Magnum MLT 4250 User Manual
MLT 4250
OPERATING/PARTS MANUAL
INTRODUCTION
This manual provides information and procedures to safely operate and maintain the light tower and generator . For
your own safety and protection from physical injury , carefully read, understand, and observe the safety instructions
described in this manual. The information contained in this manual was based on machines in production at the
time of publication. Magnum Products LLC reserves the right to change any portion of this information without
notice.
DO NOT MODIFY or use this equipment for any application other than which it was designed for .
Magnum Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing
functions. Any wiring should be in compliance with the United S tates National Electric Code (NEC), st ate and local
codes and Occupational Safety and Health Association (OSHA) guidelines.
Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC, or
can be found at www.m-p-llc.com. An engine operators manual was also supplied with the unit at the time of
shipment from the factory . The manual provides detailed operation and maintenance procedures for the engine.
Additional copies of the engine operators manual are available from the engine manufacturer.
MAGNUM PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: 920-361-4442
Fax: 920-361-4416
Toll Free: 1-800-926-9768
www.m-p-llc.com
For technical or parts QUESTIONS, please contact Magnum Products’ Customer Support or
Technical Support team at 920-361-4442. Please have your serial number available.
T o ORDER SER VICE PARTS, please contact the dealer from which your purchased the unit,
or call Magnum Products to locate a dealer in your area.
Engine Make:
Engine Serial Number:
Engine Model Number:
Generator Make:
Generator Model Number:
Generator Serial Number:
Unit Model Number:
Unit Serial Number:
Diesel engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects and other reproductive harm.
2
WARNING
CALIFORNIA PROPOSITION 65 W ARNING:
TABLE OF CONTENTS
INTRODUCTION .................................................................................................................2
T ABLE OF CONTENTS ......................................................................................................3
SAFETY NOTES................................................................................................................4
OPERA TING SAFETY........................................................................................................4
ENGINE SAFETY ..............................................................................................................5
SERVICE SAFETY ............................................................................................................5
TOWING SAFETY..............................................................................................................6
REPORTING TRAILER SAFETY DEFECTS .......................................................................6
UNIT SERIAL NUMBER LOCA TIONS.................................................................................6
SAFETY SYMBOL SUMMARY..........................................................................................7
SPECIFICA TIONS ........................................................................................................ 8 - 9
EXTERIOR LOCA TIONS ...................................................................................................10
MAIN CONTROL P ANEL COMPONENTS ........................................................................11
MAGNUM DIGIT AL CONTROLLER (MDC)................................................................ 12 - 13
GENERA TOR MONITORING ............................................................................................13
ENGINE MONITORING ............................................................................................ 14 - 15
FINE VOL TAGE ADJUSTMENT ....................................................................................... 15
MDC CONTROLLER INFORMA TION DISPLAYS, FUNCTIONS AND RESET....................16
MDC CONTROLLER - GENERA TOR OPERA TIONAL ST A TUS.........................................16
MDC CONTROLLER - ALARM MANAGEMENT ...............................................................16
MDC CONTROLLER LIST OF POSSIBLE ALARMS WITH DESCRIPTIONS..............17 - 18
MDC CONTROLLER - HISTORY ......................................................................................18
ADJUSTING THE DISPLAY BACKLIGHTING ....................................................................19
RESETTING THE “TIME TO SERVICE” REMINDER.........................................................19
GENERAT OR OUTPUT CONNECTION LUGS ..................................................................20
VOL TAGE SELECT OR SWITCH ...................................................................................... 21
AUXILIARY OUTLETS ......................................................................................................22
VOL TAGE REGULA TION..................................................................................................22
EMERGENCY STOP SWITCH ........................................................................................ 22
MAIN CIRCUIT BREAKER................................................................................................23
REMOTE ST ART TERMINAL BLOCK...............................................................................23
TRANSFER SWITCH ................................................................................................23 - 24
LIGHT TOWER SET-UP ...................................................................................................25
RAISING THE TOWER.....................................................................................................26
RAISING THE TOWER WITH OPTIONAL ELECTRIC WINCH...........................................27
LIGHT TOWER ST ART UP ...............................................................................................28
PRE-ST ART CHECKLIST .................................................................................................28
MANUAL ST ARTING OF THE GENERA T OR .............................................................28 - 30
AUTO (REMOTE) ST ARTING OF THE GENERA TOR .......................................................30
LIGHT OPERA TION..........................................................................................................31
SHUTTING DOWN THE GENERA TOR .............................................................................31
LOWERING THE TOWER ................................................................................................32
LOWERING THE TOWER WITH OPTIONAL ELECTRIC WINCH...................................... 32
REMOVING THE LIGHTS FOR TRANSPOR TA TION.........................................................33
TOWING THE TRAILER ...................................................................................................33
TRAILER WHEEL BEARINGS .........................................................................................33
LIFTING THE TRAILER..................................................................................................... 34
GENERAL MAINTENANCE..............................................................................................34
ENGINE MAINTENANCE .................................................................................................35
OPTIONAL LOWER RADIA TOR HOSE HEA TER USE AND MAINTENANCE ...................35
DERA TING FOR AL TITUDE ..............................................................................................36
TROUBLESHOOTING SHUTDOWN CONDITIONS ...........................................................36
TROUBLESHOOTING THE LIGHTS .................................................................................37
UNIT DECALS...........................................................................................................38 - 41
MANUAL WINCH MAST ASSEMBL Y........................................................................42 - 43
ELECTRIC WINCH MAST ASSEMBLY...................................................................... 44 - 45
FRAME AND COMPONENTS ...................................................................................46 - 48
GENERA TOR ASSEMBLY ...............................................................................................49
MAST JUNCTION BOX ASSEMBL Y - HARD WIRED LIGHTS...........................................50
MAST JUNCTION BOX ASSEMBL Y - QUICK DISCONNECT LIGHTS...............................51
ENCLOSURE ASSEMBL Y ........................................................................................52 - 53
AUXILIARY OUTLET P ANEL ASSEMBL Y..................................................................54 - 55
AUXILIARY OUTLET P ANEL OPTIONS.....................................................................56 - 57
LIGHT ASSEMBL Y ....................................................................................................58 - 59
ENGINE COOLING ASSEMBL Y................................................................................60 - 61
ENGINE ASSEMBL Y ................................................................................................ 62 - 63
CONTROL P ANEL ASSEMBL Y.................................................................................64 - 65
CONTROL BOX ASSEMBL Y .....................................................................................66 - 67
LUG DOOR ASSEMBL Y ..................................................................................................68
WIRING DIAGRAMS .................................................................................................69 - 75
Page
3
SAFETY NOTES
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be
followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
The following formatting options will apply when calling the readers attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
DANGER
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED,
WILL RESULT IN DEATH OR SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
NOTICE
Indicates a hazardous situation which, if not avoided,
may result in property or equipment damage.
Note: Notes contain additional information important to a procedure and will be found within the regular
text body of this manual.
OPERATING SAFETY
Before using the light tower be sure you read and understand all of the instructions! This equipment was
designed for specific applications; DO NOT modify or use this equipment for any application other than which
it was designed for. Equipment operated improperly or by untrained personnel can be dangerous! Read the
operating instructions and familiarize yourself with the location and proper use of all instruments and controls.
Inexperienced operators should receive instruction from someone familiar with the equipment before being
allowed to operate or set up the light tower. The following points should be practiced at all times:
• The area immediately surrounding the light tower should be dry, clean, and free of debris.
• Position and operate the light tower on a firm, level surface.
• NEVER start a unit in need of repair.
• Lower tower when not in use, or if high winds or electrical storms are expected in the area.
• Make certain light tower is well grounded and securely fastened to a good earthen ground.
• The tower extends up to 30 ft. (9m). Make sure area above trailer is open and clear of overhead wires
and obstructions.
• Bulbs become extremely hot in use! Allow bulb and light fixture to cool 10-15 minutes before handling.
• Keep area behind trailer clear of people while raising and lowering mast!
• NEVER raise, lower or turn mast while unit is operating!
• Trailer must be leveled and outriggers extended before raising tower. Outriggers must remain ex-
tended while tower is up.
• If for any reason any part of mast hangs up or winch cable develops slack while raising or lowering
tower, STOP immediately! Contact an authorized service representative.
• NEVER remove safety pin or pull mast locking pin while tower is up!
• NEVER use tower if insulation on electrical cord is cut or worn through.
• NEVER operate lights without protective lens cover in place or with a lens cover that is cracked or
damaged!
4
ENGINE SAFETY
Internal combustion engines present special hazards during operation and fueling! Failure to follow the
safety guidelines described below could result in severe injury or death. Also read and follow all safety
warnings described in the Engine Operator's Manual. A copy of this manual was supplied with unit when
it was shipped from the factory.
• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel
engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled,
can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or
ventilation equipment.
• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank
in an enclosed area with poor ventilation.
• DO NOT operate with the fuel tank cap loose or missing.
• DO NOT touch or lean against hot exhaust pipes or engine cylinders.
• DO NOT clean air filter with gasoline or other types of low flash point solvents.
• DO NOT remove engine coolant cap while engine is hot.
• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels in
excess of 85 DBA can cause permanent hearing loss. Wear hearing protection when working around
a running engine.
• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental
fire.
• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye
damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
corresponding terminal before performing any service on the engine or other components.
• Shut the engine down if any of the following conditions exist during operation:
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the generator overheats.
4. Sp arking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6. Operating on a combustible surface.
7. Protective covers are loose or missing.
8. If the ambient air temperature is above 1 10° F .
SERVICE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
should troubleshoot or repair electrical problems occurring in this equipment.
• Before servicing light tower, make sure the engine start switch is turned to OFF, circuit breakers are
open (off) and the negative terminal on the battery is disconnected. NEVER perform even routine
service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
• NEVER allow water to accumulate around the base of the light tower. If water is present, DO NOT
service!
• NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check
the engine and generator for any moisture and dry the unit before use.
• NEVER wash the unit with a power washer or high pressure hose.
• Open main circuit breaker before disconnecting battery cables.
• Keep hands, feet, and loose clothing away from moving parts on generator and engine.
• Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached
securely and have enough weight-bearing capacity to lift or hold the equipment safely. Always
remain aware of the position of other people around you when lifting the equipment.
5
TOWING SAFETY
Towing a trailer requires care! Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Also, some states require that large trailers
be registered and licensed. Contact your local Department of Transportation office to check on license
requirements for your particular unit.
• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
"gross vehicle weight rating" (GVWR).
• Check tires on trailer for tread wear, inflation, and condition.
• Inspect the hitch and coupling for wear or damage. DO NOT tow trailer using defective parts!
• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely
fastened to the vehicle.
• Connect safety chains in a crossing pattern under the tongue and attach the breakaway cable TO
THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer hitch.
• Make sure directional and brake lights on the trailer are connected and working properly.
• Check that all lug nuts holding wheels on are tight and that none are missing.
• Maximum recommended speed for highway towing is 45 m.p.h. Recommended off-road towing speed
is not to exceed 10 m.p.h. or less depending on terrain.
When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane
changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an area
away from heavy traffic.
A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean
and apply fresh grease each time the trailer is towed.
REPORTING TRAILER SAFETY DEFECTS
If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traf fic Safety Administration (NHTSA) in addition to notifying Magnum Product s
LLC. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in
individual problem between you, your dealer, or Magnum Product s LLC.
T o contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 or by fax at: (202)-366-
7882. Additional contact information can be found at: www .nhtsa.dot.gov .
UNIT SERIAL NUMBER LOCATIONS
Refer to the locations illustrated below to find the unit ID
tag, and trailer ID tag on your unit. Important information,
such as the unit serial number, model number and
Vehicle Identification Number (V.I.N.) for your trailer are
found on these tags. Record the information from these
tags, so it is available if the tags are lost or damaged.
When ordering parts or requesting technical service
information, you may be asked to specify this information.
V.I.N. Tag
MANUFACTURED BY/FABRIQUE PAR:
GVWR/PNBV:
GAWR/PNBE TIRE/PNEU RIM/JANTE
THIS VIEHICLE CONFORS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS
IN ECCEFT ON THE DATE OF MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN
VERTU DU REGLEMENT SUR LA VEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.
THIS VIEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
V.I.N./N.I.V.: TYPE/TYPE DE VEHICULE:
DATE OF MFG:
COLD INFL. PRESS./PRESS.
DE GONF A FROID
KPA(PSI/LPC)
SGL/DUAL
Located on inside
TM
MADE IN USA
PRODUCTS LLC
215 Power Drive
Berlin, WI 54923
1-800-926-9768
Model
Serial Number
Mfg. Code
kg
lbs
rpm hz amb. temp.
RATING: CONT. STAND BY
1 Phase
3 Phase
KW
KVA
V
V
A
A
FOR ELECTRICAL
EQUIPMENT ONLY.
®
POUR MATERIAL
LR 114630-1
ELECTRIQUE SEULEMENT.
Unit ID Tag
of panel.
TM
MADE IN USA
PRODUCTS LLC
215 Power Drive
Berlin, WI 54923
1-800-926-9768
Model
Serial Number
Mfg. Code
kg
lbs
rpm hz amb. temp.
RATING: CONT. STAND BY
1 Phase
3 Phase
KW
KVA
V
V
A
A
FOR ELECTRICAL
EQUIPMENT ONLY.
®
POUR MATERIAL
LR 114630-1
ELECTRIQUE SEULEMENT.
6
MANUFACTURED BY/FABRIQUE PAR:
GVWR/PNBV:
GAWR/PNBE TIRE/PNEU RIM/JANTE
THIS VIEHICLE CONFORS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS
IN ECCEFT ON THE DATE OF MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN
VERTU DU REGLEMENT SUR LA VEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.
THIS VIEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
V.I.N./N.I.V.: TYPE/TYPE DE VEHICULE:
DATE OF MFG:
COLD INFL. PRESS./PRESS.
DE GONF A FROID
KPA(PSI/LPC)
SGL/DUAL
SAFETY SYMBOL SUMMARY
This equipment has been supplied with numerous safety and operating decals. These decals provide important
operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care
when washing or cleaning the unit. Decal placement and part numbers can be found in the beginning of the parts
section of this manual. Below is a summary of the intended meanings for the symbols used on the decals.
UV
Safety alert symbol; Used to
alert you to potential personal
injury hazards.
Hot surface(s) nearby.
Belt/entanglement hazard; Keep
body parts clear of this area.
Fan hazard; Keep body parts
clear of this area.
Crush hazard; Keep body parts
clear of this area.
Ultraviolet radiation hazard;
Operate only with lens intact.
Asphyxiation hazard; Operate
in well ventilated area.
Dangerous voltage may be
present.
Anchor/tie down point.
Forklift here only.
Use clean diesel fuel only.
Burn/scald hazard;
pressurized steam.
Stop engine before fueling.
Fire/explosion hazard; Keep
open flames away from unit.
Lift here only.
Read and understand the
supplied operator’s manual
before operating unit.
Unit electrical ground.
7
SPECIFICATIONS
Read this manual carefully before attempting to use this light tower. The potential for property damage, personal
injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this
unit. Each manual details specific information regarding items such as set up, use and service requirements.
Specifications are subject to change without notice.
MAGNUM MODEL MLT 4250
Engine
Make/Brand ........................................................ Isuzu
Model.................................................................. 4LE1-NYGV-01
Type.................................................................... Diesel, liquid cooled, 4-stroke
Horsepower - prime hp (kW) ............................... 31.5 (23.5)
Horsepower - standby hp (kW) ........................... 34.5 (25.7)
Operating Speed rpm ......................................... 1800
Displacement in3 (L) ........................................... 134.25 (2.20)
Cylinders - qty .................................................... 4
Fuel Consumption - 100% prime gph (Lph) ....... 1.80 (6.81)
Battery Type - Group Number ............................. 2 4
Battery Voltage (Quantity per Unit) ..................... 12V (1)
Battery Rating..................................................... 720 CCA
Generator
Make/Brand ........................................................ Marathon Electric
Model.................................................................. 282NSL1505
Type, Insulation ................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kV A) ...................................... 20 (25)
Amps - 3Ø St andby - 480 (208V) A..................... 30 (69)
3Ø - Prime kW (kV A).......................................... 18 (23)
Amps - 3Ø Prime - 480 (208V) A ........................ 28 (64)
1Ø - Standby - kW (kVA) .................................... 16.0 (16.0)
Amps - 1Ø St andby - 240V A.............................. 67
1Ø - Prime - kW (kV A)........................................ 15.0 (15.0)
Amps - 1Ø Prime - 240V A ................................. 63
Frequency Hz ..................................................... 60
Power Factor ...................................................... 1 (1Ø), 0.8 (3Ø)
Dimensions
Length w/ mast stowed in (m) ............................ 170 (4.32)
Width in (m) ....................................................... 63 (1.60)
Width w/ outriggers extended in (m) ................... 140 (3.56)
Height w/ mast stowed in (m)............................. 70 (1.78)
Maximum height of tower ft (m) .......................... 30 (9.14)
Weights
Dry Weight lbs (kg)............................................. 2158 (979)
Operating Weight lbs (kg) ................................... 2556 (1159)
Capacities
Fuel T ank V olume gal (L) ................................... 56 (212)
Usable Fuel Volume gal (L)................................ 56 (212)
Coolant (incl. engine) qt (L)................................. 11.6 (11.0)
Oil (incl. filter) qt (L)............................................ 8.6 (8.1)
Maximum Run Time hrs...................................... 31
8
SPECIFICATIONS
Read this manual carefully before attempting to use this light tower. The potential for property damage, personal
injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this
unit. Each manual details specific information regarding items such as set up, use and service requirements.
Specifications are subject to change without notice.
Lighting
Lighting Type....................................................... Metal Halide
Ballast Type........................................................ Coil & Core
Lumens ............................................................... 440,000
Coverage acres (m2)........................................... 5 - 7 (20,234 - 28,328)
AC Distribution
Circuit Breaker Size............................................ 90
Volt age Selection................................................ 3 Position Switch (lockable)
Volt age Regulation .............................................. +/-1%
Volt ages Available 1Ø ......................................... 120, 139, 208, 220, 240, 277
Volt ages Available 3Ø ......................................... 208, 220, 440, 480
Trailer
Number of Axles ................................................. 1
Capacity - Axle Rating lbs (kg) ........................... 3000 (1361)
Tire Size in ......................................................... 15
Hitch - Standard.................................................. 2" Ball
Maximum Tire Pressure psi ................................ 50
9
EXTERIOR LOCATIONS
1
2
3
4
5
6
1. FUEL FILLER LOCA TION (under door): Use clean DIESEL FUEL ONL Y .
2. RADIA T OR ACCESS P ANEL: Remove this panel for engine coolant service.
3. CONTROL P ANEL LOCA TION (under door): Engine/generator controls and all circuit breakers.
4. EMERGENCY STOP SWITCH: For emergency shut down; stops engine and trips main circuit breaker .
5. EQUIPMENT OUTLETS: Circuit breaker protected outlets; 20, 30 and/or 50 amp ratings.
6. GROUND STUDS (2): For grounding generator and equipment connected to the equipment outlets.
10
MAIN CONTROL PANEL COMPONENTS
13
1
12
9
8
10
11
2
7
6
5
4
2
3
1. MAIN CIRCUIT BREAKER (90A): This breaker will disconnect power to the connection lugs.
2. LUG DOOR SAFETY SWITCHES: These switches will shut the generator down if the lug door is opened when the
generator is running.
3. GENERAT OR OUTPUT CONNECTION LUGS: These allow appropriate loads to be wired directly to the generator.
4. GENERAT OR GROUND CONNECTION LUG: This lug is for connecting a good earthen ground per any local, state
or National Electric Code (NEC) guidelines before starting the generator .
5. REMOTE START TERMINAL BLOCK: Allows connections for remote st arting of the generator.
6. CABLE ACCESS: Allows for entry of load cables to the connection lugs with the lug box door closed.
7. PHASE SELECTOR SWITCH: This switch will change the generator output between three phase and single phase
power. See the VOL T AGE SELECT OR SWITCH section for more information.
8. VOLT AGE ADJUSTMENT RHEOSTA T : Used to fine tune generator output voltage.
9. CONTROL POWER SWITCH: This is the main power switch for the controller in MANUAL or AUTO mode.
10. ENGINE CONTROL PANEL: See p ages 12 - 13 for additional information.
11. BALLAST INDICA TOR LIGHTS: Indicates power from the ballast to each light.
12. INDIVIDUAL CIRCUIT BREAKERS: One breaker is supplied for each light.
13. AUXILIARY OUTLET MAIN CIRCUIT BREAKER (100A): This breaker disconnects power to the auxiliary equip-
ment outlets.
11
MAGNUM DIGIT AL CONTROLLER (MDC)
The Magnum Digital Controller (MDC) is an enhanced digital generator controller used to start, stop and monitor the
operation of the generator and the engine. The controller constantly monitors vital generator and engine functions
for a number of pre-programmed alarm and fault conditions. When a fault condition occurs, the engine will shut
down automatically and the Liquid Crystal Display (LCD) window will display the fault that caused the shutdown; to
resume operation the fault condition must be resolved. The controller has the ability to provide the display readout
in English and Sp anish; other languages are available. A screen print out of the display screen is also available.
This controller also records a “History” of the unit’s performance which may be viewed at any time and will not be
removed or lost when the controller is powered down.
2
3
MAN AUT
0
kW
Ready
PF 0.00
RPM 0
0
1
4
5
The MDC panel consists of five sections, including: the “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine
Volt age Adjustment Screw; the “OPERA TION” keyp ad; the LCD window; the “DIAGNOSTICS” keypad; and the
“ST A TUS” Light Emitting Diodes (LED’s). The following is a brief summary of the operation of each section of the
control panel:
1. The “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine Voltage Adjustment Screw
• Control On/Off T oggle Switch
This toggle switch powers-up the control panel and the controller.
• Fine Volt age Adjustment Screw
This screw may be adjusted to set the generator output voltage after the voltage selector switch has been
changed from one phase to another. This adjustment must be accomplished within 45 seconds of start-up
so that the unit does not experience a shut down alarm for “SENSING”.
2. The “OPERA TION” Keypad
• “ENGINE STAR T” Button
The Power Screen Display must be in the “MAN” mode in the upper left corner of the LCD window and the
“Ready/Manual” LED lit in the “Status” portion of the controller . Press the green “ENGINE ST AR T” button to
start the unit.
• “ENGINE STOP” Button
Press the red “ENGINE STOP” button to shut down the unit and start the “S top V alue” timer.
• “MANUAL W” Button
Press this button to change from the Automatic (Remote) starting mode to Manual st arting mode.
• “AUTO
XX
X” Button
XX
Press this button to change from Manual starting mode to Automatic (remote) st arting mode.
12
• “ALARM CANCEL” Button
When an alarm is activated, either visually or audibly , press this button to silence or cancel the alarm.
• “FAUL T RESET” Button
Press this button to clear the fault from the LCD window after the fault has been corrected.
Press “FAUL T RESET” and “ENTER” to clear the John Deere ECU Alarm List Codes.
3. The Liquid Crystal Display (LCD)
• This window will toggle between the Generator Display Screen and the Engine Display Screen upon start-
up of the unit. By viewing these screens, the operator will be able to monitor both the engine and generator
status while the unit is running.
4. The “DIAGNOSTICS” Keypad
•“S” Scroll-Up Button
Press this button to scroll-up within the LCD window.
•“T” Scroll-Down Button
Press this button to scroll-down within the LCD window.
• “P AGE SELECT” Button
Pressing this button will select the next display screen.
• “ENTER” Button
Pressing this button will place you inside the particular display to review the generators preprogrammed
setpoints or parameters.
5. The “ST A TUS” Light Emitting Diodes (LED’ s)
• These 6 LED’s will illuminate to display the current operational status of the generator;
- Alarm/Fault: Indicates active or inactive alarms, but not reset shutdown alarms.
- Warning: Indicates an active or inactive alarm, or a warning alarm that has not been reset
- Ready/Manual: Indicates the controller is ready to start and in the manual mode.
- Ready/Auto: Indicates the unit is in the “AUTO” mode ready for the remote start signal.
- Running: Indicates the unit is running.
- Supplying Load: Indicates a load is being applied to the generator.
GENERATOR MONITORING
Generator information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Engine
information after the first 60 seconds of operation, then every five seconds thereafter . The generator display screen
will show frequency , line to neutral voltage, line to line voltage and amperage.
Note: When loading the generator , it is import ant to observe the amperage to determine the load balance on each
line of the generator. Minor load unbalances, usually 5% or less, will not cause any particular problems. Every
effort should be made to distribute the load equally between all lines.
• Hertz: Displays output frequency .
• Generator Output V olt age: Line to Neutral display, single phase (1Ø).
• Generator Output V olt age: Line to Line display, 3 phase (3Ø).
• Amps: Displays the AC output amperage produced by the generator .
13
ENGINE MONITORING
Engine information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Generator
information after the first 60 seconds of operation and then every 5 seconds thereafter . The engine display screen
will show oil pressure, engine coolant temperature, fuel level and battery voltage.
• Oil Press: Displays engine oil pressure. The display registers oil pressure between 0-100 psi.
Normal operating pressure is between 35-80 psi.
• Eng T emp: Displays the temperature of the engine’s coolant. If the coolant temperature exceeds the
Maximum Water Temperature of 230° F the engine will automatically shut down. Zero “0”
will be displayed until a minimum temperature of 100° F is reached.
• Fuel Level: Displays the relative fuel level in the fuel tank in percent (50% = 1/2 tank, 75% = 3/4
tank, etc.). If the fuel level drops below a programmed low fuel point – usually at 15%, a
low fuel warning and optional audio alarm will be activated. If the fuel level drops below
the programmed low fuel limit, usually at 5%, the engine will automatically shut down.
(Note: The MLG 25 does not display fuel level).
• Vbat: Displays the engine battery voltage. A normal reading is 13-14V on 12 volt systems and
24-26 on 24 volt systems, (with the engine running).
Additional information may be viewed while the unit is in “MANUAL” or “AUTO” mode. By pressing the “Page
Select” button, the operator will select one of the following screens; “Running” screen, “Password” screen, or
“History” screen. In each of these page selections the operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to display additional information as follows:
• “Running” screen:
The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to
display the “Alarm List” screen, “ECU Alarm List” screen, “Run Hours” screen, “ECU
V alues” screen, Engine display screen and Generator display screen.
• “Password” screen:
The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to move
the “>” cursor up or down a list of text.
• “History” screen:
The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to move
the “>” cursor up or down a list of the latest alarm or shutdown codes. Pressing the
“Enter” button at a particular selection will allow the operator to scroll to the right in the
LCD window to view the generator operating parameters at the time of the alarm or
shutdown.
14
The history of alarms or codes of the unit are saved in the digital controller. The most
A
recent alarm or code is the first to be listed, with the time/date of the alarm or code at
the bottom of the screen. The controller stores up to 1 18 codes. When full, the controller
will automatically remove the oldest file. These codes will not be lost when the control
power toggle switch is powered off.
FINE VOLTAGE ADJUSTMENT
Upon start-up of the generator , the “Running” screen of the Magnum Digital
Controller (MDC) will display “SENSING” and will countdown from 45 seconds
to “0” Zero. This is a safety feature of the controller to protect the generator
from over or under voltage upon start-up.
VOLTAGE
DJUSTMENT
RHEOSTAT
CONTROL
ON
CONTROL
OFF
“SENSING” is a 45 second time delay and count down process before the
MDC records the generator nominal output voltage. This nominal generator
voltage is then compared to the current set point voltage of the voltage selector switch. If the nominal voltage recorded by the controller is greater than or
lower than the current set point voltage of the voltage selector switch setting
by 10% or more, the controller will shut the generator down automatically . The
display will read: Wrn VG1 or 2 or 3 Under/Over and/or Sd Vg1 or 2 or 3
Under/Over. This means the controller warned (“Wrn”) or even shut down (“Sd”) the unit due to an output voltage
irregularity .
The output voltage of the generator may be adjusted after the generator is running by use of the fine voltage adjustment screw. The adjusting screw is located directly below the control On/Off toggle switch on the control panel.
This screw turns a rheostat that will provide an increase (“+”) or a decrease (“-”) in the generator output voltage as
displayed on the Power Display Screen on the control panel. When making this adjustment, if the voltage is
increased or decreased too fast or too slow, the unit will automatically shut down. This adjustment needs to be
made within the 45 second delay and countdown to “0” Zero period.
T o adjust the output voltage, check the output voltage on the Liquid Cryst al Display (LCD) window labeled Gen freq
& Hz. Look at the L1N voltage or the L12 voltage on the display . The generator nominal output voltage should be
within 10% of the voltage rating on the voltage selector switch.
To adjust the output voltage loosen the lock nut at the base of the screw and turn the screw in the desired direction
until the required voltage shown on the LCD window matches the stated voltage on the voltage selector switch.
For Example: With the voltage selector switch set to “208/120V” 3 Phase position, the voltage displayed on
the Gen freq & Hz screen must be within ± 10 % of the 208/120 position (188-228 V Line to
Line / 108-132 V Line to Neutral).
If the voltage is not set within 10% of the applied voltage or the voltage is not reset within the
45 second delay period, the generator will shut down automatically and the display will read
Wn VG1 or 2 or 3 Under/Over and/or Sd Vg1 or 2 or 3 Under/Over.
Note: Each time the voltage selector switch is changed from one setting to another, an adjustment will need to be
made to the fine voltage using this adjustment screw.
15
MAGNUM DIGITAL CONTROLLER (MDC) INFORMATION DISPLAYS, FUNCTIONS AND
No. Engine State Machine Description
1 AfterCool Engine aftercooling, Cooling Pump output is closed.
2 Cooling The generator is cooling before stop.
3 Cranking Engine is cranking.
4 EmergMan Emergency Manual gen-set operation.
5 Init Autotest during controller power on.
6 Loaded
The generator is running at nominal speed and GCB OPEN/CLOSE is
closed.
7 Not Ready The generator is not ready to start.
8 Pause Pause between start attempts.
9 Prestart Prestart sequence in process, Prestart output is closed.
10 Ready The generator is ready to run.
11 Running The generator is running at nominal speed.
12 Shutdown Shut-down alarm is activated.
13 Starting Starting speed is reached and the
Idle timer
is running.
14 Stop Stop
No. Electrical State Machine Description
1 StabilTO Stabilization Timeout
No. Type Description
1 Sensor fail (FLS)
Sensor fail is detected when measured value is 6% out of the selected
characteristic. Sensor fail indicated by ##### symbol instead measured
value.
2 Warning (WRN) When warning comes up, see list of possible alarms.
3 Shut down (SD)
When the shut-down alarm comes up the Magnum Digital Controller opens
outputs GCB CLOSE/OPEN, FUEL, SOLENOID, STARTER AND
PRESTART to stop the engine immediately.
RESET
The Magnum Digital Controller (MDC) constantly monitors vital generator and engine functions for a number of
operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and
the Liquid Crystal Display (LCD) window will show the fault that has caused the shut down. To resume operation,
the fault condition must be resolved. T o reset the controller and resume operation, press the “F AUL T RESET”
button.
MAGNUM DIGITAL CONTROLLER (MDC) – GENERATOR OPERATIONAL STATUS
The Magnum Digital Controller (MDC) displays the operational status of the generator using the following codes:
MAGNUM DIGIT AL CONTROLLER (MDC) - ALARM MANAGEMENT
The Magnum Digital Controller (MDC) is capable of displaying the following alarms:
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MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF POSSIBLE ALARMS/DESCRIPTIONS
No.
Events
Specification
Protection
Type
Information
on Binary
Output
Available
Description
1 AnInIOM Sd SD YES
Shutdown alarm configurable on the input of IG-IOM/IGS-PTM.
2 AnInIOM Wrn WRN YES
Warning alarm configurable on the input of IG-IOM/IGS-PTM.
3 Battery Flat SD YES
If the controller switches off during starting sequence due to
bad battery condition it doesn't try to start again and activates
this protection.
4 Binary Input Configurable YES
Configurable Warning/Shutdown alarms on the inputs of IL-NT.
5 ChrgAlternFail WRN YES
Failure of the alternator for charging the battery.
6 EmergencyStop SD NO
If the input
Emergency stop
is opened shutdown is immediately
activated.
7 Engine Temp Sd SD NO
Water temperature is greater than
Sd Water temp
setpoint.
8 Engine Temp Wrn WRN YES
Water temperature is greater than
Wrn Water temp
setpoint.
9 Fgen <, > SD YES
The generator frequency is out of limits given by
Gen >f
and
Gen <f
setpoints.
10 Fuel Level Sd SD YES
Fuel level is less than
Sd Fuel Level
setpoint.
11 Fuel Level Wrn WRN YES
Fuel level is less than
Wrn Fuel Leve
l setpoint.
12 GCB fail SD NO
Failure of the generator circuit breaker.
13 Igen unbl SD NO
The generator current is unbalanced.
14 Low BackupBatt WRN NO
RTC backup battery is flat.
15 Oil Press Sd SD NO
Oil pressure is less than
Sd Oil press
setpoint.
16 Oil Press Wrn WRN YES
Oil pressure is less than
Wrn Oil press
setpoint.
17 Overload SD YES
The load is greater than the value given by
Overload
setpoint.
18 Overspeed SD YES
The protection comes active if the speed is greater than
Overspeed
setpoint.
19 ParamFail NONE NO
Wrong checksum of parameters. Happens typically after
downloading new firmware or changing of the parameter. The
controller stays in INIT mode. Check all parameters write at
least one new parameter.
20 PickupFault SD NO
Failure of the magnetic pick-up sensor for speed measurement.
21 Sd IOM fail SD NO
Shutdown alarm in case of lost connection to IG-IOM/IGS-PTM
module.
22 SprinklActive WRN NO
The protection is active if the output
Sprinkler
is closed.
23 Start failed SD YES
Gen-set start failed
24 Stop fail SD YES
Gen-set stop failed.
25 Ubat WRN YES
Battery voltage is out of limits given by
Batt overvolt
and
Batt
undervolt
setpoints.
26 Underspeed SD YES
During starting of the engine when the RPM reaches the value
of
Starting RPM
setpoint the starter is switched off and the
speed of the engine can drop under
Start RPM
again. Then the
Underspeed protection becomes active. Protection evaluation
starts 5 sec
27 Vgen <, > SD YES
The generator voltage is out of limits given by
Gen <V
and
Gen >V
setpoints.
Shut down and warning fault conditions and the displayed message are described in the following table:
17
28 Vgen unbal SD NO
The generator voltage is unbalanced more than the value of
Volt unbal
setpoint.
29 Wrn ECU Alarm WRN NO
ECU alarm list is not empty.
30 Wrn RA15 fail WRN NO
Warning alarm in case of lost connection to IGL-RA15 module.
31 WrnServiceTime WRN NO
The period for servicing is set by the
NextServTime
setpoint.
The protection comes active if the running hours of the engine
reach this value.
MAGNUM DIGIT AL CONTROLLER (MDC) – HIST OR Y
No.
Record Structure
Abbreviation
Historical value
1 AIM1 IG-IOM, IGS-PTM Analog input 1 value (when configured IG-IOM, IGS-PTM)
2 AIM2 IG-IOM, IGS-PTM Analog input 2 value (when configured IG-IOM, IGS-PTM)
3 AIM3 IG-IOM, IGS-PTM Analog input 3 value (when configured IG-IOM, IGS-PTM)
4 AIM4 IG-IOM, IGS-PTM Analog input 4 value (when configured IG-IOM, IGS-PTM)
5 BIM IG-IOM, IGS-PTM Binary inputs (when configured IG-IOM, IGS-PTM)
6 BIN Binary inputs IL-NT
7 BOM IG-IOM, IGS-PTM Binary outputs (when configured IG-IOM, IGS-PTM)
8 BOUT Binary inputs IL-NT
9 Date Date of historical event in format DD/MM/YY
10 EngT IL-NT Analog input 2 value (default Water temperature)
11 FC ECU alarm FailureCode
12 FLvl IL-NT Analog input 3 value (default Fuel level)
13 FMI ECUalarm Failure Mode Identifier
14 Gfrg Generator frequency
15 Ig1 Generator current L1
16 Ig2 Generator current L2
17 Ig3 Generator current L3
18 LChr Character of the load
19 Num Number of historical event
20 OilP IL-NT Analog input 1 value (default Oil pressure)
21 PF Generator PF
22 Pwr Generator active power
23 Reason Event specification
24 RPM Engine Speed
25 Time Time of historical event in format HH:MM:SS
26 Ubat Battery voltage
27 Vg1 Generator voltage L1
28 Vg2 Generator voltage L2
29 Vg3 Generator voltage L3
The Magnum Digital Controller (MDC) controller stores a record of each important event into the history file of the
controller. The history file seat s 1 18 records. When the history file is full, the oldest records are removed.
18
ADJUSTING THE DISPLAY BACK LIGHTING
The backlighting on the Liquid Crystal Display (LCD) window may be adjusted brighter or darker by the operator
whenever the Magnum Digital Controller (MDC) is powered up.
1. Press and hold “Enter” and press “S” or “T” on the Diagnostics keypad to increase or decrease the
display contrast as needed.
2. Release the “Enter” button and the “S” or “T”buttons when the desired backlighting is attained.
Note: Anytime an “*” is displayed on the LCD, the text or set point cannot be changed with out the use of a pass-
word. Contact Magnum Products Technical Support for assistance.
RESETTING OF THE “TIME TO SERVICE” REMINDER
The Magnum Digital Controller (MDC) will display the message “ WrnServiceTime” when the unit is due for maintenance or service. The maintenance or service interval is set at 250 hours of engine running time. Once the unit has
been serviced, the “ServiceTime” reminder needs to be reset to the 250 hour interval. The following procedure
demonstrates how to reset the running hours to 250:
1. With the unit shut down, power up the controller with the “Control On/Off” T oggle Switch. The initialization
screen will be displayed. The controller will toggle automatically to the “Ready” Display screen.
2. Press the “S” button. The “Alarm List” display screen will appear. The next screen will display lines of text;
starting with the word “Password”, then “Basic Settings”, “Engine Params”, “Engine Protect” etc. The top
line has a “> “ cursor before the word ‘Password”.
3. Press the “T” button to move the “> “cursor down to the “Engine Protect” line of text.
4. Press Enter. “NextServTime” will appear at the top of the display screen on the left side, with the current
service time hour setting (250) one line below on the right side
5. Press Enter. The current run time in hours will now appear on the left side of the display screen, directly
under “NextServTime”
6. Press the “S” button and reset the current run time hour setting to 250. If you overshoot the 250 time
interval use the “T” button to get back to the 250 time interval.
7. Press “Enter” to save the current run time hour setting.
8. Move the “CONTROL ON / I” toggle switch to the “CONTROL OFF / O” position.
19
TIGHTEN CONNECTION
LUGS WITH A HEX WRENCH
GENERATOR OUTPUT CONNECTION LUGS
The generator is equipped with connection lugs behind a door below the controller face. The lugs provide connection
points for attachment of external loads to the generator . A large decal on the inside of the connection lug door
details the proper connections for selected voltages.
WARNING
It is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and
related connections to the generator. Installation should be in compliance with the National
Electric Code (NEC) as well as any local or state guidelines as required by law. Failure to follow
proper installation requirements may result in equipment or property damage, personal injury
or death.
WARNING
Before any connections are made to the generator, make sure that the main circuit breaker and
the control power switch are in the OFF “O” position. Potentially lethal voltages may be present
at the generator connection lugs.
DANGER
IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE
POTENTIALL Y LETHAL VOL T AGE T O BACKFEED ONTO UTILITY LINES. THIS MA Y RESUL T IN
INJURY OR ELECTROCUTION T O UTILITY WORKERS NEARBY . MAKE SURE THE GENERA TOR IS
SUPPL YING POWER TO AN ISOLA TED OBJECT OR BUILDING THA T IS NOT CONNECTED T O ANY
UTILITY LINES.
Connections to the lugs should be made by running the power
cables through the circular plastic bushing on the lower right side
of the control box. DO NOT make any connections directly to the
lugs without routing the cables through this bushing. The lug door
is equipped with safety interlock switches that will automatically
trip the main circuit breaker and disable the voltage regulator when
the lug door is opened. Use a hex-wrench to tighten the cable
connections.
WARNING
Never attempt to disable or modify the lug door
safety switches. Equipment damage, personal
injury or death may result.
A ground connection is located next to the connection lugs. The
unit MUST HAVE this ground lug connected to a good earthen
ground for proper operating safety . The ground connection should
be in compliance with the National Electric Code (NEC) as well as
any state or local guidelines or codes.
20
VOLTAGE SELECTOR SWITCH
The voltage selector switch is located behind the lug door , underneath the engine controller panel. The selector
switch is a three position switch that mechanically changes the connections between the generator output leads and
the connection lugs. Voltage ranges are selected by rot ating the handle on the switch to the desired voltage.
NOTICE
Never change the voltage selector switch while the engine is running!
This will cause sever arcing and damage to the switch and generator windings.
480/277V
3-PHASE
208/120V
3-PHASE
208
120
480
277
T6
T3
L3
208
120
L1
T1
T4
T7
T10
N
T11
T12
T9
L1
T7
T8
L-N
T1
L-L
T5
T2
L2
L1 - L2 = 480V L1 - N = 277V
L2 - L3 = 480V L2 - N = 277V
L3 - L1 = 480V L3 - N = 277V
N =
L1 - L2 = 208V L1 - N = 120V
L2 - L3 = 208V L2 - N = 120V
L3 - L1 = 208V L3 - N = 120V
480
277
240
120
T12
T9
T3
L3
T4
T10
T5
N
T6
T11
T8
L-N
L-L
T2
L2
N =
T6
240/120V
1-PHASE
208
120
240
120
T3
T9
L3
T8
T2
T12
240V
T11
T10
N
T5
T4 T1
120V120V
L1 - L3 = 240V L2 - N = ------L1 - N = 120V L3 - N = 120V
T7
L1
The voltage switch is equipped with a locking mechanism. Once the proper voltage has been selected, push the red
latch on the inside of the phase switch handle up and insert a padlock through the handle. By locking the handle in
place you will prevent unauthorized personnel from changing the switch settings.
Note: When the voltage selector switch is in position for 480/277V 3Ø, voltage at the two GFCI duplex convenience
outlets is 139 Volts and the voltage at the three twist-lock outlets is 240/139 Volts. When the voltage selector
switch is in position for 208/120V 3Ø, voltage at the three twist-lock outlets and the two GFCI outlets is 208/120
Volts.
21
AUXILIARY OUTLETS
The control panel is equipped with six outlets for running accessories or tools from the generator. Power is supplied to the
outlets any time the engine is running and the main circuit
breaker and the auxiliary outlet main circuit breaker are switched
in the ON “I” position.
Should the main breaker trip, or the auxiliary outlet main circuit
breaker trip, remove some of the load to the outlets before
turning them back on.
Note: To ensure proper grounding, anytime the generator is
providing power to any equipment or load panels that do not have
a grounded plug, a ground wire must be added between the
equipment and the grounding stud on the outlet panel per any
local, state or NEC codes and guidelines.
AUXILIARY OUTLET
GROUNDING STUD
VOLTAGE REGULATION
The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field.
The regulator has three screwdriver adjustable potentiometers that may be adjusted for voltage, stability and under
frequency (U/F). The voltage regulator on your unit is adjusted before shipment from the factory . Contact Magnum
Products LLC for additional information before attempting to adjust the voltage regulator .
EMERGENCY STOP SWITCH
The generator is equipped with one emergency stop switch, located on the side panel next to the auxiliary outlet
panel. The switch is clearly labeled with “EMERGENCY ST OP” and is red in color . The switch can be accessed
and activated with all doors closed and locked.
Activate the emergency stop switch by pushing the red button in until it locks down. This will trip the main circuit
breaker which will open the contact disconnecting the load to the connection lugs. This will also open the fuel
circuit, shutting down the engine and the Emergency Stop fault will be displayed on the LCD. The switch will remain
closed until it is pulled out. Note: Use the EMERGENCY STOP only when the generator must be shut down
immediately . For any other shut down, follow the detailed shut down procedure.
22
MAIN CIRCUIT BREAKER
The main circuit breaker is located on the main control panel. When the breaker is in the OFF “O” position, power is
interrupted between the customer connection lugs and the generator. Once the connections have been made to the
connection lugs and the generator has been started and allowed to reach normal operating temperature, the breaker
may be switched to the ON “I” position.
The main circuit breaker will be tripped, disconnecting power to the connection lugs, if any of the following items
occur while the unit is running:
1. Overload of the generator circuits to the connection lugs.
2. The lug box door covering the customer connection lugs is opened.
3. If the emergency stop switch is activated.
Make sure that any problems that caused the main circuit breaker to trip are corrected before returning the switch to
the ON “I” position.
NOTICE
The main circuit breaker interrupts power to the customer connection lugs only . The customer convenience outlets
have power even if the main circuit breaker is in the OFF “O” position. The auxiliary outlet main circuit breaker ,
located next to the main circuit breaker, will disconnect all power to the auxiliary outlet panel.
REMOTE START TERMINAL BLOCK
The remote start terminal block is located under the lug box door just below the voltage selector switch. It provides
a connection for installation of a remote start switch which will allow the generator to be started by a remote drycontact closure switch.
Before pressing the AUT O button, verify that the contacts on any
remote switch linked to the generator are OPEN. If the contacts on
a remote switch are closed, the generator will crank and start when
AUTO is selected on the controller . Attach the switch leads to the
two unused terminals on the generators remote start block. For
additional information on starting the generator , see the GENERATOR ST ART UP section of this manual.
TRANSFER SWITCH
When the generator is used as a standby power supply , it must be
equipped with a transfer switch which isolates it from the utility’s distribution system. A transfer switch is designed
to transfer electrical loads from the normal power source (utility) to the emergency power source (generator) when
normal voltage falls below a prescribed level. The transfer switch automatically returns the load back to the normal
source when power is restored back to operating levels.
DANGER
FAILURE TO ISOLA TE THE GENERA TOR FROM THE NORMAL POWER UTILITY CAN CAUSE
POTENTIALL Y LETHAL VOL T AGE TO BACKFEED INT O THE UTILITY LINES. THIS MA Y RESUL T IN
INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY . MAKE SURE THA T THE GENERA TOR IS
ISOLA TED BY A TRANSFER SWITCH FROM ANY LOCAL UTILITY LINES. THIS ALSO APPLIES IF THE
GENERA TOR IS BEING USED AS A BACK UP TO SOME OTHER TYPE OF POWER SUPPL Y.
23
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