that cannot easily be detected.
PAGE 5
WARNING
FIRE OR EXPLOSION CONDITIONS
Gaseous fuels such as natural gas (NG) and liquid propane (LP) are extremely explosive. Make sure the fuel supply
system is installed in compliance with local and state fuel codes and regulations. Fuel leaks when ignited, can cause fire and explosion, resulting in harm or possible death.
Before initial generator start-up, all fuel system lines must be purged and leak tested according to applicable codes by experienced service personnel. No leaks are permitted.
Do not smoke or allow open flame near generator while servicing fuel system or battery. Lead acid battery will emit a highly explosive hydrogen gas that can be ignited. Leaks in LP or NG system can be ignited. Both are conditions that can cause fire and/or explosion, leading to possible death.
Do not operate generator if smell of fuel is detected.
Wipe up any oil spills immediately. Remove any debris that has accumulated inside or around generator base and housing.
Always maintain a scheduled inspection of entire fuel system and starting battery, looking for leaks or other negative conditions.
CAUTION
Following is a list of potential events that might result in minor or moderate injury or damage to the generator.
Never operate generator with oil dipstick partially seated or completely missing.
Never operate generator without air cleaner and cover in place.
Always check oil drain hose or radiator drain hose for leaks.
Generator operating speeds beyond 3750 RPM increase risk of operator injury and engine damage.
Never insert any objects through generator cooling slots.
The control panel and wiring access area doors
must be installed at time of operation.
If connected electrical items overheat, disconnect them immediately.
Immediately shut down generator if it looses electrical output, shows sparks, smokes, emits flames, vibrates, or shows any other abnormal operation.
Do not modify generator design.
Do not modify carburetion system, as it is factory
set for C.A.R.B./EPA emissions certification.
This concludes the limited hazard listing. However, GILLETTE cannot possibly anticipate every possible hazard. Therefore, the warnings in this manual, plus the warning tags and decals attached to the generator are not all inclusive. If the generator operator has a different operating method, other than described in this manual, than operator becomes responsible to make sure that different procedure, work method, or operating method is totally safe, against harm and hazards to operators, buildings or environments.
UNPACKING AND INSPECTION
After receiving the generator, note that it is mounted on a heavy wood skid base and protected by a multiply cardboard container. While the transportation carrier is still present, note the condition of skid and cardboard box. If noticeable damage is apparent, immediately remove cardboard box and inspect generator for possible freight damage. If damage occurs, make a note of damage on carrier’s freight bill and have truck driver sign his name on the freight bill, under “Consignor’s memo of loss or damage”.
If shipping container shows damage of any kind, and time does not permit container removal for actual generator inspection, while transportation carrier is still available, be sure to:
Make note of container damage “with possible interior product damage” on carrier’s freight bill.
Have truck driver sign his name on freight bill under “Consignor's Memo of Loss or Damage”.
This action will help prove your case against shipper. Always save shipping materials in the event that gen­set must be sent back to factory due to need of extensive repairs.
If damage is noticed after carrier leaves, contact the carrier for “concealed damage” form. NOTE: Missing or damaged parts on generator, is not a warranty claim.
PAGE 6
GENERATOR CONTENTS
The GILLETTE home generator set is supplied with the following components:
Home generator system within soundproofed all weather metal enclosure (Depending on option choice, this can be an open set or a super-silent enclosure add).
Residential muffler system for quiet operation.
Choice of (3) gen-set mounting systems:
A) Base direct mounting to concrete slab.
B) Base direct mounting to crushed gravel base,
secured in ground with ground stakes.
C) Base with plastic pad for floating mount on
crushed gravel.
3/4” NPT female coupling for gas connection.
Four lifting holes with cover plugs.
Two locking door keys (NOTE: One key fits all
locks.)
One spare 20 amp fuse. (Located just above fuse holder in control panel wiring area)
Diagnostic LED panel.
One owner/operator panel.
NOTE: All accessory items will be pre-mounted and wired to generator. If separate automatic transfer switch (ATS) is ordered, it is placed on top of generator shipping box and steel banded in place.
AUTOMATIC TRANSFER SWITCH (ATS)
DANGER
If this generator set is used to provide
temporary electric power to circuits when loss of normal utility power occurs, it is required by National Electric Code, to install an automatic transfer switch (ATS).
The ATS must isolate the home electrical system from the utility electrical distribution system when the home generator is operating (see NEC 700, 701, and
702). Failure to isolate an electrical system with an approved ATS will result in damage to home generator and also can result in severe injury or
death to utility power workers who may receive electrical back-feed shock from the home
generator set.
The automatic transfer switch is an optional selection and can be used with any model GILLETTE home generator set. All installation procedures, operating cautions, and warranties are responsibility of the separate manufacturers of the ATS.
PRE-INSTALLATION PLANNING
The beginning installation requires some thought and planning. The following illustrations are meant to familiarize reader with typical installation circumstances and to plan the best installation possible.
First, Federal, State, and local codes may be a factor. The local fire department can be of help on learning these codes. As with all generators, your generator must be installed in accordance with current NFPA-37 and NFPA-70 standards. Contact your local electrical inspector or city hall to insure you are aware of all codes and regulations. Contact your natural gas supplier to verify that increased BTU gas demand can be handled with existing NG gas meter. The same is true for LPG fueled generators.
The most common fuel mistakes are:
A) Not a dedicated fuel line from fuel source to generator, on either LPG or Natural Gas fuel.
B) Not having a dedicated primary fuel regulator for only the generator, while using LPG tank.
C) Wrong fuel pressures. (See fuel pressure information on page 14)
D) Not understanding that fuel pipe diameter must increase in direct proportion to fuel line length. (See gas charts on page 12 for further details)
E) Wrong primary regulator. This is a common problem, using an existing regulator on a LPG Tank is typically too small for the supply needed for a generator.
Locate the generator site. It should be as close as possible to the natural gas meter, and as close as possible to the home electrical distribution panel.
Determine the type of generator anchoring. There are three types:
1) ACCEPTABLE: Generator is mounted on a composite (plastic) pad, placed on a bed of pea gravel or crushed stone. It “floats” in place. (See Illustration #1)
2) ACCEPTABLE: Generator is mounted directly on a bed of pea gravel or crushed stone (no composite
PAGE 7
3) PREFERRED: Generator is mounted directly on a concrete slab, 4 inches thick, extending 6 inches beyond generator perimeter, and bolted in place. This method is for those locals with “high wind” considerations. (See Illustration #3)
If gravel bed is chosen, its perimeter must be eight inches larger than generator base. Dig a rectangular area six inches deep, cover with landscape cloth (so drainage can take place) and fill with pea gravel or crushed stone. Final gravel level must be two to three inches higher than original level to ensure water run­off away from generator. A normal plastic landscape border can be used between grass and gravel area to provide a more attractive installation.
Compact and level the stone. Place generator on stone using either the “composite” pad (optional equipment) or place aluminum generator base directly on gravel, using ground stakes for a fixed installation.
GROUND
GENERATOR BASE
GRAVEL BED
GRASS
ILLUSTRATION #2: Generator is placed on top of gravel bed. The ground stakes are driven through the slots in generator base, to hold it in place on gravel bed. CAUTION: Make sure there is no
underground electric wires, gas lines, sprinkler lines, or any other vulnerable items, directly in the path of these two ground stakes.
BOLTED TO
CEMENT PAD
BOLTED TO
PAD
GENERATOR BASE
COMPOSITE PAD
GRAVEL BED
GRASS
ILLUSTRATION #1: Composite pad bolted to generator base and placed over a bed of crushed stone or gravel.
SUGGESTIONS FOR GENERATOR LOCATIONS
OCCUPIED
BUILDING
#2
5'
GENERATOR
(B)
DANGER
TOXIC FUMES
MAY ENTER
BUILDING
APPROX.
10'
5'
PREFERRE D
GAS
METER
(A)
#1
GENERATOR
(B)
ACCEPTAB LE
(A) = SPS M ODELS
(B) = SPP MO DELS
GENERATOR BASE
CEMENT PAD
ILLUSTRATION #3: Generator base is bolted directly to a poured concrete slab (provided by others). Notice that all three illustrations provide bolting or staking methods that are always secured from inside the generator housing, behind locked doors. This is designed to deter theft of your home standby generator set.
1) Always install your generator within 20 feet from natural gas meter. Further distances may cause “starving” of fuel from generator engine.
2) Exhaust end must always be turned away or parallel with building and minimum 5 feet away.
3) Exhaust end is not to be directed towards play areas, patios, under canopies or overhangs, or where people or animals congregate.
4) Do not install generator under deck of house.
5) Furnace and other air intakes should be minimum 10 feet
(A)
from exhaust end
6) Windows and doors on adjacent walls, to be closed at all times, during generator operation.
7) Nearest roof overhang vent should be 10 feet from exhaust end
8) If electrical distribution center panel is far away from gas meter, locate generator close to gas meter. Installation costs are lower, if electric wiring is oversized for long distances, to utility point rather than oversized fuel lines to gas meter.
GRASS
PAGE 8
TYPICAL EMERGENCY GENERATOR INSTALLATION PRACTICES
MIN IMUM 5 FT
(1) Drawing shows a typical gas utility approach on how to bring natural gas fuel to the gen-set. The fuel from utility is connected by dedicated fuel line, to the installed 4 ounce, 7” water column secondary regulator, inside gen-set housing. CAUTION: Consult your natural gas supplier about your meter size. Most meters must be replaced with a larger BTU size, due to larger demand of BTU’s from generator. The same procedure is also used with LPG: a 6 ounce, 11” water column, dedicated primary regulator is placed at fuel outlet of “vapor withdrawal” LPG tank. Fuel is piped directly to LPG 6 ounce, 11” water column secondary regulator, inside gen-set housing.
(2) Drawing shows chosen circuit connection: Load circuits are selected based on importance of needs, plus the starting and running amps. All connected loads should not exceed the amp size of generator. The auto transfer switch should equal or exceed total amp load of (F), smaller distribution panel.
When “Chosen” load is matched to gen-set amp size, the gen­set is never overloaded.
(3) Drawing shows full load connection: The gen-set output is applied to the entire load of the utility electrical distribution panel. For this installation, the auto transfer switch, must be of same amp size as utility power. This is the easiest, lower priced electrical installation, but subject to gen-set shutdown whenever load amps exceed gen-set amp capacity.
(A) Drive a corrosion resistant steel stake, into ground and attach a 10 gauge stranded copper wire from stake to ground lug on outside of gen-set. This bleeds off any potential lightning strike and any static electricity, which can occur on metal parts of ungrounded generators. For a non-separately
derived system (where normal electric utility power is in building and gen-set is a back-up emergency power supply), the gen-set neutral must connect only to utility power neutral and not to the ground stake. The best place
for these two neutrals to meet (generator and utility neutral), is in the automatic transfer switch. However, still connect gen-set mechanical ground to the stake. All factory gen-sets, have a “floating neutral” ready to be connected to utility neutral, by installer.
(B) Normal utility power meter and power inlet to panel.
(C) Safety disconnect switch, sized to ATS amp rating. (D) Auto transfer switch with UL-1008 label and NEMA-1
housing for inside installation. Consult factory for NEMA-3R, outside installations.
(E) Original electric utility distribution panel.
(F) Separate, smaller distribution panel, with chosen circuit
loads.
HELPFUL INSTALLATION TIPS
Mound the gen-set location upwards at least 1 inch from normal terrain, for proper drainage. Fill an area 6 inches larger than gen-set mounting pad perimeter and 3 inches deep, with crushed gravel. This provides flexible settling of gen-set and mounting pad. NOTE: Specific locales may require a cement pad installation.
Gen-set must be located minimum 5 feet from all structures. This clearance will provide for ample service room.
Watch out for roof overhangs. Snow, ice, or rain should not be allowed to accumulate on roof, and cascade onto gen-set roof.
Check prevailing wind direction. Winds should blow toward the engine end of housing, which is the normal cool air intake end. The opposite end is hot air discharge.
Engine exhaust from generator end is hot and dangerous. Exhaust must be allowed to dissipate into free air zone, with no obstructions (air conditioner condenser, buildings, plants, trees, living quarters, etc.) within 5 feet.
Control wires and load wires should be made in (2) different circuit runs to auto transfer switch, to avoid any
possible magnetic interference between the two. These lines should be underground for best protection.
Don’t allow snow, ice, or debris to accumulate around and on gen-set. If possible, plant a short hedge or a series of evergreens, as a protective “wall”, 5 feet from gen-set on windward (engine) side, to stop such accumulation, and still
PAGE 9
KNOW YOUR GILLETTE HOME GENERATOR
Compare the following illustrations and individual component locations, with your actual GILLETTE home generator system. This will help familiarize yourself with the entire generator set.
Control, Wiring, & Generator End
2)
1)
Cool Air Input
LEFT SIDE FACING ENGINE END WITH SERVICE PANEL REMOVED
1) Ground Wire to Ground Stake (Electrician)
2) Two Electrical Knockouts (Electrician)
3) Oil fill.
4) Engine.
5) Spark plug (Replace every 300 hours of use).
3)
4)
5)
6)
7)
Engine End
8)
Cool Air Input
9)
6) Oil cooler.
7) Oil filter (Replace every 200 hours).
8) Oil drain with flexible drain hose. NOTE: Change oil after every 50 hours of use.
9) Dry fuel gas input (Always use flexible fuel line).
12)
13)
14)
11)
Engine End
10)
Cool Air Input
RIGHT SIDE FACING ENGINE END WITH SERVICE PANEL REMOVED
10) 12 VDC battery charger. Installer must connect 120 volt, 1 phase utility power to this charger.
11) 12 VDC engine starter motor.
12) Spark plug (replace every 300 hours of use).
13) Air cleaner element (Clean every 50 hours, replace at 300 hours).
15)
16)
Hot Muffler Area
17)
Generator End
Cool Air Input
18)
15) Oil dipstick.
16) Muffler. CAUTION: Hot to the touch when in use.
17) Generator.
18) Battery tray (see page 16 for installation and caution use).
PAGE 10
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