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Generac ASPAS1CCL015 Portable Generator User Manual

Contents

1. __ ov V VIN ov1g Lee pn 8 pzz 039 Co anqa IHI3IVNH3IV L i Yl Is tui 00 OL z3 8 L i AO aa 0001 L3 T MOTI S ama ove Z30113 ge i S SIS 3SVHd L A0YZ 02 L GL NOILOANNOO LNdLNO Bas v LJ El Lo I LL R H 1 P 3 A 9 Z SE bv S 0 4nd EN ania NMO d H LO L E i II Hl E Wiring Diagram Control Panel Drawing No 0F5245 Carrier Liquid cooled 15 kW Generators Section 8 Electrical Data MOTISA ere LL TT T T D s EE OLVNLOV OU WEI PL v6l 98 HONH3AO5 OL 0 8 L ga t amig HL L OL SL t EL ch LL OL6 8 4 9 S f EZ mg an1g dod _ ELECTRICAL DATA lt g lt 4 Carrier Section 8 Electrical Data Carrier Liquid cooled 15 kW Generators ELECTRICAL DATA WI lt Control Panel Drawing No 0F5244 ical Schematic Electr omg 09 hdl 31lVNd31 Iw 8 Kita qat AIM GASNNN ALVINSNI SWALSAS 1 1 A802 HOS SHIM MOTA SWALSAS 11 A0ve HOS SHIM 3N18 ASN NOILOANNOO HOLIMS H34SNVHL OVHANAD QYVAONVLS HO LYVLS SHIM c LL 8 L cS L L cl ESL NOILOANNOO HOLIMS d34SNVd1 ZEN NOILISOd 440 NI NMOHS VSI YOLVINDAY FOVLIOA uA SCYVOE TVNIAH31 Ce LSL ONISNAS ALITILA H3WHO4JSNVu1 HOLIMS 3SIOH3X3 LAS NS HOLIMS IWANVW SSO 0 LNV LMS ANHN3SSV NOISSSY dNS VS Y
2. warninc A Gaseous fuels such as natural and LP propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Figure 1 3 Engine Protective Devices HIGH COOLANT LOW COOLANT TEMPERATURE LEVEL SWITCH SWITCH e Geste Eat SWITCH N M PEBOI D C C CIC ra Be Ka Section 1 General Information Carrier Liquid cooled 15 kW Generators 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 72 HIGH COOLANT TEMPERATURE SWITCH This normally o
3. 4 5 2 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 4 5 3 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See Section 3 5 Weekly Exercise Cycle 4 5 4 INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 5 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels in Section 4 4 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks Carrier Liquid cooled 15 kW Generators MAINTENANCE 2 9 4 5 7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage Section 4 Maintenance 4 5 8 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect a
4. Place a sign on the generator control panel and the transfer switch indicating the day and time the generator will be exercising NOTE If battery terminals are disconnected the exercise timer needs to be reset for correct automatic exer cise operation Figure 3 2 Set Exercise Switch O Q FUSE FAULT 15 A INDICATOR AGC SET EXERCISE TIME ON Carrier 13 MAINTENANCE Section 4 Maintenance Carrier Liquid cooled 15 kW Generators 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A EVERY THREE MONTHS 1 Check battery state of charge and condition 2 Inspect and test fuel system 3 Check transfer switch 4 Inspect exhaust system 5 Check engine ignition system 6 Check fan belts B ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature C ONCE ANNUALLY 1 Test engine governor Adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system D FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or six months whichever comes first 2 Retorque cylinder head See Torque Specs Section 1 13 3 Retorque intake and exhaust manifold See Torque Specs Section 1 13 E EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator F EVERY 800 OP
5. Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 3 On oo NOOR WD 15 amp fuse blown 7 5 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch 1 Defective AUTO OFF MANUAL switch oF O N Open disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open NOTE TROUBLESHOOTING CORRECTION 1 2 3 o ES SE ee St e SE Replace fuse Replace fuse Tighten clean or replace battery cables as necessary
6. rT ITEM PART NO 0A4355 0E2844 036434 036449 0E0109 0C1318 0D8657 0E0170 0D9437 060366 039253 022145 022129 045771 0A8974 027837 QTY N RRR BRD ww Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Muffler Drawing No 0E0773 A DESCRIPTION MANIFOLD EXHAUST 1 5L NIPPLE TOE 1 5NPTX5 5 BLK IRON BOLT U 5 16 18 X 2 09 SADDLE 2 INCH PIPE EXHAUST 1 5L STNDRD amp ACSTC FLEX PIPE EXHAUST SUPPORT RADIATOR 1 5L MITSU BLANKET EXHAUST 1 5L MITSU MUFFLER 1 5L ACOUSTIC amp S TANDARD STRAP MUFFLER 6 DIA SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR CAP RAIN 2 SCREW RHM 1 4 20 X 2 1 4 PARTS qp ies Co Carrier 43 Section 10 Warranty WARRANTY Carrier Liquid cooled 15 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provid
7. 18 Carrier Section 4 Maintenance Carrier Liquid cooled 15 kW Generators MAINTENANCE 5 o Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to be done Comp to be done Comp Required to be done Date 3months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually 10 hrs 30 hrs 50 hrs 100 hrs Disable the unit from operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary Check the air inlets and f necessary Check the battery electrolyte level if accessible Adjust as necessary Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 1 esch Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or
8. Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides See Section 6 Installation Diagram 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY generator output are con nected to an approved transfer switch The transfer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER SUPPLY SWITCH TO LOAD CIRCUITS Eh ees Se Va oil MAI CIRCUIT BREAKER Carrier recommends the use of a Carrier transfer switch in conjunction with this generator Carrier 9 INSTALLATION Ip Section 2 Installation 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within the wattage amperage capacity dur ing utili
9. Replace contactor Replace starter motor Remove change or replace battery Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact a dealer facility Auto reset Wait five min and attempt restart Under normal operating conditions if repair of generator set or replacement of any parts is necessary dur ing the warranty period you must contact a dealer Failure to have the repair or replacement performed by a Carrier dealer will result in non coverage of warranty repair cost Carrier 21 NOTES Section 6 Notes Carrier Liquid cooled 15 kW Generators 22 Carrier INSTALLATION iagram D ion Section 7 Installat Carrier Liquid cooled 15 kW Generators Drawing No 0E1533 B SINSWLSVdWOo OILSNUOY 3 sd J3H1V3M LAN v E NOILIANNOD el VA dl el SVD IVANLYN 90 61 NS C341Salv 42 9N ONIGNNOSD L 0S 1 CT3ALIA3a4 SOOT HLIM NMOHS 2 MJIA adi L 6 Se vS9 Gorsel c 16 2 JLON SC JLON Cin a SH dvd SS322w Soe NOLVIGVS taa 08 91 6S4 22 1 MIIA JOI
10. b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Carrier 45 Section 10 Warranty WARRANTY Carrier Liquid cooled 15 kW Generators CARRIER TWO YEAR LIMITED WARRANTY FOR PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Carrier warrants that its generator will be free from defects in material and workmanship for the items and period set forth below Carrier will at its option repair or replace any part which upon examination inspection and testing by a Carrier Dealer is found to be defective All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Carrier prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE AND TWO 100 one hundred percent transferable coverage on Labor and Part s listed ENGINE All Compone
11. serviced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equipment 2 11 1 PRIOR TO INITIAL START UP caution amp A 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 types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Carrier 11 OPERATION Section 3 Operation IT Carrier Liguid cooled 15 kW Generators Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict complian
12. the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire N because they generate hydrogen gas The fol lowing procedure are to be followed e DO NOT SMOKE when near batteries e DO NOT cause flame or spark in battery area and e Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries The recommended battery is Group 26 12V negative ground 525 CCA 75 AH minimum All batteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in Section 4 Maintenance A negative ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the stand by generator has been properly installed
13. 1 1 1 1 1 PO OO N OO A HSH HS HS HS es N o Carrier Liquid cooled 15 kW Generators DESCRIPTION PANEL BACK amp BOTTOM PANEL LH SIDE PANEL FRONT W SILKSCREEN PANEL RH SIDE C PANEL SML BRK DECAL WARNING REMOVE FUSE LIGHT 12VDC 02A LED RED PILOT HOLDER FUSE FUSE 15A X AGC15 SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD ASSEMBLY REGULATOR POTTED TFMR ASM CMA 240 12V PP LOGIC ASM 50 60HZ HARN CONTROL PANEL 1 5L MITSU NOT SHOWN RELAY SOLENOID 12VDC PNL MNT CIRCT BRK 4 X 1 ETA 46 500 P BLOCK TERM 20A 7 X 6 X 1100V BLOCK TERM 20A 2 X 6 X 1100V BLOCK TERM 20A 20 X 6 X 1100V ASSY L C ELECT GOV DECAL CUST CONNT PRE PACK1 5L DECAL TERMINAL STRIP PRE PACK NUT SPACER 250 PCB SCREW PPH TAPPING 6 X 5 8 SS SCREW PHM M6 1 0 X 20MM WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW PHTT M4 0 7 X 16 ZYC WASHER SHAKEPROOF EXT 10 STL Section 9 Exploded Views and Parts PARTS Ce LISTS Control Panel Drawing No 0F5240 VO ITEM PARTNO QTY DESCRIPTION 30 0C2267 14 SCREW HHTT M5 0 8 X 12 BP 31 023897 15 WASHER FLAT 10 ZINC 32 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0E2514 1 STRAIGHT WIRE CONNECTOR 1 1 2 36 0A1354A 1 REGULATOR DC ALT 37 074908 4 SCREW HHTT M5 0 8 X 10 BP 38 020911 4 SCREW PPHM M5 0 8 X 30 ZINC 39 051713 5 WASHER FLAT M5 40 049226 5 WASHER LOCK M5 41 051716 5 NUT HEX M5 0 8 G8 YEL CHR 4
14. A passa dA L ai erg sod 9 371NO Y3T44NW GO 2 LATLAD LSAVHX3 Bi ae Sa aac CaCne Di am LAN pt NIC TID 931158 _A2I ce ae oN 8 HON be ge a aa Ta s 68 ii il SNOILOSNNOD 32IAM3S ANIONS il SSHONI Wu SLINA dAl ili S r iil sq 098 Du O6E LINN 319 Viva IHDT3R ND LOO 4 ill 0 BI Gr I WING LIT INIT NIVW F r LAOHLIM JVNDII D SlIN n reg ill LNAWLAYdWOD HLIM GNVONVLIS LSAVYHXS X33433 DI Da E ii 99 8 X 8 9 O22 x 291 SNOISNIWIG 3CQISNI AVSL AS3311v8 W31SAS GNU BAILYOIN LTHA 21 zZ l ee J3NVd TONING NI G3dIADNd SINIM TOMLNOD dOLS LNVLS eae JILYWOLNY 3NIDN3 NV Sava Oe 3Y 901 SINIOd NOILISNNOD I dAl 7v3 12373 SE SEAN 60 2 ont EC LNINdLOOs 2eug r ee 0981 23 Carrier HOLIMS TWANVI SSO OLNV LMS div SZ INNI SSNS Hd HOLVINDSY FOVLIOA ANN3SSv NOISSSYdNS VS SdWY SI ASN d SOd dlHIS TVNINHSL QuvO8 LINDHIO yOVd 3dd 9d NOILOANNOO ANIONS 93 SOd Z dIHLS TVNINH31 s 10018 WHLNAN gN u3yyvaug OI 282 SOd 02 dlHIS a GEN n g H32V3H8 LINOHIO 199 ONISNAS ALMILA HNH4SNHL lHon LANYA Au YHOLIOWAVO dg HOLIMS 3SIOH3X3 13S HOIVISHOIVNH311y SY qN35q31 ONIHv38 OL 1S3S019 pp 0v311 03H HLIM HSN I y NOILOANNOO OSI Kei HOLIMS HIEN 9g s WS or 0 JET UNE SNOLLOSNNOO HOLIMS M3YOS aml d K l cSL H3dSNVHI NON HH H34TOH Hsnug gp 27 OQ do RES i i ISL Wu HH SET i aaen e gt BH EW d a rae Se ee Lt d ha cc S i zN
15. FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters Carrier 15 OPERATION OD Section 4 Maintenance Carrier Liquid cooled 15 kW Generators Figure 4 2 Oil Filter BMS OIL FILTER caution After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 4 5 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 3 Figure 4 3 Engine Air Cleaner Air Cleaner E gt 4 xX ERK KX KKK SL See XK Gei e Ge E SH amp Doors Removed for Clarity See the Scheduled Maintenance Section 4 7 for air cleaner maintenance 1G Carrier 4 5 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 4 7 1 Clean the area around the base of the spark plugs to k
16. HHC M10 1 25 X 25 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 ZINC STAMPING ENG FOOT SPACER 41 X 75 X 12 STL ZNC NUT HEX M10 1 5 G8 YEL CHR SCREW SHC 5 16 18 X 2 G8 8 NZ STARTER 12V SPACER 56 X 1 X 37 ST ZNC SCREW HHC M10 1 5 X 60 G8 8 ENGINE PLATE SLEEVE DOWEL BLHSG SCREW HHC M10 1 5 X 70 G8 8 SCREW HHC M10 1 5 X 90 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX 5 16 18 STEEL SCREW HHC M10 1 25 X 20 G8 8 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M10 1 25 X 45 G8 8 GUARD CRANKSHAFT 1 5L NUT HEX M8 1 25 G8 YEL CHR SCREW SHC M8 1 25 X 25 G12 9 SCREW HHC 5 16 18 X 1 G5 ADAPTER THERMOSTAT GASKET THERMOSTAT THERMOSTAT 195 DEG GASKET INLET MANIFOLD MANIFOLD INTAKE MACHINED Section 9 Exploded Views and Parts ITEM PART NO QTY 0E0561 0A6751 077996 026925 061012 039253 0A5110 0A7006 025507 022500B 0A8584 036277 042574 026073A 0A6701 039414 0A5568 051769 0A4804A 0A5839 0A1354B 0A4839 055816 049811 0E1936 0A2628 0A5275 0A4814 0A45310244 001852 0912970066 070928 069860C 069811 075443 Carrier Liquid cooled 15 kW Generators Engine Drawing No 0F5273 po ha po N cO A O 2 PARTS qp as OG DESCRIPTION ASSY WATER LEVEL SENSOR C E PL SW TMP 245 DEG 3 8 NPT CAP ANTIFREEZE RUBBER PLUG STD PIPE 3 8 STEEL SQ HD PLUG STD PIPE 1 8 SCKT HD SCREW HHC M8 1 25 X 20 G8 8 PIPE
17. WATER INLET O RING 1 1 16 X 1 5 16 X 1 8 WASHER SHAKEPROOF EXT 7 16 STL SPACER 41 X 75 X 25 ST ZNC SWITCH OIL PRESSURE ELBOW 90D STREET 1 8 ADAPTOR 1 8 NPTF TO 1 8 28 PLUG STD PIPE 1 4 STEEL SQ HD SCREW HHC M10 1 5 X 110 G8 8 SCREW HHC M8 1 25 X 35 G8 8 SCREW HHC M12 1 25 X 55 G8 8 WASHER LOCK M12 PULLY CRANKSHAFT 1800 RPM 1 5L BRACKET ALT SUPPRT DC ALTERNATOR 12V ARM ADJUST ALTERNATOR SCREW HHC M6 1 0 X 70 G8 8 WASHER FLAT M6 FAN COOLING 15 PULLEY FAN 95 DIA V BELT 3 8 X 32 1 8 1 5L SPACER PULLEY FILTER OIL ADAPTER DRAIN OIL GROUND WIRE STARTER CLAMP HOSE OIL DRAIN HOSE ASM OIL DRAIN CAP HEX 1 4NPT BRASS SCREW CRMPTIT 1 4 20 X 5 8 Carrier 35 Ass Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators adiator Drawing No KO Radiator Drawing No 0F5274 E cO lt C r ib N sai lt gt s o Q G ha ii s O GC d w LU o m c u lt j oc lt LL LI N oza P f 11 BOTTOM ONLY 36 Carrier PART NO 0D8657 0A5734 0A6237 0A6238 047290A 065852 0A2111 099502 083709 052250 0A7275 022097 035461 022473 0E0726 076749 075443 056892 0A6284 0A6258 029032 031669 060035 022127 046627 0C7649 0C2454 QTY BL BR BR BHO sl B GW P B P Section 9 Exploded Views and Parts Carrier Liquid cooled
18. a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION A DX 4 A Connecting this generator to an electrical sys tem normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distri bution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy A Ifan open bottom is used the engine genera tor is to be installed over non combustible materials and should be located such that com bustible materials are not capable of accumu lating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standards and regula tions pertaining to the installation This genset must be installed on a level surface The base frame must be level within 1 2 inch all around caution amp After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regulations 2 1 1 NFPA STANDARDS The following p
19. adjust as necessary Task Comp Date Initials Carrier 19 Section 4 Maintenance MAINTENANCE Carrier Liquid cooled 15 kW Generators 13 14 15 16 17 18 19 20 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to be done Comp to be done Comp Required to be done Date 3months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually 10 hrs 30 hrs 50 hrs 100 hrs Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Change the engine oil filter s filter s Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service problems Return the unit to standby required 20 Carrier Task Comp Date Initials Section 5 Troubleshooting Carrier Liquid cooled 15 kW Generators 5 1 TROUBLESHOOTING POINTS CAUSE PROBLEM
20. applica tion Use the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas Performed monthly or following each 10 hours of operation of the unit and requires approximately D man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the control panel fuse Turn off utility supply to engine water heater Turn off the battery charger by turning off utility supply to the transfer switch Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby
21. com Part 1 44 Carrier Section 10 Warranty Carrier Liquid cooled 15 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired
22. g LP FUEL SYSTEM A A I ee Zo NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for simultaneous fuels has been made A DIG A Serious injury or damage may occur if not con A figured properly Please consult a dealer with any questions 1 13 TORQUE SPECIFICATIONS Cylinder Head 15 90 90 ft lb Intake Manifold rra 13 ft lb Exhaust Manifold l I 13 ft lb Carrier 7 INSTALLATION DI Section 2 Installation 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service SJ or latest available Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Below 32 F 0 C SAE 10W or 15W 40 NOTE Synthetic oil is highly recommended when the generator will be operating in ambient tempera tures which regularly exceed 90 F and or fall below 30 E caution amp Any attempt to crank or start the engine before A it has been properly serviced with the recom mended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base ant
23. or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the
24. or the use of counterfeit and or grey market parts not made supplied or approved by Generac Warranty service can be arranged by contacting Generac Power Systems Inc IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Carrier Two Year Limited Warranty for Prepackaged Emergency Automatic Standby Generators which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Carrier Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Carrier Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty serv ice evidence must be presented showing the date of the sale to the original purchaser owner To arrange for emissions equipment warranty or if you have any questions regarding your warranty rights and respon sibilities you should contact Generac at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 www generac
25. pro ceed as follows Check that load circuits are connected to the utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position OPERATION Section 3 Operation Carrier Liquid cooled 15 kW Generators IT 34 WEEKLY EXERCISE CYCLE The generator will start and exercise once every seven days During this weekly exercise the unit runs for about 20 minutes and shuts down Transfer of loads to generator output does not occur during the exer cise To select day and time for exercising proceed as follows Set the AUTO OFF MANUAL switch to OFF Set generator main circuit breaker to OFF or OPEN Locate the rocker switch on the control panel iden tified with the words Set Exercise Time Figure 3 2 Push Set Exercise Time switch to ON position for 20 to 30 seconds and then release Switch will spring back into its original position when released Wait 30 seconds before setting the AUTO OFF MANUAL switch to AUTO position caution amp A If the AUTO OFF MANUAL switch is switched too soon the engine may start If engine does start it will shut down automatically in about two 2 minutes Set the generator main circuit breaker to its ON or CLOSED position Generator is now programmed to start and exer cise every seven days thereafter on day and time of day the switch was actuated
26. setup for normal operation when required 2 A break 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 80 hours of operation after purchase of the unit and requires approximatelu 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a dealer 3 An operational 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 semi annually or following each 50 hours of operation of the unit and requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a dealer 4 A mid level 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 annually or following each 100 hours of operation of the unit and requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a dealer
27. 0912970064 023762 0912970063 022264 067035 022127 OF4487A 022473 022097 0D2023 0F3390 037337 0D2023 0D8664A 0D8664B Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Enclosure Drawing No 0F4490 DESCRIPTION ROOF ACSTC amp STND CMPRTMNT 1 5L DUCT CENTER 1 5L SUPPORT RADIATOR 1 5L MITSU BRACE SIDE 1 5L MITSU DOORWELDMENT 1 5EPS CORNER POST REAR RH SIDE 1 5L DOOR REAR COMPARTMENT 1 5L BRACE REAR 1 5L MITSU CORNER POST REAR LH SIDE 1 5L LATCH amp CAM SCREW TH FRM M6 1 X 16 N WA Z JS SCREW PHM 10 32 X 5 8 ZINC NUT HEX M5 0 8 G8 YEL CHR WASHER LOCK 10 ASSEMBLY BASE DOOR GROUND WIRE WASHER SHAKEPROOF EXT 10 STL GRD WIRE ASS Y 99HSB WASHER LOCK 8 M4 SCREW PPHM 8 32 X 5 16 NUT HEX 1 4 20 STEEL ASSEMBLY COVER ACCESS WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 GASKET CLIP ON SELF GRIPPING LATCH AND CAM NUT HEX JAM 3 8 24 SS GASKET CLIP ON SELF GRIPPING DUCT LH SIDE 1 5L DUCT RH SIDE 1 5L Gi LISTS Carrier 31 Q Ass Section 9 Exploded Views and Parts gt Carrier Liquid cooled 15 kW Generators VO Control Panel Drawing No 0F5240 32 Carrier ITEM CONDOR WD PART NO QTY 0D9322 0D9332 OF5246A 0D9330 0E3783 064009 032300 022676 0E4494 082573 083048 083264 076009A 0E0331A 056739 049350 047822 048766 057335 098647 0E1454 0E1459 072566 080882 0A8955 022097 022473 0C2212 023762 1 1 1 1 1 1 1 1 1
28. 15 kW Generators Radiator Drawing No 0F5274 DESCRIPTION SUPPORT RADIATOR 1 5L MITSU RADIATOR 1 5L VENTURI 1 5L MODINE GUARD FAN 1 5L MODINE ASSY RAD DRAIN HOSE SPRING CLIP HOLDER 37 62 SCREW SWAGE 10 32 X 5 16 Z YC CLAMP HOSE 24 B1 06 2 00 CLAMP WIRE HOSE 573 551 TAPE FOAM 1 X 1 12 LG FOAM 1 5 X 1 ADH BAK WASHER LOCK M6 1 4 BARBED STR 1 4 NPT X 3 8 WASHER FLAT 1 4 ZINC BRACKET WATER BOTTLE 1 5L MIT TANK COOLANT RECOVERY SCREW CRMPTIT 1 4 20 X 5 8 SCREW CRIMPTITE 10 24 X 3 8 HOSE LOWER RADIATR HOSE UPPER RADIATR HOSE 9 32 ID 36 LG BOLT CARR 1 4 20 X 1 3 4 JS500 SPACER 41 X 75 X 87 ST ZNC NUT HEX 1 4 20 STEEL CAP RADIATOR CLAMP HOSE 38 87 SCREW TH FRM M6 1 X 16 N WA ZS FAN GUARD KIT 0E3596 NOT USED WITH LEVEL ONE GUARDING LISTS age Carrier 37 38 Carrier Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Fuel System Drawing No 0E0774 E L P VAPOR ITEM PART NO QTY YX LT me 1 2 075580 1 3 0E1006 1 4 039253 2 5 022145 2 6 022129 6 7 045771 2 8 0A7040 1 9 032552 1 10 029032 1 11 0E1056 1 12 029032 1 13 0A5547 1 14 048031C 4 15 0D1509 1 16 0E0591 1 17 059402 1 18 037561 1 19 0E1028 1 20 059401 1 2 091526 4 22 049226 4 23 026307 1 24 062522 1 25 022127 1 26 022259 2 27 050279 1 28 0A6125 2 29 0D8492T 1 30 0E1104 1 A1 0E0668 1 32 0E0590 1 33 005133 1 A4 0E0665 1 35 0E1108 1 36 0331
29. 2 036261 4 RIVET POP 125 X 129 133 30 43 0D9334 1 PANEL TOP 44 061979 1 BUS BAR 45 022237 1 WASHER LOCK 3 8 46 022241 1 NUT HEX 3 8 16 STEEL 47 057073 1 JUNCTION BLOCK 3 8 16 48 055440 1 SCREW HHC M5 0 8 X 25 G8 8 49 0D8671 1 HINGE CONTINUOUS 1 5L CNTL PNL 50 0912970080 1 WIRE ASSEMBLY 51 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 52 033121 1 SCREW HHC 10 32 X 1 2 53 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 54 022158 1 NUT HEX 10 32 STEEL 55 022152 1 WASHER LOCK 10 56 0A3968 1 CAPACITOR FILTER ASY 57 0C2323 2 SCREW PHTT 6 32 X 5 8 ZYC Carrier 33 Carrier Liquid cooled 15 kW Generators Section 9 Exploded Views and Parts Engine Drawing No 0F5275 LISTS PARTS d GE gue RB Sh id r k log d DIA 3HVMGHVH a 2 dNNdHaLYM i 24 Carrier ITEM CONDOR WD PART NO QTY 0A4531 022473 057822 0A45310258 0A4355 0E2632 022097 022507 052212 046526 022131 002499 055993 045772 023586 020692 0A7005 052243 0A4772 070901 051735 056768 022145 022129 022259 052213 047411 052830 0F3856 045771 058306 030795 OA2711A 048665 075885 0A45310257 0E1100 cO 62 29 h pro ro ro ro no OHA ro DESCRIPTION ENGINE 1 5L WASHER FLAT 1 4 ZINC CLAMP HOSE 8 53 1 00 GASKET EXHAUST MANIFOLD MANIFOLD EXHAUST HEAT SHIELD EXH 1 5L WASHER LOCK M6 1 4 SCREW HHC 1 4 20 X 1 2 G5 SCREW
30. 38 1 37 022152 1 38 0E0645 1 39 063463A 1 40 0E1558 1 41 057823 2 42 0E1111 1 43 042907 2 44 002454 2 gt SHOWN IN OTHER VIEW INCLUDED IN ITEM 19 CARBURETOR ASY Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Fuel System Drawing No 0E0774 E DESCRIPTION WELDMENT MOUNTING BASE FLANGE FUEL INLET ASSY REGULATOR 1 5L N G OR LPV SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR BRACKET RAD HOSE BARBED EL 90 5 16 X 1 8 NPT HOSE 9 32 ID 11 FUEL HOSE ASSM NAT GASIL PV HOSE 9 32 ID 6 5 COVER AIR CLEANER CLAMP HOSE BAND 1 4 DECAL INLET PRESSURE ADAPTER CARB TO AIR CLNR FILTER ELEMENT NUT WING 1 4 20 NYLK CARBURETOR ASSY 1 5L CARBURETOR GASKET SCREW PPHM M5 0 8 X 12 ZNC WASHER LOCK M5 ELBOW 90D STREET 3 4 STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL NUT HEX 5 16 18 STEEL DECAL FUEL INLET NG STUD 5 16 18 X 1 25 F THR DECAL EMISSION CTRL 1 5 NG 2005 10 15KW NATURAL GAS GASKET AIR CLEANER ADAPTER O RING 2 028 1 38 X 1 50 X 06 VENTURI 18MM O RING 29 82 X 2 62 SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM 10 32 X 5 8 WASHER LOCK 10 LEVER THROTTLE STOP BARBED STR 3 8NPT X 1 2 WS HOSE LPG amp NAT GAS 1 2 ID 23 LG CLAMP HOSE 10 56 1 06 PLATE GAS REGULATOR MOUNTING SCREW HHC M8 1 25 X 16 G8 8 SCREW TH FRM M6 1 X 16 NWA ZS Gi LISTS Carrier 39 Cp es Section 9 Expl
31. 90 second span 1 7 6 DC FUSE This clearly labeled fuse is located on the front panel of the control system It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating Carrier normally uses an AGC fuse rated at 15 amps part number 022676 1 8 UNPACKING Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 9 LIFTING THE GENERATOR warnings amp A When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS MOGE u u unun mnan naima ASPAS1CCL015 Ru Single Rated Max Cont AC Power Output KW 15 Rated Voltage volts E 120 240 No of a is Gus mm 4 Driven Speed Of Rotor a a 1800 Rotor Excitation System Direct excited brush type Rotor Stator Insulation a Class F 1 10 2 ENGINE SPECIFICATIONS IV 2 EN Mitsubishi Displacemen
32. AC output results Typically the two hot leads in the circuit are Wires No 11 and 44 The Neutral leads are the junction of Wires 22 and 33 Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for each unit is described in Figure 1 2 Figure 1 2 Main Circuit Breaker Model Rating Phase ASPAS1CCLO015 15 000 1 62 5 Actual Current C B Rating over rating Circuit Breaker 70 112 70A BQ2 Amp Rating of CB structured under model 4 Carrier 1 6 GENERATOR FUEL SYSTEM The generator has been factory tested and adjusted using a natural gas fuel system If propane LP requirements gas is preferred refer to Section 1 12 Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas and at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel being used Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A separate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability
33. ARING CARRIER REAR ASSY HOLDER BRUSH SCREW PPHM M4 0 7 X 16 COVER REAR BEARING CARRIER BOLT STATOR X 16 LG SCREW RHM 10 24 X 2 WASHER LOCK 10 FAN amp RING GEAR ASSEM KEY SQ 3 8 X 1 STEEL SPACER FLEX PLATE PLATE FLEX SCREW HHC M12 1 75 X 40 G8 8 WASHER LOCK M12 SCREW HHC M10 1 5 X 35 G8 8 WASHER LOCK M10 NUT HEX M10 1 5 G8 YEL CHR PLUG PLASTIC 3 8 NPT FLEX CONDUIT 1 BLACK NOT SHOWN WASHER FLAT 3 8 M10 ZINC SPACER ROTOR SHAFT SCREW HHC M12 1 25 X 25 G8 8 WASHER FLAT M12 DECAL WARN ENG START WASHER SHAKEPROOF INT 8 WASHER FLAT 34 ID X 75 OD DECAL DANGER STANBY UNITS LISTS age Carrier 41 PARTS ies OG ITEM PART NO 1 077483 2 038804D 3 038805B 4 0742600131 5 022131 6 046526 7 052213 8 075763 9 0D8668 13 050331A 14 050331 15 0C2454 16 025507 17 027482 42 Carrier Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Battery Drawing No 0E0770 B STARTER STARTER SOLENOID TO ENGINE BLOCK QTY DESCRIPTION TI BATT 12VDC 75 AH 26 NOT INCLUDED CABLE BATT RED 4 X 20 00 CABLE BATT BLK 4 X 23 00 ASSY WIRE 16 RED 1 6 WASHER FLAT 3 8 ZINC WASHER LOCK M10 SCREW HHC M10 1 25 X 20 G8 8 BOOT BATTERY CABLE BRACKET BATTERY HOLD DOWN 1 5 BATTERY POST COVER RED BATTERY POSTCOVER BLACK SCREW TH FRM M6 1X16 N WA Z JS WASHER SHAKEPROOF EXT 7 16 STL WASHER SHAKEPROOF EXT 5 16 STL N N wo
34. ATIOWLNOO GYVOd LINDYIO ddd LINN 10HLNO9 HONYSAODS N99 yov1g YHOLVNLOV NMOH AOSD MOTISA OL 39NVHO CRL lal ON NOS YOLVOIGNI LINVA LHOM 1 3NI NI SdAV SZ 3SNd Id SdNV SL 3Sr1d d NOILOANNOO 3NISN3 93 ONIGNIM NOILV1I9X3 Add Su3ayyvat8 UCI L gO YOLIOVdVO dv YHOLVLS HOLVNYALTIV SV YOLOY HOLVNYALIV HY ASVHd Adve 0cl NOILOANNOO YAWOLSNOD 6ce El NH 00 E r 93 CO 9 93 8 93 2 04 l 93 ert 01 93 6 93 SE 25 Carrier Section 8 Electrical Data Carrier Liquid cooled 15 kW Generators ELECTRICAL Se i DATA F Wiring Diagram 1 5L Engine Drawing No 0E0343 B LOS 4 0 49 13 14 67 14 13 Ill MDs 85 3 lt 85 0 0 0 85 wi CH LI Loun Te I j tt TT PANEL H _ 0 CONNECTION um IE 9 NO O gt cO 48 RED D LEGEND CC CONTROL CONTACTOR 2 V DIS DISTRIBUTOR D ES DCA DC ALTERNATOR BATTERY FS FUEL SOLENOID GRD GROUND LOS LOW OIL PRESSURE SWITCH SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH WLS WATER LEVEL SENSOR TO ELECTRONIC GOVERNOR GOVERNOR ee CONTROLLER ACTUATOR CONNECTOR SA Carrier TO CONTROL PANEL TERMINAL STRIP TO DC VOLTAGE REGULATOR TO CONTROL PANEL GOVERNOR CONTROL UNIT Section 8 Electrical Data Carrier Liquid cooled 15 kW Generators I i f I ELECTRICAL Electrical Schemati
35. Carrier Owner s Manual Liquid cooled Prepackaged Standby Generators Model Number ASPAS1CCL015 Been ms es m r mma bm e KN lt T f Ka FEIS E m s a em waku 7 ge A s ee U r a E eg eng en fe en wass H n w e ku ms rDvah es e T w A Not intended for use in critical life support applications AA caution amp ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMIPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit INTRODUCTION Thank you for purchasing a Carrier home standby generator system Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Carrier Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to al
36. ERATING HOURS 1 Retorque cylinder head See Torque Specs Section 1 13 2 Retorque intake and exhaust manifold See Torque Specs Section 1 13 3 Check engine compression 4 Check valve clearance 4 2 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 grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See Section 7 for installation drawings and vent locations 14 Carrier warninc amp The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system 4 3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution amp If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 44 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil l
37. Failure to isolate the two electric system power sources from each other by such means will result in dam age 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 per sonnel disable the generator s automatic start circuit bat tery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insu lation Keep the
38. HE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL CARRIER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CARRIER S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state Revision 10 01 04 Part No 0F4163 Rev 0 01 20 05 Catalog No 03AS PA4 Form No OMASPASL1507 1 Printed in U S A
39. On CB igus lasu eT Loo 5B tee ain u E wa pas v 828 88 8 3838588 2 i ERR PRR CA gt a ca w age eed sg Du po wen S KZ s By A 2 z R m SCHT YC HOTO wu d tals C goe a K ASSY 0760094 FORs0WZ Rated power of generator is subject to and limit ed by such factors as ambient temperature alti tude engine condition and other factors Engine power will decrease about 3 for each 1000 feet above 3000 feet and will decrease an additional 1 5 for each 10 F above 77 F Maximum output power of the generator is limited by maximum engine power 1 75 PCB OPERATION LED S LED 1 is RED The LED is ON when utility sensing is NOT available to the circuit board This LED will function only when the AUTO OFF MANUAL switch is set in the AUTO position LED 2 is YELLOW This LED is ON when the cir cuit board battery charger is on This LED will cycle ON and OFF with the battery charger 4 85 hours on the 4 85 hours OFF GS Carrier Section 1 General Information Carrier Liquid cooled 15 kW Generators LED 3 is GREEN This LED will flash when the cir cuit board has load voltage available to it This LED will function when voltage is available across T1 and T2 1 76 OVERCRANK SHUTDOWN After 90 seconds of crank rest cycles this function ends cranking if the engine fails to start in that
40. TIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available from the American National Standard Institute 1430 Broadway New York N Y 10018 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing Five feet allowance of space is recommended on all sides Local codes may supercede this recommendation Carrier Liquid cooled 15 kW Generators INSTALLATION Hh Section 2 Installation Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE 2 3 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts
41. WITH TIE WRAP AS SHOWN 7 16 aa WIRE HARNESS ITEM CONDOR WY PART NO 0D8656 027482 070936 070936C 039253 022145 022129 045771 071956 051730 021991 0D9335 0D9336 002454 047411 022097 022473 055414 049813 026850 0A1694 QTY 1 2 2 2 8 12 16 4 4 4 1 2 2 16 1 1 1 1 5 1 2 Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Mounting Base Drawing No 0E0768 B DESCRIPTION BASE MOUNTING 1 5L STNRD amp ACSTC WASHER SHAKEPROOF EXT 5 16 STL DAMPENER VIBRATION VIB ISO 70 75 DURO SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR WASHER FLAT M8 SCREW HHC M8 1 25 X 60 G8 8 EARTH STRAP PANEL SUPPORT PANEL BRACKET SCREW TH FRM M6 1 X 16 N WA Z JS SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC LUG SLDLSS 2 8 X 17 64 CU NUT HEX M6 X 1 0 G8 YEL CHR WASHER SHAKEPROOF EXT 1 4 STL 1 1 2 BUTTON PLUG Gi LISTS Carrier 29 Carrier Liquid cooled 15 kW Generators Section 9 Exploded Views and Parts Enclosure Drawing No 0F4490 WELD STUD UNDER ROOF PANEL FOR ACCESS COVER CABLE FASTENER TO SECURE USE DOOR LATCH GROUND WIRE USE LOCTITE ON NUTS ITEM 26 30 Carrier ITEM CONDOR OO N PART NO QTY 0D8666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 002454 033530 051716 022152
42. actory trained and are capable of han dling all of servicing needs When contacting a Carrier Dealer about parts and service always supply the complete model number and serial number of the unit as given on the front cover of this manual and on the DATA LABEL affixed to the unit YOUR CARRIER DEALER IS Dealer Name Address City Zip Code Phone Number Model No Serial No INTRODUCTION Zug eegener eer eeegeetet IPC SAFETY RULES eet 2 Section 1 GENERAL INFORMATION 4 IL GCA e E 4 12 Transfer SWIICh eege 4 1 3 Automatic System Operation 4 1 4 Generator AC Connection Systems 4 15 Main Circuit Breaker 4 1 6 Generator Fuel System 5 1 7 Engine Protective Devices 5 LO Unpacking akc ieee ie eos ene 6 1 9 Lifting the Generator 6 1 10 Specifications 6 1 11 Fuel Consumption T 1 12 Reconfiguring the Fuel System 7 1 13 Torque Specifications 7 1 14 Engine Oil Recommendations 8 1 15 Coolant Recommendations 8 1 16 Before Installation 8 Section 2 INSTALLATION 8 2 1 Standby Generator Install
43. artial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only fac tory approved parts Before performing any maintenance on the generator dis connect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc N ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous volt ages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insul
44. ated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If people must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static elec tricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in haz ardous and possibly fatal electrical shock Connecting this unit to an electrical system normally sup plied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating
45. ation 8 2 2 Generator LOCAL OR eege ege 9 2 3 Generator Mounting and Support 9 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 Carrier Liquid cooled 15 kW Generators Table of Contents Kee CONTENTS Section 3 OPERATION 12 3 1 Control Console Components 12 3 2 Manual Transfer and Startup 13 3 3 Automatic Operation 13 3 4 Weekly Exercise Cycle 13 Section 4 MAINTENANCE 14 4 1 Maintenance Performed by Authorized Service Facilities 14 AD C OONN SyS E 14 4 3 Overload Protection for Engine DC Electrical Syste dee 14 4 4 Checking Fluid Levels 14 4 5 Maintenance Owner Operator C EE 15 4 6 Miscellaneous Maintenance 16 4 7 Scheduled Maintenance 18 Section 5 TROUBLESHOOTING 21 5 1 Troubleshooting Po
46. bout 3 8 to 3 4 inch Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DX A A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine 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 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 4 2 counterclockwise and remove Dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN 6 Remove OIL
47. c 1 5L Engine Drawing No 0A7182 C me DATA WTS LOS WLS 0 12V BATTERY RED W BLACK LEGEND CC CONTROL CONTACTOR DCA DC ALTERNATOR FS FUEL SOLENOID GRD GROUND ISC IGNITION SYSTEM CONTACT LOS LOW OIL SWITCH SM STARTER MOTOR ACTUATOR WTS WATER TEMPERATURE SWITCH CONNECTOR WLS WATER LEVEL SWITCH GOVERNOR ACTUATOR Carrier 27 PARTS gies Co 4 6 17 Y 8 TO A ib S 18 H d s E me be EC Ca i SY CARBURETOR ARM REF 11 ITEM PART NO D 098290 098941A 9 098958A NM i 098942A x 098225 043146 i 022097 084543A 7 i 098783 e 037398 i e 0E1326 x 0A7106 i 074031 N e 029333A i k 022507 l e 022473 5 064526 j 0E1694 8 Carrier Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Governor Assembly Drawing No 0E1331 B DESCRIPTION ASM MOTOR STEPPER HOUSING GOVERNOR CONNECTOR CONNECTOR INTERFACE ASSEMBLY COVER CONNECTOR HOUSING SCREW FHM 2 X 5 8 SELF TAP SCREW HHC M6 1 0 X 10 G8 8 WASHER LOCK M6 1 4 SCREW PHM M3 0 5 X 12MM LEVER STEPPER MOTOR NUT LOCK HEX 10 32 NYL INS ASSY CARBURETOR LINKAGE ROD BRACKET STEPPER MOTOR LIQUID NEOPRENE TIE WRAP 7 4 X 19 BLK UL SCREW HHC 1 4 20 X 1 2 G5 WASHER FLAT 1 4 ZINC SCREW TAP HWH 6 25 X 3 8 ZINC SPRING ANTI LASH ITEM 13 NEOPRENE COATING N 15 SECURE WIRE HARNESS we
48. ce with applicable codes standards and regulations 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications Section 1 10 for more information 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULT mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications Section 1 10 and Engine Oil Recommendations Section 1 14 NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications Section 1 10 and Coolant Section 1 15 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm 12 Carrier 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or gr
49. crank Overspeed Low oil pressure High coolant temperature Low coolant level 3 1 3 15 AMP FUSE The fuse protects the control console s DC control circuit against electrical overload If the fuse has melted open because of an overload engine cranking and startup cannot occur If replacement of the fuse is necessary use only an identical 15 amp fuse Type AGC part number 022676 3 1 4 7 5 AMP INLINE FUSE This inline fuse is connected in the 15A line that runs between the AUTO OFF MANUAL switch and position 10 of the 76009A PCB This fuse protects the start fuel field boost and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outputs NOTE This fuse will not remove the positive battery input power from the PCB when it opens This means the exercise timer will not be reset If this fuse does open carefully check the wiring to the start fuel field boost and transfer outputs before replacing the fuse 3 1 5 SET EXERCISE TIME SWITCH This switch allows for programming the generator to start and exercise automatically See Weekly Exercise Cycle Section 3 5 3 2 MANUAL TRANSFER AND START UP To transfer electrical loads to the STANDBY GEN ERATOR power source side and start the engine manually refer to the Owner s Manual of the particu lar transfer switch 3 5 AUTOMATIC OPERATION To set the system for fully automatic operation
50. d and inspected by a dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 6 2 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 DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion w
51. ed as installation guide for this equipment NOTE It is essential to use the latest version of any stan dard to ensure correct and current information 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE avail able same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRICAL SYS TEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Carrier 3 GENERAL INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven gen erator set The generator is designed to supply elec trical power that operates critical electrical loads during utility power failure The unit has bee
52. ed there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications
53. eep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Scheduled Maintenance Section 4 7 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 5 0 6 mm 0 020 0 025 inch by carefully bending the ground electrode Figure 4 4 Figure 4 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 5 0 6 mm 0 020 0 025 inch 1 lt Tp La Catt O O w is 4 5 13 COOLANT CHANGE Every year have a dealer drain flush and refill the cooling system See SPECIFICATIONS Section 1 10 for cooling system recommendations 4 6 MISCELLANEOUS MAINTENANCE 4 4 6 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Apply a coat of automotive type wax once a year to help pre vent corrosion Once each year have the generator cleane
54. er switch Control system interconnections consist of N1 N2 T1 T2 and leads 23 and 194 Control system inter connection leads must be run in a conduit that is sep arate from the AC power lead Recommended wire gauge sizes for this wiring depends on the length of the wire as recommended below MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE 461 TO 730 FEET 223M 731 to 1 160 feet 354m 1 161 to 1 850 feet 565m No 12 AWG 2 10 BATTERY INSTALLATION A DIG A Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel do not connect battery cables until the NORMAL source voltage at the transfer switch is correct and the system is ready to be put into operation Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permi
55. ert person nel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their defi nitions are as follows A DIE A After this heading read instructions that if not strictly complied with will result in serious person al injury including death or considerable property damage warninc amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa A tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Carrier The operator is r
56. esponsible for proper and safe use of the equipment Carrier strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Carrier also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Carrier Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or work manship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Carrier Dealer for serv ice aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by a Carrier Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact a Carrier Dealer for assistance Service tech nicians are f
57. evel Figure 4 1 at least every 20 hours of operation or prior to use A Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recom mended oils Figure 4 1 Oil Dipstick and Oil Fill Cap H SS N e Ce Q lt OIL DIPSTICK E Ki 4 4 2 BATTERY FLUID Check battery electrolyte fluid at least once a month Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 4 4 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Section 1 10 e Add recommended coolant mixture as necessary Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact a dealer Inspect cooling system and coolant recovery sys tem for leaks 4 5 MAINTENANCE OWNER OPERATOR CAN PERFORM 45 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels in Section 4 4
58. extinguisher properly charged and be familiar with its use Consult the local fire department for any questions pertaining to fire extinguishers SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Carrier Liquid cooled 15 kW Generators N EXPLOSION HAZARDS ZA Properly ventilate any room or building housing the gener ator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Carrier generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air Install leak detectors accordingly STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be us
59. hat purpose a GROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations A DX A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result 10 Carrier Carrier Liquid cooled 15 kW Generators Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG 2 8 GENERATOR AC NEUTRAL CONNECTIONS Carrier uses an UNGROUNDED AC neutral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the excessive current opens the load circuit breaker or collapses the generator field The actual result depends on the electrical characteristics of the particular installed generator warning A Failure to connect the generator neutral prop erly will result in unbalanced line to neutral voltages Resulting high voltages will cause equipment damage 2 9 TRANSFER SWITCH SIGNAL CONNECTIONS It is necessary to connect the control wires between the generator and the transf
60. hich can shatter the battery causing blindness or other serious injury 4 6 3 BATTERY MAINTENANCE The battery should be inspected per the Scheduled Maintenance Section 4 7 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer Carrier Liquid cooled 15 kW Generators MAINTENANCE O Section 4 Maintenance A Dita A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flu
61. i freeze and deionized water Cooling system capacity is about 8 U S quarts 7 6 liters Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution amp A Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating It is also recommended that any soluble oil inhibitor is NOT used for this equipment 8 Carrier Carrier Liquid cooled 15 kW Generators 1 16 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in Sections 2 5 and 2 6 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power The critical essential loads may need to be grouped together and wired into a sepa rate emergency distribution panel The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses
62. ints 21 Section 6 NOTES 22 Section 7 INSTALLATION DIAGRAM 0eeeec00 A9 Section 8 ELECTRICAL DATA 24 Section 9 EXPLODED VIEWS AND PARTS LISTS 28 Section 10 WARRANTY 44 Carrier 1 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Carrier Liquid cooled 15 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment A A WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm A WARNING A This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operat ing or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed oper ated and maintained Many accidents are caused by failing to fol low simple and fundamental rules or precautions Carrier cannot anticipate every possible circumstance that might involve a hazard The warnings in
63. n facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the oper ation of 120 and or 240 volts single phase loads These models are available They are rated as follows Model ASPASI1CCLOI15 Provides 15 000 watts 15 kW of single phase power warninc amp If this generator is used to power electrical A load circuits normally powered by a utility power source it is required by code to install a transfer switch The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power work ers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system includes a matched automatic transfer switch which is intended to be used in con junction with the generator It is supplied with a NEMA 3R enclosure The NEMA 3R enclosure is weather proof and can be used indoors or outdoors Follow these rules Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any c
64. nts ALTERNATOR All Components TRANSFER SYSTEM All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks scrapes dents or scratches to the painted enclosure should be repaired promptly by the owner THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING e Carrier generators that utilize non Carrier replacement parts e Carrier generators utilizing non Carrier automatic transfer switches e Any Carrier generators used as rental or trailer mounted applications e Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist e Costs of normal maintenance adjustments installation and start up e Steel enclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised e Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts e Failures due but not limited to accident misuse abuse negligence or improper installation As with all mechanical devices the Carrier engines need periodic part s service and replacement to perform well e Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear h
65. oded Views and Parts Carrier Liquid cooled 15 kW Generators KO Alternator Drawing No 0A9348 F To Engine Crankshaft SOS Wb 7 WMA Wk 4 Wk AAA d NNANASAN To Blower 40 Carrier ITEM PART NO QTY 1 098671 1 098681 1 098675 1 098936 1 2 0A5336A 1 3 0A1659 1 4 071912 4 5 049226 4 6 051713 4 7 022129 4 8 098672 1 098673 1 098674 1 098682 1 098683 1 098684 1 098676 1 098677 1 098678 1 097620 1 098937 1 097621 1 9 0A5382 1 10 075591 1 11 075476 4 12 0A5601 1 13 075554B 4 14 0A9375 4 15 022152 4 16 097146 1 17 042558 1 18 0A5061 1 19 0A4989 1 20 053557 1 21 051769 6 22 049541 4 23 046526 4 24 045772 4 26 087599 1 27 077043E 1 28 022131 4 29 072578 1 30 0A7043 5 31 049808 5 32 058589 1 33 023365 4 35 0A8830 4 36 072080 1 USED ON PRE PACKAGED UNITS ONLY Section 9 Exploded Views and Parts Carrier Liquid cooled 15 kW Generators Alternator Drawing No 0A9348 F DESCRIPTION ASSY ROTOR 10KW ASSY ROTOR 15KW ASSY ROTOR 20KW ASSY ROTOR 25KW HOUSING BLOWER SCREEN AIR OUTLET SCREW PPHM M5 0 8 X 8 SS WASHER LOCK M5 WASHER FLAT M5 WASHER LOCK M8 5 16 ASSY STATOR 10KW A ASSY STATOR 10KW D ASSY STATOR 10KW GJK ASSY STATOR 15KW 1PH A ASSY STATOR 15KW 3PH D ASSY STATOR 15KW 1PH GJK ASSY STATOR 20KW 1PH A ASSY STATOR 20KW 1PH D ASSY STATOR 20KW 1PH GJK ASSY STATOR 25KW 1PH A ASSY STATOR 25KW 1PH D ASSY STATOR 25KW 3PH D BE
66. olocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane e Damage related to rodent and or insect infestation e Products that are modified or altered in a manner not authorized by Carrier in writing e Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s e Failure due to misapplication e Telephone cellular phone facsimile internet access or other communication expenses e Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period e Expenses related to customer instruction or troubleshooting where no manufacturing defect is found e Rental equipment used while warranty repairs are being performed e Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc e Overnight freight costs for replacement part s e Overtime labor e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY CARRIER MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you CARRIER S ONLY LIABILITY SHALL BE T
67. orro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors Failure to utilize a Carrier transfer switch with this generator will void the warranty Section 1 General Information Carrier Liquid cooled 15 kW Generators 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with its transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors utility power source voltage Should that voltage drop below a pre set value and remain at such a low state for a preset amount of time the generator cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can power them When utility source voltage has been restored the switch re transfers back to the utility source voltage and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase three wire generator AC connection system Figure 1 1 The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can supply 120 volts AC 60 Hertz When the two windings are connected in series a 240 volts 60 Hertz
68. ound rod Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 CONTROL CONSOLE COMPONENTS The components of a liquid cooled generator control console Figure 3 1 are as follows Figure 3 1 Liquid Cooled Generator Panel Q Q FUSE FAULT 15 A INDICATOR AGC AUTO SET il EXERCISE TIME ON OFF MANUAL 3 1 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows e Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 4 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engine With OFF selected operation will not be possible A DI A A With switch set to AUTO engine can crank and start suddenly without warning Such automat ic start up normally occurs when UTILITY source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on con trol console 3 1 2 FAULT INDICATOR LAMP The lamp goes ON when one or more of the following engine faults occurs and when engine shuts down Over
69. owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including
70. pen N O thermostatic switch has sensing tip which is immersed in captive coolant Should coolant temperature exceed about 230 F 110 C the switch contacts close which causes the engine to shut down automatically Figure 1 5 Figure 1 5 High Coolant Temperature Switch 1 73 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shutdown To prevent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatical ly shuts down Figure 1 6 on page 6 Carrier 5 1 7 4 OVERSPEED SHUTDOWN The Pre pack circuit board on liquid cooled units receives AC frequency rpm signals directly from the stator AC power windings via sensing leads S15 and 16 Should AC frequency exceed about 72 Hz cir cuit board action will automatically shutdown the engine Figure 1 7 Figure 1 7 Control Module Assembly Circuit Board G FEE i i oe STANDBY o w I WME HEE eas i THEa S s Nis UE Si Li UA are CB
71. rature engine condi tions and other environmental factors Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges Section 1 General Information Carrier Liquid cooled 15 kW Generators 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for 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 Port 1 of the demand regulator Figure 1 8 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas Ge SA ER EE Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 FUEL HOSE FUEL HOSE I BRASS HOSE BRASS HOSE FITTING FITTING OUT OUT le E PORT1 PORT 2 V HOUSING J HOUSING PORTS PORTS m
72. sh the affected area immediately with clear water A Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging waRNING amp 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 UTILITY power supply is turned OFF or sparking may occur at the battery posts g as the cables are attached and cause an explo sion 4 6 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 525 0 deg F NOTE The BCI number should be located directly on the battery PERIODIC REPLACEMENT PARTS Part Name Part Number Oil Filter 0A4531A244 046627 059402 0A45310275 Radiator Cap Air Cleaner Spark Plug Carrier 17 Section 4 Maintenance MAINTENANCE Carrier Liquid cooled 15 kW Generators 4 7 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets The established intervals in the schedule are the maximum recommended when the unit is used in an average service application They will need to be decreased performed more frequently if the unit is used in a severe
73. t 92 inches 1 5 liters Cylinder Arrangement a 4 in line Valve Arrangement Overhead Cam SLE E u uuu ous gasaanabapayashas 1 3 4 2 Number of Main Beangs A 5 Compression Ratio l a 9 to 1 No of Teeth on Flywheel cecsessssesssessesssssessssersserseses 104 Ignition Timing at 1800 NON eegener eege 35 degrees BTDC Spark Plug Gap 0 020 0 025 inch Recommended Spark Plugs GNaMmDION sesope ani RN11YC4 AIS 30 50 psi Crankcase Oil Capacily 3 0 U S quarts 2 8 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery Belle E Pusher Type Cooling System Capacity 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base 1 11 FUEL CONSUMPTION 15 kW Models Using Natural Gas 2 7 Cu ft per hour Using LP Gas sseveeeeee 110 cubic ft 3 1 gal per hour NOTE Fuel consumption is given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot and LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient tempe
74. t fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immediately with clear water warninc amp A Do not dispose of the battery in a fire The bat A tery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short cir cuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 10 1 VENTED BATTERIES caution amp The electrolyte is a dilute sulfuric acid that is A harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures are to be observed e Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes flush thor oughly and immediately with water and seek med ical attention and Carrier Liquid cooled 15 kW Generators INSTALLATION LED Section 2 Installation e Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbon ate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until
75. this manual and on tags and decals affixed to the unit are therefore not all inclu sive If using a procedure work method or operating technique that Carrier does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe A Dia A Despite the safe design of this generator operating this equipment imprudently neglecting its mainte nance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator A Parts of the generator are rotating and or hot during operation Exercise care near running gen erators GENERAL HAZARDS For safety reasons Carrier recommends that this equip ment be installed serviced and repaired by a Carrier Dealer or other competent qualified electrician or installa tion technician who is familiar with applicable codes stan dards and regulations The operator also must comply with all such codes standards and regulations 2 Carrier SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries Installation opera
76. tion servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accor dance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforemen tioned codes standards laws and regulations The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict com pliance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even p
77. ty power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set When this method is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements It must have an ampere rating equal to or greater than the total amperage rating of the emergency distribution panel circuit Have it installed between the building s main dis tribution panel and the emergency distribution panel 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the gener ator to be overloaded when this isolation method is employed The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must be equal to or greater than the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution panel 2 7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods For t
78. ublished standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 NOTE It is essential to use the latest version of any stan dard to ensure correct and current information NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available NOTE It is essential to use the latest version of any stan dard to ensure correct and current information Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 e AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NA

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