CAC / BDP FOR BYPASS AND FAN POWERED HUMIDIFIERS, Owner'S Manual

Page 1: ...ew standard of reliability Serial Number 4 2L 48kW Models Not intended for use in critical life support applications ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY CAUTION Cover138 Rev A 07 08 Part No 0H0170 ...

Page 2: ...rator Set Lubrication 8 1 Prior to Initial Start up 8 1 Engine Coolant 8 1 Belt Tension 8 1 Electrical System 8 1 Initial Inspection for Genset Start up 8 1 Start up Checklist 8 2 Preparation for Start up 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Tra...

Page 3: ... the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon mon oxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate...

Page 4: ...ns will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the g...

Page 5: ...al safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this e...

Page 6: ...r factor etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking ...

Page 7: ...iced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling ...

Page 8: ...ust be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate ...

Page 9: ... not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This ty...

Page 10: ...cfm Governor Type Electronic Frequency Regulation Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Spin on Cartridge Crankcase Oil Capacity 5 0 U S qts COOLING SYSTEM Type Pressurized Closed Recovery Water Pump Belt Driven Fan Speed 1300 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air including alternator and combustion air...

Page 11: ...s are configured to run on natural gas from the factory To reconfigure the fuel system from NG to LP follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port of the demand regulator see Figure 6 2 Figure 6 2 Reconfigure the Fuel System NEUTRAL N1 N2 23 194 186 178 To Generator Control Panel Utility In Load Out Gen Transfer Switch 4 14 GA WIRES TO GEN...

Page 12: ...he Cam Sensor is factory set to the FULL coun ter clockwise position Tampering with the posi tion of the Cam Sensor could result in engine failure IGNITION POWER UP INPUT 56 LINE INPUT When battery voltage is applied to this input the igni tion will power up For the ignition to power itself down the battery voltage must be removed from this input DIAGNOSTIC BLINK PATTERNS RED LED During normal ign...

Page 13: ...breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit...

Page 14: ...uced in the alternator power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 5 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 5 Stator Power Winding Connections 3 phase 120 240V 6 Lead E2 E1 E3 7 2 Standby...

Page 15: ...he dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation PRIOR TO INITIAL START UP Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended ty...

Page 16: ...n the valve to the engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pressure It must be as listed in the Specifications Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the man ual position The engine should now crank and start Check voltage at ...

Page 17: ...ransfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When...

Page 18: ... oil filter After initial change service engine oil and filter at 150 oper ating hours or six 6 months whichever comes first EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high gra...

Page 19: ...s been removed from the con trol box The 120VAC supply to the battery charger is switched OFF The NEGATIVE battery cable has been REMOVED CHECK ENGINE OIL LEVEL Refer to the Checking Fluid Levels section CHECK BATTERY Check battery fluid level each week as outlined under Check Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary EXERC...

Page 20: ...e is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 10 3 counterclockwise and remove...

Page 21: ...d If insulation resistances are excessively low the generator may require drying BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine D...

Page 22: ...ttery has completely discharged remove it from the generator for recharging Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as ...

Page 23: ...setup for normal operation when required 2 A wear in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit This inspection contains some maintenance tasks which require special tools equipm...

Page 24: ... 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level and specific gravity if accessible Adju...

Page 25: ...d damage Replace as necessary 11 Check the engine valve clearance lash Adjust as necessary 12 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 13 Test the engine and transfer switch safety devices Correct and or adjust as necessary 14 Initiate an automatic start and transfer of the unit to site load and exercise it for at...

Page 26: ...gh for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 19 Perform an engine oil analysis send a sample to a lab for results Change the engine oil and filters if the analysis results indicate this is required 20 Change the engine oil 21 Replace the engine oil filter s 22 Replace engine spark plugs Clean and re gap or replace ...

Page 27: ...ecommended in SPECIFICATIONS Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defectiv...

Page 28: ...Standby Generator Sets Notes ...

Page 29: ...Standby Generator Sets Notes ...

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Page 31: ... HSB 9 077043A 1 CONDUIT FLEX 38 ID 60 10 038150 4 WASHER FLAT 8 ZINC 11 023454 1 KEY WOODRUFF E 12 077043E 1 CONDUIT FLEX 1 0 ID 35 LG 13 04576100BU 4 STUD M14 2 0 570 G5 ZINC 14 052646 4 WASHER FLAT M14 15 043123 4 WASHER LOCK M14 16 051779 4 NUT HEX M14 2 0 G8 YEL CHR 2 17 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 18 072879 1 SPACER 69 X 2 75 X 37 ST ZNC 2 19 0F8408 4 SCREW HHC M10 1 50 X 16 G10 9 2...

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Page 33: ... IGN MOD 2 4L TURBO 1 UL CIRCUIT BREAKER ED A 0F3328 1 COVER ED CB SHORT STND C 0D5552 1 CB 0050A 3P 480V S ED4 LL 0D5553 CB 0060A 3P 480V S ED4 LL 0D5554 CB 0070A 3P 480V S ED4 LL 0D5556 CB 0090A 3P 480V S ED4 LL 0D9693 CB 0125A 3P 480V S ED4 LL D 0F0492 1 INSULATOR CB S ED 3P E 048927 4 SCREW RHM 10 32 X 4 1 2 F 023897 4 WASHER FLAT 10 ZINC G 022152 4 WASHER LOCK 10 H 022158 4 NUT HEX 10 32 STEE...

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Page 35: ...3 BUS BAR 200A LUG ADAPTOR 1 W W CB 2 TERMINAL COVER CB X 0G3259 1 DECAL TERMINAL SHOCK HZD BI 7 UL CIRCUIT BREAKER 400AF A 0F4187 1 COVER CB C2 C4 400AF C 0F4166 REF CIRCUIT BREAKERS 400A FRAME D 0F1733 1 DECAL CUSTOMER CONNECT INSIDE E 042419 4 SCREW RHM 10 32 X 4 F 023897 4 WASHER FLAT 10 ZINC G 022152 4 WASHER LOCK 10 H 022158 4 NUT HEX 10 32 STEEL J 0C2454 9 SCREW THF M6 1 X 16 N WA Z JS K 02...

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Page 37: ...U 12 022447 1 WASHER SHAKEPROOF INT 1 4 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHER SHAKEPROOF INT 3 8 17 0G52280ST03 1 ENGINE FOOT L H 4 2L CPL 18 045764 1 SCREW HHTT M4 0 7 X 8 BP 19 059981 4 SCREW HHC M10 1 5 X 30 C10 9 20 022302 4 WASHER LOCK 7 16 21 022131 4 WASHER FLAT 3 8 M10 ZINC 22 065852 1 SPRING CLIP HOLDER ...

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Page 39: ...POST COVER BLACK 9 038804U 1 CABLE BATT RED 1 X 28 00 10 038805J 1 CABLE BATT BLK 1 X 30 00 NEG 11 045771 1 NUT HEX M8 1 25 G8 YEL CHR 12 022129 1 WASHER LOCK M8 5 16 13 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 2 SCREW THF M6 1 X 16 N WA Z JS 16 042568 2 SCREW HHC M6 1 0 X 20 G8 8 17 022097 2 WASHER LOCK M6 1 4 18 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 19 0...

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Page 41: ... 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 1 6 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 7 0G0190 1 PLATE AIR CLEANER TOP 2 4L 8 037561 1 NUT WING 1 4 20 NYLK 1 APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON ONE END OF I N 6 STUD THAT SCREWS INTO I N 2 CARB ADAPTER ...

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Page 43: ...7 1 SHAFT FAN DRIVE 38 0F2461 1 RETAINER BEARING 39 022145 15 WASHER FLAT 5 16 M8 ZINC 40 022129 12 WASHER LOCK M8 5 16 1 41 039414 1 SCREW HHC M8 1 25 X 35 G8 8 42 082774 1 KEY WOODRUFF 4 X 19D 43 0G5465 1 HOSE RADIATOR LOWER FRONT 44 0G5459 1 HOSE RADIATOR UPPER FRONT 45 049813 8 NUT HEX M6 X 1 0 G8 YEL CHR 46 052644 1 SPACER 5 X 1 5 X 25 STL ZINC 47 0C8566 16 SCREW HHFC M6 1 0 X 20 G8 8 48 0C24...

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Page 45: ...IDLER 2 58 0D8025 1 BOLT HEX FL HD M8 1 25 X 28 59 0G1738A 1 CAP ANTIFREEZE RUBBER 8 5DIA 60 048031M 1 CLAMP HOSE BAND 75 61 0G5601 1 STRAP INTAKE ACTUATOR 62 077996 2 CAP ANTIFREEZE 5 8 ID X 1 2 LG 63 0G55800ST03 1 BRACKET DC ALTERNATOR LH 4 2L 2 64 0E9868A 1 ALTERNATOR DC W OUT PULLEY 65 0G0638A 1 SPACER ALTERNATOR 4 2L G3 66 048031C 2 CLAMP HOSE BAND 50 67 0E9974 2 CAP VINYL 3 8 ID X 1 DP BLK 6...

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Page 49: ...4 SCREW SHC M6 1 0 X 18 G12 9 RECONFIGURING THE FUEL SYSTEM Note All models are configured to run on natural gas from the factory To reconfigure the fuel system from NG to LP follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port of the demand regulator See Detail A 3 Disconnect the power wires from the fuel solenoid located on top of the regulator...

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Page 51: ... 8 SS 13 0G6401 4 SCREW HHC M10 1 5 X 45 SS FTH 14 0E8816 2 EXHAUST FLANGE 2 PIPE 15 049721 6 SCREW HHC M6 1 0 X 35 G8 8 BLK 16 022097 6 WASHER LOCK M6 1 4 17 022473 8 WASHER FLAT 1 4 M6 ZINC 18 036797 3 BOLT U 5 16 18 X 2 25 19 022259 6 NUT HEX 5 16 18 STEEL 20 070006 6 WASHER LOCK M8 SS 21 088775 4 WASHER FLAT 3 8 SS 22 022241 10 NUT HEX 3 8 16 STEEL 23 0F3794B 1 EXHAUST BLANKET 700MM LONG NOT S...

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Page 53: ...C 2 INSULATION DUCT 30 0F3890B 4 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 078115A 6 WASHER SELF LOCKING DOME 8 32 34 0G5892E 1 INSULATION LOWER SPLITTER 35 042568 2 SCREW HHC M6 1 0 X 20 G8 8 36 0912970094 2 ASSY WIRE 14 AWG 34 8 GRN YEL 37 022447 2 WASHER SHAKEPROOF INT 1 4 38 0G5892B 1 INSULATION REAR WRAP 39 0F8869D 1 KEY VISE ACTION LATC...

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Page 69: ...5 2 SEAL COVER 3 18X12 7X382 27 0F6305A 1 SEAL COVER 3 18X12 7X283 28 0F5886 2 SCREW HHPM M5 0 8 X 12 29 051713 11 WASHER FLAT M5 30 049226 11 WASHER LOCK M5 31 0F5752F 1 RES WW 15R 5 25W QK CONN 32 0F5884 2 SCREW PHTT M3 5 0 6 X 10 33 0F5896 2 SCREW PHTT M3 5 0 6 X 16 34 074076 2 SCREW PHM M3 0 5 X 10 BLACK 35 0C3990 2 SCREW PHTT M4 0 7 X 10 ZYC 36 080823 4 SCREW PPHM M5 0 8 X 50 ZNC 37 051716 9 ...

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Page 71: ... B 0C2454 3 SCREW THF M6 1 X 16 N WA Z JS 3 C4 UNITS A 0F9832A 1 SHIELD CONTROL STAND C4 B 0C2454 3 SCREW THF M6 1 X 16 N WA Z JS 4 C5 UNITS A 0F9832C 1 SHIELD CONTROL STAND C5 0F9832D 1 SHIELD CONTROL STAND C5 0F9832EGS0R 1 SHIELD CONTROL STAND C5 0F9832HGS0R 1 SHIELD CONTROL STAND C5 0F9832JGS0R 1 SHIELD CONTROL STAND C5 B 0F9832FGS0R 1 SHIELD CONTROL STAND C5 C 0C2464 3 SCREW THF M6 1 X 16 N WA...

Page 72: ... W Morris St D Indianapolis IN 46231 Printed in U S A Edition Date 07 08 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No OMASPFY048A 01 Replaces NEW ...