Page 1
contents
specifications .......................................................... 4
Generator ................................................................ 4
Engine ..................................................................... 5
Fuel Consumption ................................................... 5
Mounting Dimensions .............................................. 6
Mounting Dimensions .............................................. 7
Major Features ........................................................ 8
Part 1 - GENEral iNformatioN ....................... 9
1.1 Generator Identification ................................... 10
Introduction ......................................................10
1.2 Installation Basics ............................................ 11
Introduction ......................................................11
Selecting A Location ........................................11
Grounding The Generator ................................11
The Fuel Supply ...............................................11
The Transfer Switch / Load Center ...................11
Power Source And Load Lines .........................13
System Control Interconnections .....................13
Natural Gas Fuel Interconnections ..................13
1.3 Non-prepackaged Interconnections ................ 14
Connect a Pre-2008 Load Center Switch
To a Current or Future
Air-Cooled Generator. ..................................14
Connect a 2008 And Later Load Center
Switch to a Pre-2008
Air-Cooled Generator. ..................................15
1.4 Preparation Before Use ................................... 16
General ............................................................16
Fuel Requirements...........................................16
Fuel Consumption ............................................16
Reconfiguring The Fuel System .......................16
Engine Oil Recommendations .........................18
1.5 Testing, Cleaning and Drying........................... 19
Meters ............................................................19
The Vom ...........................................................19
Measuring AC Voltage .....................................19
Measuring DC Voltage .....................................19
Measuring AC Frequency ................................19
Measuring Current ...........................................20
Measuring Resistance .....................................20
Electrical Units .................................................21
Ohm’s Law .......................................................21
Visual Inspection ..............................................22
Insulation Resistance .......................................22
The Megohmmeter...........................................22
Stator Insulation Resistance Test (12-20 kW) ..... 23
Stator Insulation Resistance Test (8-10 kW) ....... 23
Rotor Insulation Resistance Test (8-10 kW) ........ 24
Rotor Insulation Resistance Test (12-20 kW) ...... 24
Cleaning The Generator...................................24
Drying The Generator ......................................24
1.6 Engine-Generator Protective Devices ............. 25
General ............................................................25
Low Battery ......................................................25
Low Oil Pressure Shutdown .............................25
High Temperature Switch .................................25
Overspeed Shutdown ......................................25
Rpm Sensor Failure .........................................25
Overcrank Shutdown .......................................26
1.7 Operating Instructions ..................................... 27
Control Panel ...................................................27
To Select Automatic Operation ........................28
Manual Transfer To “Standby”
and Manual Startup .....................................28
Manual Shutdown And
Retransfer Back To “Utility” ..........................28
1.8 Automatic Operating Parameters .................... 29
Introduction ......................................................29
Automatic Operating Sequences .....................29
Part 2 - ac GENErators .................................. 31
2.1 Description and Components .......................... 32
Introduction ......................................................32
Engine-Generator Drive System ......................32
The AC Generator ............................................32
Rotor Assembly ................................................32
Stator Assembly ...............................................33
Brush Holder And Brushes (12-20 kW) ...........34
Other AC Generator Components ...................34
2.2 Operational Analysis ....................................... 35
Rotor Residual Magnetism...............................35
Field Boost (12-20 kW) ....................................35
Operation (8/10 kW) .........................................36
Operation (12-20 kW) ......................................36
2.3 Troubleshooting Flowcharts ............................. 37
Problem 1 – Generator Produces Zero
Voltage or Residual Voltage (12-20 kW) ... 37-38
Problem 2 – Generator Produces Zero
Voltage or Residual Voltage (8/10 kW) ........38
Problem 3 – Generator Produces
Low Voltage at No-Load...............................39
Problem 4 – Generator Produces
High Voltage at No-Load ..............................39
Problem 5 – Voltage and Frequency Drop
Excessively When Loads are Applied ..........40
2.4 Diagnostic Tests .............................................. 41
Introduction ......................................................41
Safety ............................................................41
Test 1 – Check Main Circuit Breaker ................41
Test 2 – Check AC Output Voltage ...................41
Test 4 – Fixed Excitation Test/Rotor
Amp Draw Test ....................................42
Test 5 – Wire Continuity (12-20 kW) ................43
Test 6 – Check Field Boost (12-20 kW) ...........44
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