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O&M Manual for Eaton Standby Liquid Cooled Generator SetsInstructional Booklet

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Owner’s Manual1. Introduction to the Owner’s Manual . . . . . . . . . . . . . . 22. Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . 33. Components of the Standby Generator Set . . . . . . . . . 54. Operation of the Standby Generator Set . . . . . . . . . . . 105. Routine Maintenance 14

Installation, Maintenance, and Troubleshooting Manual6. Introduction to the Installation, Maintenance, and

Troubleshooting Manual . . . . . . . . . . . . . . . . . . . . . . 197. Warning and Cautions. . . . . . . . . . . . . . . . . . . . . . . . 198. Components of the Standby Generator Set . . . . . . . . . 229. Installation and Handling . . . . . . . . . . . . . . . . . . . . . . 2210.Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3211.Engine Preparation and Operation. . . . . . . . . . . . . . . . 3212.Standby Generator Set Control . . . . . . . . . . . . . . . . . 3913.Operation of the Standby Generator Set . . . . . . . . . . . 4514.Generator Set Maintenance and Troubleshooting . . . . . 4915.Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Appendix E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Appendix F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Appendix G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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Instructional BookletPage 2 Effective: November 2006 O&M Manual for Eaton Standby

Liquid Cooled Generator Sets

For information on how to contact authorized, trained, and certi-fied technicians in your area, contact the Eaton Cutler-Hammer Standby Generator Support Line at 800 975-8331.

Owner’s Manual

1 Introduction to the Owner’s ManualThis Eaton Electrical liquid cooled generator set is one of a family of standby generator sets, fueled by either natural gas (NG) or liq-uid propane (LP), specifically designed for residential and light commercial use. Table A-1 in Appendix A lists all Eaton Electrical standby liquid cooled generator set models and general specifica-tions. Table A-2 in Appendix A lists the accessories available for all standby liquid cooled generator sets.Your Eaton Electrical liquid cooled standby generator set has been extensively tested and is ready to be installed, setup, and to be connected to the natural gas fuel supply following the local regula-tions.

This Owner’s Manual section of this document is intended for use by the owner/user of the generator and covers ONLY the normal Operation and Routine Maintenance. For the installation and setup information needed by the installation technician(s), refer to the Installation, Maintenance, and Troubleshooting Manual section of this document.

This Owner’s Manual has been prepared to detail the Operation and Routine Maintenance of your generator set. Following the procedures and suggestions in this manual will help to ensure that your generator set keeps operating at maximum performance and efficiency for a long life.Note: If the generator set is located in a dirty or dusty environment, routine maintenance may have to be performed more frequently to keep the gener-ator set running properly.Note: Always ensure that adjustments, repairs, and installations are per-formed by authorized, trained, and certified technicians.

1.1 Generator Set IdentificationEvery generator set is uniquely identified by a model and serial number listed on the rating plate that is generally affixed to the control panel door. This information is required when ordering spare parts or when service or warranty work is required. For your future convenience, take a moment and record those num-bers on the lines provided below.

Model Number:Serial Number:Date Purchased:Date Installed/Commissioned:

WARNINGTHE INSTALLATION AND SETUP OF YOUR RESIDENTIAL GENERA-TOR SET MUST BE PERFORMED BY AUTHORIZED, TRAINED, AND CERTIFIED TECHNICIANS. INCORRECT INSTALLATION AND SETUP CAN CAUSE DEATH, SERIOUS PERSONAL INJURY, AND / OR PROP-ERTY DAMAGE.

WARNINGDO NOT ATTEMPT TO OPERATE YOUR RESIDENTIAL GENERATOR SET UNTIL YOU HAVE COMPLETELY READ THIS OWNER’S MAN-UAL. IT IS ALSO IMPORTANT TO CLOSELY REVIEW AND UNDER-STAND ALL SAFETY WARNINGS AND CAUTIONS AND ALL OPERATING AND ROUTINE MAINTENANCE PROCEDURES CON-TAINED WITHIN THIS MANUAL.

WARNINGTHE INSTALLATION AND SETUP OF YOUR GENERATOR SET MUST BE PERFORMED BY AUTHORIZED, TRAINED, AND CERTIFIED TECH-NICIANS. INCORRECT INSTALLATION AND SETUP CAN CAUSE DEATH, SERIOUS PERSONAL INJURY, AND / OR PROPERTY DAM-AGE.

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Instructional BookletEffective: November 2006 Page 3

O&M Manual for Eaton Standby Liquid Cooled Generator Sets

2 Warnings and CautionsEaton Electrical residential standby generator sets are designed to be safe when installed, setup, and used in the correct manner. Responsibility for safety, however, rests with the technicians who install, setup, and maintain the equipment and the owner/user who uses the generator set.Following the safety precautions and suggestions detailed in this section will minimize the possibility of accidents, injury, or dam-age. Before performing any procedure or operating technique, it is up to the user to ensure that it is safe.

2.1 Symbols and Standardizations

In this section and throughout this Owner’s Manual, this symbol is used in conjunction with the words DANGER, WARNING, and CAUTION to alert the user of hazards of which to be aware.

DANGER: Signifies a hazard that WILL result in death or seriousinjury.

WARNING: Signifies and hazard that COULD result in death orserious injury.

CAUTION: Signifies a hazard or situation that MIGHT result inminor injury or equipment damage.

In addition, the following hazard symbols will appear to identify the type of Danger, Warning, and Caution.

When an important piece of information is necessary for the proper operation or routine maintenance of the generator set, it will be identified by the word NOTE. For example:

Note: The generator set may be stopped at any time by pushing the Emer-gency Stop button.

2.2 General• Read and understand all safety precautions and warnings before

operating or performing routine maintenance on the generator set.

• Failure to follow the instructions, procedures, and safety pre-cautions in this manual may increase the possibility of accidents and injuries.

• Never start the generator set unless it is safe to do so.• Do not attempt to operate the generator set with a known

unsafe condition.• If the generator set is unsafe, fit danger notices and disconnect

the battery negative (-) lead and turn off the fuel supply so that it cannot be started until the condition is corrected.

• Disconnect the battery negative (-) lead and turn off the fuel supply prior to attempting any repairs or cleaning inside the enclosure.

• Operate this generator set only in full compliance with relevant National, Local, or Federal Codes, Standards or other require-ments.

2.3 Fire and ExplosionFuels and fumes associated with generator sets can be flammable and potentially explosive. Proper care in handling these materials can dramatically limit the risk of fire or explosion. However, safety dictates that fully charged BC and ABC fire extinguishers are kept on hand. The owner/user MUST know how to operate them.• Gaseous fuels are highly explosive. Ensure the generator set

room, if installed indoors, is properly ventilated according to gas regulations. Use of a suitable leak detection system is also rec-ommended.

• Natural gas is lighter than air and, as a result, tends to settle in high places. LP gas on the other hand is heavier than air and will therefore settle in low areas. Extreme caution is therefore required when entering such areas.

• Keep the area, the floor, and the generator set clean. When spills of oil, battery electrolyte, hydraulic fluid or coolant occur, they should be cleaned up immediately.

• Never store flammable liquids near the engine.• Store oily rags in covered metal containers.• Do not smoke or allow sparks, flames, or other sources of igni-

tion around gas pipes or batteries. Fuel gases are explosive. Hydrogen gas generated by charging batteries is also explosive.

• Turn off the natural gas fuel supply and disconnect the power to the battery charger before making or breaking connections with the battery or before breaking any gas pipe or line.

• Keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals, to avoid arcing. Sparks and arcing might ignite gas or vapors.

• Do not attempt to operate the generator set with any known gas leaks in the fuel system.

• The excessive build-up of unburned gases in the exhaust sys-tem can create a potentially explosive condition. This build-up can occur during such operations as repeated failed start attempts, air flap valve testing, or hot engine shutdown. Open exhaust system purge plugs, if equipped, and allow the gases to dissipate before attempting to restart the generator set.

HOT SURFACEEXPLOSION

TOXIC FUMESFIRE

ELECTRICAL SHOCK NOISE

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2.4 MechanicalThe generator set is designed with guards for protection from moving parts. Care must still be taken to protect the user and equipment from other mechanical hazards when working around the generator set.• Do not attempt to operate the generator set with safety guards

removed. While the generator set is running, do not attempt to reach under or around the guards to perform routine mainte-nance or for any other reason.

• Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts, and other moving parts.

Note: Some moving parts cannot be seen clearly when the gener-ator set is running.• Keep access doors on enclosures, if equipped, closed and

locked when not required to be open.• Avoid contact with hot oil, hot coolant, hot exhaust gases, hot

surfaces, and sharp edges and corners.• Wear protective clothing including gloves and hat when working

around the generator set.• Do not remove the radiator filler cap until the coolant has

cooled. Then loosen the cap slowly to relieve any excess pres-sure before removing the cap completely.

• Ethyl Ether starting aids are not recommended. They will reduce the efficient working life of the engine.

2.5 ChemicalGas, oils, coolants, lubricants, and battery electrolyte used in this generator set are typical of the industry. However, they can be hazardous to personnel if not treated properly.• Do not swallow or have skin contact with oil, coolant, lubri-

cants, or battery electrolyte. If swallowed, seek medical treat-ment immediately.

• Do not wear clothing that has been contaminated by oils or lubricants.

• Wear an acid resistant apron and face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing, seek medical treatment immediately.

2.6 NoiseGenerator sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 89 dBA. Pro-longed exposure to noise levels above 85 dBA is hazardous to hearing. Please see Appendix A, Table A-1 for decibel ratings of the individual generator sets.• Ear protection should be worn when operating or working

around an operating generator set without a sound attenuating enclosure.

2.7 ElectricalSafe and efficient operation of electrical equipment can be achieved only if the equipment is correctly installed, operated, and maintained.• The generator set must be connected to the load only by trained

and qualified electricians who are authorized to do so, and in compliance with relevant Electrical Codes, Standards, and other regulations. Where required, their work should be inspected and accepted by the inspection agency prior to operating the generator set.

• Ensure the generator set is effectively grounded/earthed in accordance with all relevant regulations prior to operation.

• The generator set should be shutdown with the battery nega-tive (-) terminal disconnected and the fuel supply turned off prior to attempting to connect or disconnect load connections.

• Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground.

• Do not touch electrically energized parts of the generator set and/or interconnecting cables or conductors with any part of the body or with any non-insulated conductive object.

• Be sure all electrical power is disconnected from electrical equipment being serviced.

• Keep all electrical equipment clean and dry.• Have authorized, trained, and certified technicians replace any

wiring where the insulation is cracked, cut, abraded, or other-wise degraded.

• Have authorized, trained, and certified technicians replace ter-minals that are worn, discolored, or corroded.

• Have authorized, trained, and certified technicians keep all ter-minals clean and tight.

• Have authorized, trained, and certified technicians insulate all connections and disconnected wires.

• Use only Class BC or Class ABC extinguishers on electrical fires.

2.9 First Aid For Electric ShockIn case of electric shock, contact emergency services immedi-ately.




3 Components of the Standby Generator SetIt is important to know the location of the major components of your Eaton Electrical standby generator set and their function. The following sections will identify each major component and give a short description of each.

3.1 Standby Generator Set Description and IdentificationYour Eaton Electrical generator set has been designed as a com-plete package to provide superior performance and reliability. Fig-ures 1 and 2 identify the major components of a typical generator set. However, every set will be slightly different due to the size and configuration of the major components.

Figure 1. Major Components of a Typical Eaton Electrical Standby Liquid Cooled Generator Set Powered by a Ford Engine.

1. Gas Engine,

2. Air Filter,

3. Radiator/Cooling System,

4. Alternator,

5. Base Frame,

6. Vibration Isolators,

7. Control Panel,

8. Output Circuit Breaker, and

9. Solenoid Gas Valve.

1

2

3

4

5

6

7

8

9




Figure 2. Major Components of a Typical Eaton Electrical Standby Liquid Cooled Generator Set Powered by an Isuzu Engine.

1. Generator Set Rating Label: Each Eaton Electrical residential standby generator set is provided with a Rating Label gener-ally affixed to the alternator housing or control panel door. This label contains the information needed to identify the gen-erator set and its operating characteristics.

1. Gas Engine,

2. Air Filter,

3. Radiator/Cooling System,

4. Alternator,

5. Base Frame,

6. Vibration Isolators,

7. Control Panel,

8. Output Circuit Breaker,

9. Solenoid Gas Valve, and

10. Starter Motor

12 34

5 6

7 8

9

10




Figure 3. Typical Generator Set Rating Label.This information includes, but is not limited to the:• Model Number;• Serial Number;• Output Characteristics (such as voltage, phase and

frequency);• Output Rating in kVA and kW; and• Rating Type (basis of the rating).For reference, this information also appears in the Technical Data Sheet supplied with your generator set. The model and serial numbers uniquely identify the generator set and are needed when ordering spare parts or obtaining service or warranty work for the set.

2. Engine: The engine powering your residential standby genera-tor set has been chosen for its reliability. The engine is of the 4-stroke, spark ignition type and is fitted with all of the neces-sary equipment to provide a reliable power supply.

Figure 4. Typical Engine Powering the Generator.

The necessary equipment includes, among others:• An Air Filter;• An Electronic Close Control Engine Speed Governor (incorpo-rating a throttle and gas carburetor).The generator set is supplied with a fuel train consisting of a fuel regulator and an automatic fuel shutoff valve.

3. Air Filter: The air filter delivers clean combustion air that mixes with the fuel to power the engine.

Figure 5. Typical Air Filter.

4. Radiator/Cooling System: The engine cooling system is com-prised of a radiator, a high capacity pusher fan, and a thermo-stat. Note that the air is "pushed" through the radiator so that the cooling air is drawn past the alternator, then past the engine, and finally through the radiator.


Instructional BookletPage 8 Effective: November 2006

O&M Manual for Eaton StandbyLiquid Cooled Generator Sets

Figure 6. Typical Radiator and Cooling System.Note: The alternator has its own internal fan to cool the alternator compo-nents.

5. Alternator: The output electrical power is normally produced by a screen protected and drip-proof, self-exciting, self-regu-lating, brushless alternator that is fine tuned to the output of the specific generator set. On models larger than 25 kW, a sheet steel terminal box is mounted on top of the alternator.

Figure 7. Typical Generator Set Alternator.

6. Base Frame: The engine and alternator are coupled together and mounted on a heavy-duty steel base frame.

Figure 8. Typical Generator Set Base Frame.




7. Vibration Isolators: The generator set is fitted with vibration isolators that are designed to reduce engine vibration being transmitted to the foundation on which the generator set is mounted. These isolators are fitted between the engine/alter-nator feet and the base frame.

Figure 9. Typical Generator Set Vibration Isolator.

8. Control System and Panel: The generator set is fitted with a Deep Sea Electronics (DSE) 703 Automatic Start Control Module to control the operation and output of your generator set and to protect the generator set from possible malfunc-tions. See the Installation and Maintenance portion of this manual for detailed information concerning the control sys-tem/panel in your generator set.

Figure 10. The DSE 703 Control Panel and Emergency Stop Button.

9. Output Circuit Breaker: To protect the alternator, a suitably rated circuit breaker selected for the generator set model and output rating is supplied. It is mounted in a steel enclosure mounted by the generator control panel.

Figure 11. Typical Generator Set Output Circuit Breaker.

10. Solenoid Fuel Valve: The solenoid fuel valve controls the flow of fuel to the engine. It is used by the DSE 703 Control Module and the Emergency Stop button to start and stop fuel flow to the engine.

Figure 12. Typical Generator Set Solenoid Control Valve.




11. Starter Motor (and Engine Electrical System): The engine electrical system is negative ground/earth 12 Vdc. This sys-tem includes an electric starter motor, battery (customer sup-plied) and battery rack (that may also be located on the floor next to the generator set for some of the larger generator sets), and a battery-charging alternator.

Figure 13. Typical Generator Set Starter and Battery-charging Alternator.

3.2 Silencer and Exhaust SystemAn exhaust silencer system is provided with the generator sets. The silencer and exhaust system reduce the noise emission from the engine and directs exhaust gases to safe outlets.

4 Operation of the Standby Generator Set4.1 Control SystemThe Eaton Electrical liquid cooled standby generator set is equipped with an advanced electronic control system. It is con-trolled by the Deep Sea Electronics (DSE) 703 Automatic Start Control Module.This control system allows the user to manually or automatically control the generator set. The control system has protection cir-cuits to sound an optional alarm and even shutdown the set if problems occur.The procedures detailed in this section are required to prepare the generator set for operation, starting and stopping it for the first time after installation, and starting and stopping it normally. Note that Section 4.2, Pre-Start Checks are applicable with all control systems. Sections 4.3, and 4.4 cover operation of the Autostart Control Systems.

4.2 Pre-Start Checks (Applicable to All Control Systems)The following checks should be performed prior to starting the generator set.

Step 1: Ensure the control panel is in the “Stop” Mode.

Figure 14. The Stop Button on the Control Panel.

CAUTIONFOR GENERATOR SETS IN WALK-IN TYPE ENCLOSURES, ENSURE THAT ALL VIBRATION ISOLATOR RESTRAINTS ARE REMOVED BEFORE STARTING THE GENERATOR SET.

WARNINGAS GENERATOR SETS WITH AUTOSTART CONTROL PANELS CAN BE REMOTELY STARTED WITHOUT WARNING, ALWAYS ENSURE THE CONTROL PANEL IS IN THE “STOP” MODE BEFORE CARRYING OUT ANY CHECKS OR PROCEDURES.

Stop Button




Step 2: Check the engine oil and coolant levels. Replenish the engine oil and coolant, as needed, using the recom-mended fluids. See the oil specifications in Tables 1 and 2 (on page 15). See the coolant requirements in Section 5.3.5.

Figure 15. Typical Location of the Oil Dip Stick and Radiator Cap.Note: When adding coolant to the radiator system, always pour slowly to help prevent air from becoming trapped in the engine.

Step 3: Check the condition and tension of the fan and engine alternator belts. Tighten the belts if necessary.

Figure 16. Typical Location of the Fan and Engine Alternator Belts.

Step 4: Check all hoses for loose connections or deterioration. Tighten all connections or replace hoses as necessary.

Step 5: Check the battery terminals and cables for corrosion. Clean the terminals and cables as necessary.

Figure 17. Example of a Corrosion Free Battery Terminal and Connector.

WARNINGDO NOT REMOVE THE RADIATOR CAP WHEN THE COOLANT IS HOT. DO NOT ADD LARGE AMOUNTS OF COLD COOLANT TO A HOT SYSTEM AS SERIOUS DAMAGE COULD RESULT.

WARNINGDO NOT SMOKE OR USE AN OPEN FLAME IN THE VICINITY OF ANY FUEL SUPPLY OR STORAGE SYSTEM.

Radiator Cap

Oil Dipstick

WARNINGBEFORE TIGHTENING THE FAN OR ENGINE BELTS, DISCONNECT THE BATTERY NEGATIVE (-) LEAD TO ENSURE THE ENGINE CAN-NOT BE ACCIDENTALLY STARTED.

FanBelt




Step 6: Check the control panel and the overall generator set for heavy accumulation of dust and/or dirt. If found, clean the control panel and/or generator set as necessary. An accumulation of dust and/or dirt can pose an electrical hazard or give rise to cooling problems.

Step 7: Clear the area around the generator set of any insecure items that could inhibit operation or cause injury. Ensure the cooling air ventilation screens are clear.

Figure 18. Cooling Air Ventilation Screens.

Step 8: Regularly check the entire generator set for signs of leaks from the fuel system, cooling system, or lubrication seals.

Step 9: Periodically drain the exhaust system condensate traps, if equipped.

Figure 19. Exhaust System Condensate Traps.

Step 10: Ensure the alternator output circuit breaker is in the "OFF" (handle down) position.

Figure 20. Alternator Output Circuit Breaker in the “Off” Position.

4.3 Normal Manual Startup/ShutdownThe following procedure should be used for manual starts of the generator set.Note: The generator set may be stopped at any time by pushing the “Stop” button on the DSE 703 control panel.

Figure 21. The “Stop” Button on the Control Panel.

Step 1: Complete Pre-Start checks as detailed in Section 4.2.

Note: The engine will not start if any fault indicators are illuminated. Ensure the faults have been corrected prior to attempting to start the gen-erator set.

WARNINGDO NOT SHORT THE POSITIVE AND NEGATIVE TERMINALS TOGETHER.

Condensate Trap

Stop Button




4.3.1 Manual StartStep 2: Press the Manual button on the DSE control panel. The

engine will automatically crank up to three (3) times or until the engine fires. If the engine does not fire, the con-trol system locks-out on "Fail to Start" and illuminates a fault lamp on the control panel. If this happens, refer to the Troubleshooting guide in Section 14.6.

4.3.2 When the Engine Has StartedStep 3: Check for any abnormal noise or vibration.

Step 4: Check for fluid leakage or leaks in the exhaust system.

Step 5: Check the control panel for indications of abnormal oper-ation.

Step 6: Switch the Alternator Output Circuit Breaker to "ON" (handle up).

Figure 22. Alternator Output Circuit Breaker in the “On” Position.Note: Load can now be applied to the generator set. However, the maxi-mum step load that can be accepted in any one step is dependent on the operating temperature of the set. With the generator cold (not more than 20°C [68°F]), the maximum step load acceptance is approximately 50% of rated output. However with the generator set at the normal operating temperature (approximately 80°C [176°F]), the maximum step load can be 70-100% of the rated power depending on the generator set model. All Eaton generator sets up to 75 kVA can accept a 100% load as listed on the nameplate on the control panel door.

4.3.3 ShutdownStep 7: To shutdown the generator set, turn the load off by

switching the Alternator Output Circuit Breaker to "Off" (handle down). Allow the generator set to run without load for a few minutes to cool. Then press the “Stop” button on the DSE 703 control panel. The generator set will shutdown.

4.4 Automatic Startup/ShutdownThe following procedure should be used to prepare the generator set for start from a remote location.Note: The generator set may be stopped at any time by pressing the “Stop” button on the DSE 703 control panel.Note: Pressing the “Emergency Stop” button also illuminates the LED above !1 on the control panel.


Note: The engine will not be able to start if any fault indicators are illumi-nated. Ensure the faults have been corrected prior to attempting to start the generator set.

Automatic StartStep 2: Ensure that any remote Stop buttons are released. Set

the DSE control panel to the “Auto” position by pressing the “Auto” button. The LED near the “Auto” button will illuminate.

Step 3: Switch the Alternator Output Circuit Breaker to "On" (handle up). The generator set is now ready to automati-cally start when it receives a remote start signal. When the start signal is removed, it will automatically stop.

WARNINGIN CASE OF AN EMERGENCY WHERE IMMEDIATE SHUTDOWN IS NECESSARY, THE EMERGENCY STOP PUSHBUTTON SHOULD BE PUSHED IMMEDIATELY WITHOUT DISCONNECTING THE LOAD.




5 Routine Maintenance5.1 GeneralA good routine maintenance program is the key to long generator set life. Table B-1 in Appendix B contains the recommended rou-tine and preventative maintenance schedules for all Eaton Electri-cal liquid cooled standby generator sets.Note: Preventative maintenance and service should ONLY be carried out by qualified technicians. Records of this work should be kept to aid in devel-oping an efficient maintenance program.

In general, the generator set should be kept clean. Do not permit liquids, such as oil film, to accumulate on any internal or external surfaces or on, under, or around any acoustic material, if fitted. Wipe down surfaces using a water-based industrial cleaner. Do not use flammable solvents for cleaning purposes.Any acoustic material with a protective covering that has been torn or punctured should be replaced immediately to prevent accu-mulation of liquids or oil film within the material.

5.2 Routine Preventative MaintenanceDepending on the application of the generator set, requirement for routine preventative maintenance will vary. The preventative maintenance requirements associated with the engine are detailed in this section. They should be reviewed in conjunction with this section. Maintenance intervals for the engine may be more fre-quent than those shown in this section.

5.2.1 Weekly or at Each Startup• A walk around inspection should be performed on a weekly

basis and prior to starting the engine. The pre-start checks con-tained in Section 4.2 should be performed during this walk around.

• Procedures for performing the checks on the engine can be found in Section 5.3 of this manual that may contain additional requirements to those in Section 4.2.

5.2.2 Every Two WeeksNote: For residential standby generator sets that have not been run.

• Perform a walk around inspection prior to starting the engine. The pre-start checks contained in Section 4.2 should be per-formed during this walk around.

• Perform an operational check on the generator set by starting and running the set for five (5) minutes only.

5.2.3 Every MonthNote: For standby generator sets that have not been run on load.

• Perform a walk around inspection prior to starting the engine. The pre-start checks contained in Section 4.2 should be per-formed during this walk around.

• Perform an operational and load check on the generator set by starting and running the generator set on at least 50% load for one to two (1 to 2) hours.

5.2.4 Every Six Months or 250 Hours:• Perform the daily procedures (see Section 5.2.1).• Have a trained, qualified technician check:

1. All control system safety devices;

2. All battery cap vents / fluid levels;

3. All exhaust connections;

4. All electrical connections; and

5. All fuel connections.

• Have a trained, qualified technician also:1. Perform other engine non-routine maintenance as speci-

fied in the Section 14 of the Installation, Maintenance and Troubleshooting section of this manual.

2. Start the engine and observe the instrument panel to ensure that the engine controller is operating properly.

5.2.5 Alternator Preventative MaintenanceThere is no routine maintenance required on the alternator. How-ever, periodic inspection of the alternator winding condition and periodic cleaning by a trained, qualified technician is recom-mended. See the Installation and Maintenance section of this manual for more detailed information.

5.3 Engine Routine Maintenance

5.3.1 Checking the Oil LevelThe oil level should be checked frequently and maintained between the Full and Add marks on the dipstick. Allow a few minutes after shutting the engine off for the oil to drain down before checking.

Figure 23. Typical Generator Set Engine Dipstick.

Add oil as needed. It is normal to add some oil between oil changes. The amount will vary with the severity of operations. When adding or replacing engine oil, be sure it meets the specifi-cations listed in Table 1.

CAUTIONDO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE ADD MARK ON THE DIPSTICK. DAMAGE TO THE INTERNAL COM-PONENTS COULD OCCUR.

Full

Add




Table 1. Recommended Oil Viscosities.***

Notes:* = Not recommended for severe service operation.** = All Eaton Electrical liquid cooled generator sets are shipped from the factory with 10W-30

oil.***= API Categories SG or SH.

5.3.2 Changing the Engine OilChanging the engine oil on a regular basis will help ensure the long life of your Eaton Electrical standby liquid cooled generator set. The specific manufacturer’s recommendations for periodic oil changes are listed in Table 2.

Table 2. Oil Capacity.

Before beginning the oil change process, ensure that the following tools and materials are available.

Needed Tools and Materials:• Replacement Oil (see Table 2 for the oil capacity for your spe-

cific generator set model and Table 1 for the recommend vis-cosity);

• Oil Drain Pan or Container (suitable to hold the full oil capacity for your generator set engine – see Table 2);

• Appropriate Sized Open-end or Box Wrench;• Funnel; and• Shop Rags or Paper Towels.

5.3.1.1 Procedure

Step 1: Ensure the control panel is in the “Stop” position.


Step 2: If the generator set has been run, make sure to allow enough time for the engine and oil to cool before attempt-ing to change the oil.

Step 3: Open the right enclosure access panel.

Step 4: Using an appropriate sized open-end or box wrench, remove the oil drain plug from the oil drain outlet that is built into the right frame rail.

WHEN OUTSIDE TEMPERATURE IS CONSISTENTLY USE SAE VISCOSITY NUMBER

Single Viscosity Oils

-10 to +60°F (-23.3 to 15.6°C) 10W*

+10 to +90°F (-12.2 to 32.2°C) 20W-20

Above +32°F (0°C) 20W-30

Above +50°F (10°C) 20W-40

Multi-Viscosity Oils

Below +10°F* (-12.2°C) 5W-20*

Below +60°F (15.6°C) 5W-30

-10 to 90°F (-23.3 to 32.2°C) 10W-30**

Above -10°F (-23.3°C) 10W-40 or 10W-50

Above +20°F (-6.7°C) 20W-40 or 20W-50

MODEL # CHGEN10000I

CHGEN15000I

CHGEN17500I

CHGEN20000

CHGEN25000I

CHGEN25000

Total Oil Capacity, U.S. gal. (L)

1.2 (4.5) 1.2 (4.5) 1.2 (4.5) 1.1 (4.3) 1.2 (4.5) 1.1 (4.3)

Oil Pan Capacity, U.S. gal. (L)

1.1 (4.0) 1.1 (4.0) 1.1 (4.0) 1.0 (3.8) 1.1 (4.0) 1.0 (3.8)

MODEL # CHGEN30000

CHGEN35000

CHGEN45000

CHGEN55000

CHGEN75000

Total Oil Capacity, U.S. gal. (L)

1.5 (5.7) 1.5 (5.7) 1.5 (5.7) 1.5 (5.7) 1.5 (5.7)

Oil Pan Capacity, U.S. gal. (L)

1.2 (4.7) 1.2 (4.7) 1.2 (4.7) 1.2 (4.7) 1.2 (4.7)

WARNINGAS GENERATOR SETS WITH AUTO-START CONTROL PANELS CAN BE REMOTELY STARTED WITHOUT WARNING, ALWAYS ENSURE THE CONTROL PANEL IS IN THE “STOP” MODE BEFORE CARRYING OUT ANY CHECKS OR PROCEDURES.

WARNINGDO NOT ATTEMPT TO CHANGE THE OIL WHILE HOT. SERIOUS PER-SONAL INJURY COULD OCCUR.

CAUTIONTURN OFF THE FUEL SUPPLY AND DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL BEFORE PERFORMING THIS PROCEDURE.

Stop Button




Figure 25. Typical Location of the Oil Drain Outlet in the Right Frame Rail of the Generator Set.

Step 5: Position an appropriate sized oil pan or container at the oil drain outlet built-in to the right frame rail.

Step 6: Reach in through the right access panel and move the oil drain lever to the “Open” position. As the lever is opened, ensure the drain pan or container is still in a suit-able position to catch the oil as it drains from the outlet.

Figure 26. Typical Location of the Oil Drain Lever.

Step 7: Allow the oil to drain until all oil has stopped coming out of the oil drain outlet.

Step 8: Once all oil has drained, move the oil drain lever to the “Close” position.

Step 9: Install and tighten the oil drain plug removed in Step 4.

Step 10: Closely inspect the drained oil for signs of foam or a “milky” appearance. If either is detected, contact a trained, qualified technician to check the generator set for possible causes.

Step 11: If the oil has a normal appearance, dispose of the waste oil according to local oil disposal rules and regulations.

Step 12: Remove the oil fill cap from the engine’s valve cover.

Figure 27. Typical Location of the Oil Fill Cap.

Step 13: Insert the funnel into the oil fill opening and slowly pour new oil in to the funnel. Continue to add new oil until the oil capacity identified in Table 2 for your generator set has been reached.

Note: If the oil is being changed but not the oil filter, reduce the amount of oil poured into the engine by approximately 1 qt. (0.95 L) to account for the oil retained in the filter.

Step 14: Remove the funnel, making sure no oil drips onto any engine/exhaust surface and install the oil fill cap.

Step 15: Start and run the generator set with no load for approxi-mately one (1) minute. Turn off the generator set and check the oil level by means of the markings on the oil dipstick.

Figure 28. Typical Location of the Oil Dipstick.

Step 16: If the dipstick shows the oil level to be low, add oil a lit-tle at a time until the proper oil level is reached.

Oil Drain Outlet

Open Position

Closed Position




5.3.3 Changing the Engine Oil FilterChanging the engine oil filter on a regular basis will help ensure the long life of your Eaton Electrical standby liquid cooled generator set. Changing the engine oil filter at the same interval is recommended by the engine manufacturer (see Table B-1 in Appendix B).Before beginning the process to change the oil filter, ensure that the following tools and materials are available.

Needed Tools and Materials:• Replacement Oil (see Table 2 for the oil capacity for your specific

generator set model and Table 1 for the recommend viscosity);• Replacement Oil Filter (Eaton Electrical recommends using genu-

ine “GENPART” oil filters);• Oil Drain Pan or Container (suitable to hold the full oil capacity for

your generator set engine – see Table 2);• Secondary Drain Pan or Container (to catch any oil the drains

from the filter during removal);• Oil Filter Wrench;• Appropriate Sized Open-end or Box Wrench;• Funnel; and• Shop Rags or Paper Towels.

5.3.3.1 Procedure

Step 1: Drain the oil by following Steps 1 through 8 of Section 5.3.2 – Changing the Engine Oil.

Step 2: Locate the oil filter on your generator set engine.

Figure 29. Typical Location of the Oil Filter.

Step 3: Position the secondary oil drain pan or container directly below the oil filter.

Step 4: To remove the oil filter, use an appropriate oil filter wrench to turn the oil filter counter-clockwise until it is loose on the fitting. Turn the filter by hand until it is completely off the fitting.

Note: It is common for oil to run down the sides of the filter during removal.

Step 5: Clean the filter mounting base and fitting on the engine block with a clean rag or paper towel.

Step 6: Match the filter surface on the new oil filter with the gasket surface on the original oil filter to ensure a match.

Step 7: Lightly coat the gasket surface of the new filter with clean engine oil and hand tighten until the gasket contacts the base, then tighten another half turn. DO NOT use an oil fil-ter wrench to tighten the filter.

Step 8: Install the new oil engine by following Steps 9 through 16 of Section 5.3.2 – Changing the Engine Oil.

Step 9: After the proper oil level has been reached, check the area around the oil filter for any signs of leaks.

5.3.4 Changing the Air FilterChanging the air filter on a regular basis will help ensure the long life and economical functioning of your Eaton Electrical standby liq-uid cooled generator set.Your air cleaner filters air entering the engine induction system and acts as a silencer. Air that contains dirt and grit, if able to enter the engine, will cause severe damage to the cylinder walls and piston rings. Damage to the cylinder walls and piston rings will cause high oil consumption and short engine life. A restricted or dirty air cleaner will also cause a rich fuel mixture. Therefore, it is extremely important that the air cleaner be serviced at the manufacturer’s rec-ommended intervals (see Table B-1 in Appendix B).

Before beginning the process to change the air filter, ensure that the following tools and materials are available.

Needed Tools and Materials:• Replacement Air Filter (Eaton Electrical recommends using genu-

ine “GENPART” air filters);• Blade Screwdriver; and• Shop Rags or Paper Towels.

5.3.4.1 Procedure

WARNINGAS GENERATOR SETS WITH AUTO-START CONTROL PANELS CAN BE REMOTELY STARTED WITHOUT WARNING, ALWAYS ENSURE THE CONTROL PANEL IS SWITCHED OFF BEFORE CARRYING OUT ANY CHECKS OR PROCEDURES.

WARNINGDO NOT ATTEMPT TO CHANGE THE OIL FILTER WHILE HOT. SERI-OUS PERSONAL INJURY COULD OCCUR.

CAUTIONTURN OFF THE FUEL SUPPLY AND DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL BEFORE PERFORMING THIS PROCEDURE.

WARNINGDO NOT HANDLE A HOT OIL FILTER WITH BARE HANDS. A HOT OIL FILTER AND THE OIL IT CONTAINS CAN CAUSE SERIOUS PER-SONAL INJURY.

CAUTIONTHE AIR FILTER MUST BE SERVICED MORE FREQUENTLY THEN THE MANUFACTURER’S RECOMMENDED INTERVALS IF THE GENERA-TOR SET IS USED IN SEVERE DUST CONDITIONS.





Step 1: Using a blade screwdriver, loosen the hose clamp secur-ing the air filter to the throttle body.

Figure 30. Typical Location of the Air Filter and Clamp.

Step 2: Pull the air filter away from the throttle body. Remove and save the clamp but discard the original air filter.

Step 3: Using a shop rag or paper towels, clean any dirt, dust, or oil film from the area of the throttle body where the air fil-ter mounts.

Step 4: Slide the original hose clamp onto the new air filter.

Step 5: Align the air filter with the throttle body then push the air filter onto the throttle body until properly seated.

Step 6: Using a blade screwdriver, tighten the hose clamp to secure the air filter to the throttle body.

5.3.5 Checking the Coolant Level and RadiatorCheck the coolant level in the radiator daily, ONLY when the engine is cool.

When the coolant is cold, maintain the coolant level at approxi-mately 0.75 to 1.5 in. (19.5 to 38.1 mm) below the filler neck seat on the radiator.

Figure 31. Proper Coolant Level When the Engine is Cold.

Whenever coolant level checks are made check condition of radia-tor cap rubber seal. Make sure it is clean and free of any dirt par-ticles. Rinse off with clean water if necessary. When replacing cap on radiator, also make sure radiator filler neck is clean.Use only a quality permanent-type ethylene glycol coolant contain-ing a corrosion inhibitor. The antifreeze mixture must be an effi-cient coolant at all ambient temperatures and must provide protection against corrosion. It must also have a specification at least as good as the requirements of ASTM D3306-74: “Ethylene Glycol Base Engine Coolant”. An antifreeze concentration of 40% is recommended. Refer to the coolant mixture chart on the con-tainer for additional antifreeze protection information.Do not use alcohol or methanol antifreeze, or mix them with the specified coolant. Plain water may be used in an emergency, but replace it with the specified coolant as quickly as possible to avoid damage to the system.Inspect the exterior of the radiator for obstructions. Remove all leaves, bugs, dirt, or foreign material with a soft brush or cloth. Use care to avoid damaging the fins. If available, use compressed air or a stream of water in the opposite direction to normal airflow.Check all hoses and connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they should be replaced.

WARNINGDO NOT ATTEMPT TO CHANGE THE AIR FILTER WHILE THE ENGINE IS HOT. SERIOUS PERSONAL INJURY COULD OCCUR.

WARNINGNEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING OR HOT. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOL-ING SYSTEM OR ENGINE AND/OR PERSONAL INJURY.

TO AVOID SCALDING, USE EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. IF POSSIBLE, WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.

DO NOT ADD COOLANT TO AN ENGINE THAT HAS BECOME OVER-HEATED UNTIL THE ENGINE COOLS. ADDING COOLANT TO AN EXTREMELY HOT ENGINE CAN RESULT IN CRACKED BLOCK OR CYLINDER HEAD.

Hose Clamp

Air Filter




Installation, Maintenance, and Troubleshooting Manual

6 Introduction to the Installation, Maintenance, and Troubleshooting ManualThis manual is intended for use by the authorized, trained, and certified installer and maintenance / repair technician. It docu-ments the complete installation, maintenance, and troubleshoot-ing procedures for Eaton Electrical’s standby liquid cooled generator sets. For information on the normal Operation and Rou-tine Maintenance, refer to the Owner’s / User’s portion of this manual.This Eaton Electrical generator set is one of a family of standby liquid cooled generator sets specifically designed for residential and light industrial use. Table A-1 in Appendix A lists all Eaton Electrical standby liquid cooled generator set models and general specifications. Table A-2 in Appendix A lists the accessories available for all standby liquid cooled generator sets.All Eaton Electrical standby liquid cooled generator sets have been extensively tested and are ready to be installed, setup, and con-nected to the natural gas (NG) or liquefied propane (LP) fuel sup-ply following the local regulations.

These Installation, Maintenance, and Troubleshooting sections have been prepared to detail the installation, maintenance, and troubleshooting of this generator set. Following the procedures and instructions in these sections will help to ensure successful installation, startup, maximum performance, and long life of the generator set.Note: If the generator set is to be located in a dirty or dusty environment, routine maintenance may have to be performed more frequently to keep the generator set running properly.

6.1 Generator Set IdentificationEvery generator set is uniquely identified by a model and serial number listed on the rating plate that is generally affixed to the control panel door. This information is required when ordering spare parts or when service or warranty work is required. For your future convenience, take a moment and record those num-bers on the lines provided below.

Model Number:Serial Number:Date Purchased:Date Installed/Commissioned:

7 Warnings and CautionsEaton Electrical standby liquid cooled generator sets are designed to be safe when installed, setup, used, and maintained in the cor-rect manner. Responsibility for safety, however, rests with the technicians who install, setup, and maintain the equipment and the owner/user who uses the generator set.Following the safety precautions and suggestions detailed in this section will minimize the possibility of accidents, injury, or dam-age. Before performing any procedure or operating the generator set, it is up to the technician and user to ensure that it is safe.

7.1 Symbols and Standardizations

Throughout this Installation, Maintenance, and Troubleshooting Manual, this symbol is used in conjunction with the words DAN-GER, WARNING, and CAUTION to alert the user of hazards of which to be aware.DANGER: Signifies a hazard that WILL result in death or serious injury.WARNING: Signifies a hazard that COULD result in death or seri-ous injury.CAUTION: Signifies a hazard or situation that MIGHT result in minor injury or equipment damage.In addition, the following hazard symbols will appear to identify the type of Danger, Warning, and Caution.

When an important piece of information is necessary for the proper installation, operation, or maintenance of the generator set, it will be identified by the word NOTE. For example:

Note: The generator set may be stopped at any time by pushing the “Stop” button on the control panel.

WARNINGTHE INSTALLATION AND SETUP OF THIS STANDBY LIQUID COOLED GENERATOR SET MUST BE PERFORMED BY AUTHORIZED, TRAINED, AND CERTIFIED TECHNICIANS. INCORRECT INSTALLA-TION AND SETUP CAN CAUSE DEATH, SERIOUS PERSONAL INJURY, AND / OR PROPERTY DAMAGE.

HOT SURFACEEXPLOSION

TOXIC FUMESFIRE

ELECTRICAL SHOCK NOISE




7.2 General• Read and understand all safety precautions and warnings before

operating or performing routine maintenance on the generator set.

• Failure to follow the instructions, procedures, and safety pre-cautions in this manual may increase the possibility of accidents and injuries.

• Never start the generator set unless it is safe to do so.• Do not attempt to operate the generator set with a known

unsafe condition.• If the generator set is unsafe, fit danger notices and disconnect

the battery negative (-) lead so that it cannot be started until the condition is corrected.

• Disconnect the battery negative (-) lead prior to attempting any repairs or cleaning inside the enclosure.

• Install and operate this generator set only in full compliance with relevant National, Local, or Federal Codes, Standards or other requirements.

7.3 Installation and HandlingSection 4 of this manual covers procedures for the installation and handling of Eaton Electrical standby liquid cooled generator sets. It should be carefully read and understood before moving / lifting or installing the generator set.The following safety precautions should be noted during handling and installation.• Make electrical connections and gas connections in compliance

with relevant Electrical and Gas Codes, Standards, or other requirements. This includes requirements for grounding, ground / earth faults, and gaseous fuel systems.

• Gaseous fuel systems must be in compliance with all relevant Codes, Standards, and other requirements concerned with stor-age, piping, handling, installation, and use of these hazardous fuels. The complete fuel system must be purged and leak tested before being put into service with further checks for leaks to be conducted thereafter on a regular basis. Any leaks found must be corrected immediately.

• Engine exhaust emissions are hazardous to personnel. Ensure hot exhaust silencers, piping, and turbochargers, if equipped, are clear of combustible material and are guarded for personnel protection per safety requirements. Ensure that fumes from the exhaust outlet will not be a hazard.

• Never lift the generator set by attaching to the engine or alter-nator lifting lugs. Use a sling with a "spreader bar" connected to the base frame.

Figure 32. Sling with a Spreader Bar Being Used to Lift the Generator Set.• Ensure the lifting rigging and supporting structure is in good

condition and has a capacity suitable for the load.• Keep all personnel away from the generator set when it is sus-

pended.• Make sure all personnel are out of the generator set enclosure

or container, if equipped, before closing and latching enclosure doors.

• Do not install or use the generator set in any classification of hazardous environment unless it has been specifically designed for that environment.

7.4 Fire and ExplosionFuels and fumes associated with generator sets can be flammable and potentially explosive. Proper care in handling these materials can dramatically limit the risk of fire or explosion. However, safety dictates that fully charged BC and ABC fire extinguishers are kept on hand. The installer, maintenance technician, and owner/user MUST know how to operate them.• Gaseous fuels are highly explosive. Ensure the generator set

room, if installed indoors, is properly ventilated according to gas regulations. Use of a suitable leak detection system is also rec-ommended.

• Natural gas is lighter than air and, as a result, tends to settle in high places. LP gas on the other hand is heavier than air and will therefore settle in low areas. Extreme caution is therefore required when entering such areas.

• Keep the area, the floor, and the generator set clean. When spills of oil, battery electrolyte, hydraulic fluid, or coolant occur, they should be cleaned up immediately.

• Never store flammable liquids near the engine.• Store oily rags in covered metal containers.• Do not smoke or allow sparks, flames, or other sources of igni-

tion around gas pipes or batteries. Fuel gases are explosive.• Turn off or disconnect the power to the battery charger before

making or breaking connections with the battery or before breaking any gas pipe or line.

• Keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals, to avoid arcing. Sparks and arcing might ignite gas or vapors.

Spreader Bar




• Do not attempt to operate the generator set with any known gas leaks in the fuel system.

• The excessive build-up of unburned gases in the exhaust sys-tem can create a potentially explosive condition. This build-up can occur during such operations as repeated failed start attempts, air flap valve testing, or hot engine shutdown. Open exhaust system purge plugs, if equipped, and allow the gases to dissipate before attempting to restart the generator set.

7.5 MechanicalThe generator set is designed with guards for protection from moving parts. Care must still be taken to protect the user and equipment from other mechanical hazards when working around the generator set.• Do not attempt to operate the generator set with safety guards

removed. While the generator set is running, do not attempt to reach under or around the guards to perform routine mainte-nance or for any other reason.

• Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts, and other moving parts.

Note: Some moving parts cannot be seen clearly when the generator set is running.

• Keep access doors on enclosures, if equipped, closed and locked when not required to be open.

• Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces, and sharp edges and corners.

• Wear protective clothing including gloves and hat when work-ing around the generator set.

• Do not remove the radiator filler cap until the coolant has cooled. Then loosen the cap slowly to relieve any excess pres-sure before removing the cap completely.

• Ethyl Ether starting aids are not recommended. They will reduce the efficient working life of the engine.

7.6 ChemicalGas, oils, coolants, lubricants, and battery electrolyte used in this generator set are typical of the industry. However, they can be hazardous to personnel if not treated properly.• Do not swallow or have skin contact with oil, coolant, lubri-

cants, or battery electrolyte. If swallowed, seek medical treat-ment immediately.

• Do not wear clothing that has been contaminated by oils or lubricants.

• Wear an acid resistant apron and face shield or goggles when servicing the battery. If electrolyte is spilled on skin or cloth-ing, seek medical treatment immediately.

7.7 NoiseGenerator sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 89 dBA. Pro-longed exposure to noise levels above 85 dBA is hazardous to hearing. Please see Appendix A, Table A-1 for decibel ratings of the individual generator sets.• Ear protection should be worn when operating or working

around an operating generator set without a sound attenuating enclosure.

7.8 ElectricalSafe and efficient operation of electrical equipment can be achieved only if the equipment is correctly installed, operated, and maintained.• The generator set must be connected to the load only by

trained and qualified electricians who are authorized to do so, and in compliance with relevant electrical codes, standards, and other regulations. Where required, their work should be inspected and accepted by the inspection agency prior to oper-ating the generator set.

• Ensure the generator set is effectively grounded/earthed in accordance with all relevant regulations prior to operation.

• The generator set should be shutdown and the battery negative (-) terminal disconnected prior to attempting to connect or dis-connect load connections.

• Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground.

• Do not touch electrically energized parts of the generator set and/or interconnecting cables or conductors with any part of the body or with any non-insulated conductive object.

• Replace the generator set terminal box cover as soon as con-nection or disconnection of the load cables is complete. Do not operate the generator set without the cover securely in place.

• Connect the generator set only to loads and/or electrical sys-tems that are compatible with its electrical characteristics and that are within its rated capacity.

• Be sure all electrical power is disconnected from electrical equipment being serviced.

• Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut, abraded, or otherwise degraded. Replace terminals that are worn, discolored, or cor-roded. Keep terminals clean and tight.

• Insulate all connections and disconnected wires.• Use only Class BC or Class ABC extinguishers on electrical

fires.

7.9 First Aid For Electric ShockIn case of electric shock, contact emergency assistance immedi-ately.




8 Components of the Standby Generator SetIt is important to know the location of the major components of your Eaton Electrical standby liquid cooled generator set and their function. Refer to Section 3 in the Owner’s Manual portion of this document for detailed information.

9 Installation and Handling9.1 GeneralThis section discusses factors important in the effective and safe installation of the Eaton Electrical standby liquid cooled generator set.

9.2 EnclosuresInstallation and handling is greatly simplified when the generator set has been equipped with an enclosure. This may be a weather-proof version or designed for sound attenuation. These enclo-sures provide a self-contained generator set system that is easily transportable and requires minimal installation. They also auto-matically give protection from the elements and protection from unauthorized access.

Note: The enclosure is painted with RAL1013 - Pearl White. The color is a standard color that can be mixed by any paint supplier

9.3 Moving the Generator SetThe generator set base frame is specifically designed for ease of moving the set. Improper handling can seriously damage compo-nents.Using a forklift, the generator set can be lifted or, for minor loca-tion adjustments, carefully pushed/pulled by the base frame. If pushing, do not push the base frame directly with the fork. Always use wood between the forks and the base frame to spread the load and prevent damage.

For ease of lifting, open generator sets and generator sets fitted with enclosures have lift points provided on the base frame as standard. For a single lift, such as lifting the generator set to install it, the lift points provided on the base frame may be used. Points of attachment should be checked for cracked welds or loose nuts and bolts before lifting.A spreader bar is required to prevent damaging the generator set (see Figure 33). It should be positioned over the center of gravity (nearer the engine), not the center of the set, to allow a vertical lift. Guide ropes should be used to prevent twisting or swinging of the generator set once it has been lifted clear of the ground. DO NOT attempt to lift the generator set in high winds.

WARNINGBEFORE CLOSING THE ENCLOSURE OR ENCLOSURE DOORS, ENSURE ALL OBSTRUCTIONS (ESPECIALLY HANDS AND FINGERS) ARE CLEAR TO PREVENT DAMAGE OR INJURY.

WARNINGNEVER LIFT THE GENERATOR SET BY ATTACHING TO THE ENGINE OR ALTERNATOR LIFTING LUGS.

ENSURE THE LIFTING RIGGING AND SUPPORTING STRUCTURE IS IN GOOD CONDITION AND IS SUITABLY RATED.

KEEP ALL PERSONNEL AWAY FROM THE GENERATOR SET WHEN IT IS SUSPENDED.




Figure 33. Proper Lifting Arrangements for Generator Sets with and without an Enclosure.Place the generator set down on a level surface capable of sup-porting its weight. This manner of lifting should only be used for a single lift for installation.If the generator set is to be air lifted by helicopter, it should be lifted using a sling.

9.4 LocationSelecting a location for the generator set can be the most impor-tant part of any installation procedure. The following factors are important in determining the location:• Adequate ventilation.• Protection from the elements such as rain, snow, sleet, wind

driven precipitation, floodwater, direct sunlight, freezing tem-peratures, or excessive heat.

• Protection from exposure to airborne contaminants such as abrasive or conductive dust, lint, smoke, oil mist, vapors, engine exhaust fumes, or other contaminants.

• Protection from impacts from falling objects such as trees or poles, or from motor vehicles or lift trucks.

• Clearance around the generator set for cooling and access for service: at least 3.3 ft (1.0 m) around the set and at least 6.6 ft (2.0 m) headroom above the set.

• Limited access to unauthorized personnel.• 120 V receptacle (from the Utility power source) to power any

generator set accessories such as the heater blanket, battery charger, etc.

9.4.1 Typical InstallationWhen selecting the location for the standby liquid cooled genera-tor set, careful consideration should be given to how the genera-tor set will be integrated into the existing electrical system. Installation in close proximity to the main breaker panel, with either easy access to the main NG line or an area where the LP tank will be placed is preferred. Figures 34 through 38 show examples of installations and wiring diagrams for typical installa-tions.

Figure 34. Typical Installation Using NG Fuel.

Figure 35. Typical Installation Using LP Fuel.

Without Enclosure With Enclosure

ControlWiring

PowerCables

1

43

2

1 Automatic Transfer Switch2 Standby Liquid Cooled Generator Set3 Emergency Distribution Panel4 Utility Panel5 120 V Receptacle (typically located inside the generator set)

5

NGSource

ControlWiring

PowerCables

1

43

2

1 Automatic Transfer Switch2 Standby Liquid Cooled Generator Set3 Emergency Distribution Panel4 Utility Panel5 120 V Receptacle (typically located inside the generator set)

5

LP Fuel Tank

LP Fuel Line




Figure 36. Diagram of a Typical Installation (Critical Loads Only).

Figure 37. Typical Electrical System with Standby Generator Set.

Figure 38. Diagram of a Typical Installation.

9.5 Installation Codes and Standards

The installation of all Eaton Electrical liquid cooled generator sets MUST meet or exceed all applicable national and local codes and standards. These include, but are not limited to following codes of the National Fire Protection Association (NFPA):• NFPA 37 Standard for the Installation and Use of Stationary

Combustion Engines and Gas Turbines• NFPA 54 National Fuel Gas Code• NFPA 58 Liquefied Petroleum Gas Code• NFPA 70 National Electrical Code• NFPA 110 Standard for Emergency and Standby Power

SystemsIt is the responsibility of the installer to ensure that the installation meets or exceeds all applicable national and local codes and stan-dards.

9.6 Foundations and Vibration IsolationThe Eaton Electrical standby liquid cooled generator set is shipped assembled on a rigid base frame that precisely aligns the alterna-tor and engine and needs only be bolted down to a suitably pre-pared surface.

9.6.1 FoundationA reinforced concrete pad makes the best foundation for the gen-erator set. It provides a rigid support to prevent deflection and vibration. Typically the foundation should be 6.0 to 8.0 in. (152.4 mm to 203.2 mm) deep and at least as wide and long as the gen-erator set. See Table 3 for recommended dimensions. The ground or floor below the foundation should be properly prepared and should be structurally suited to carry the weight of the foundation pad and the generator set.

Note:Shown with Transfer Switch intended as service entrance equipment

MainBreakerPanel

Watt-HourMeter

TransferSwitch

1

Generator

2

DisconnectSwitchor Fuse

PowerCables

ControlWiring

120 VReceptacle

(typically located inside the

generator set)

CircuitBreaker

Watt-HourMeter

TransferSwitch

Generator(Source 2)

Utility(Source 1)

CircuitBreaker

Main BreakerPanel

HouseholdLoads

To 120 VReceptacle forGenerator SetAccessories




Figure 39. Typical Foundation for a Liquid Cooled Standby Generator Set.Note: If the generator set is to be installed above the ground floor, the building structure must be able to support the weight of the generator set, any fuel storage, and accessories.Note: The foundation MUST comply with all relevant building codes.

Table 3 contains the suggested concrete pad dimensions for each Eaton Electrical liquid cooled standby generator set.

Table 3. Recommended Concrete Pad Dimensions.

If the area around the generator set may be wet from time to time, the pad should be raised above the floor. This will provide a dry footing for the generator set and for those who connect, ser-vice, or operate it. It will also minimize corrosive action on the base frame.

9.6.2 Vibration IsolationTo minimize engine vibrations being transmitted to the foundation, the generator set is fitted with vibration isolators. On all Eaton generator sets, these isolators are fitted between the engine/alter-nator feet and the base frame. This allows the frame to be rigidly bolted to the foundation. The sets should be securely bolted to the ground through the frame.

Figure 40. Typical Vibration Reduction Techniques.

Vibration isolation is also required between the generator set and its external connections. This is achieved by use of flexible con-nections in the fuel lines, exhaust system, radiator air discharge duct, electrical conduit for control and power cables, and other externally connected support systems.

9.7 Combustion Air InletAir for engine combustion must be clean and as cool as possible. Normally this air can be drawn from the area surrounding the gen-erator set via the engine mounted air filter.

9.8 Cooling and VentilationThe engine, alternator, and exhaust piping radiate heat that can result in a temperature high enough to adversely affect the perfor-mance of the generator set. It is therefore important that ade-quate ventilation is provided to keep the engine and alternator cool. Proper airflow requires that the air come in at the alternator end of the set, pass over the engine, through the radiator and out of the radiator end of the set.

Figure 41. Proper Airflow through the Generator Set System.

CATALOG NUMBER LENGTH, IN. (MM) WIDTH, IN. (MM) DEPTH, IN. (MM)

CHGEN10000I(S) 59.1 (1348.7) 34.0 (863.6) 7.0 (177.8)

CHGEN15000I(S) 59.1 (1348.7) 34.0 (863.6) 7.0 (177.8)

CHGEN17500I(S) 59.1 (1348.7) 34.0 (863.6) 7.0 (177.8)

CHGEN20000(S) 67.0 (1701.8) 34.0 (863.6) 7.0 (177.8)

CHGEN25000I(S) 59.1 (1348.7) 34.0 (863.6) 7.0 (177.8)

CHGEN25000(S) 67.0 (1701.8) 34.0 (863.6) 7.0 (177.8)

CHGEN30000(S) 91.2 (2316.5) 41.1 (1043.9) 7.0 (177.8)

CHGEN35000(S) 91.2 (2316.5) 41.1 (1043.9) 7.0 (177.8)

CHGEN45000(S) 91.2 (2316.5) 41.1 (1043.9) 7.0 (177.8)

CHGEN55000(S) 101.2 (2570.5) 42.2 (1071.8) 7.0 (177.8)

CHGEN75000(S) 101.2 (2570.5) 42.2 (1071.8) 7.0 (177.8)

A

B

C

C = 6 to 8 in. (152.4 to 203.2 mm).

(See Table 3 for recommended dimensions.)

B = At Least as Wide as the Generator Set.A = At Least as Long as the Generator Set.

2 1

Item Description 1. Air Inlet Opening 2. Air Exit Opening




9.9 ExhaustThe purpose of the engine exhaust system is to direct the exhaust outside of the genset, to a location and height where the fumes and odors will not become an annoyance or hazard, and to reduce noise. Eaton generator sets include a silencer in the exhaust sys-tem within the enclosure. For information on acceptable exhaust back pressure, See Appendix F, Table F-1.

Figure 42. Typical Exhaust System.

9.10 Fuel SystemThe fuel system for the generator set must be capable of deliver-ing a clean and continuous supply of fuel to the engine that will ensure instant availability of fuel to facilitate starting and keep the engine operating. In some cases, gaseous-fueled generators can be fueled either with natural gas (NG) or liquefied propane gas (LP). Local gas codes regulating the installation of such fuel sup-ply systems vary widely, and therefore, local gas distributors or installers must be consulted when installing such systems.Note: It is the responsibility of the installer to ensure that all applicable reg-ulations and codes are complied with when installing a fuel supply system for use by a standby generator set.

Gaseous fuel systems MUST be in compliance with all relevant codes, standards, and other requirements concerned with the storage, piping, handling, installation, and use of these hazardous fuels. It is also important that the generator set is properly venti-lated according to gas regulations. Use of a suitable leak detec-tion system is also recommended.In most cases, generator sets will be supplied with a factory-fitted fuel system. This fuel system will be comprised of components that will enable operation on one gaseous fuel type, such as NG, LP vapor, or LP liquid. Some generator sets are also available with dual fuel systems that will allow operation on either NG gas and LP vapor or NG and LP liquid. These factory-fitted fuel system components must be considered as only part of an overall fuel supply system. The installer is again responsible for ensuring that the complete fuel supply system is compliant with all applicable regulations and codes.Table 4 provides a summary of the fuel connection sizes at the generator set based on fuel type and engine size.

Table 4. Generator Set Fuel Connection Sizes.

2

1

Item Description 1. Exhaust Silencer 2. Rain Cap

WARNINGENGINE EXHAUST EMISSIONS ARE HAZARDOUS TO PERSONNEL.

ENSURE THE HOT EXHAUST SILENCERS, PIPING, AND TURBO-CHARGERS, IF FITTED, ARE CLEAR OF COMBUSTIBLE MATERIAL AND ARE GUARDED FOR PERSONNEL PROTECTION PER SAFETY REQUIREMENTS.

ENSURE THAT FUMES FROM THE EXHAUST OUTLET WILL NOT BE A HAZARD.

MANUFACTURER ENGINE EATON CAT # NGCONNECTION (NPT)

LP VAPORCONNECTION (NPT)

LP LIQUIDCONNECTION (NPT)

Isuzu 4ZB1 CHGEN 10000I(S)CHGEN 15000I(S)CHGEN 17500I(S)CHGEN 25000I(S)

0.75“ 0.75” 0.25”

Ford LRG425 CHGEN 20000(S)CHGEN 25000(S)

0.75“ 0.75” 0.25”

Ford ESG642 CHGEN 30000(S)CHGEN 35000(S)CHGEN 45000(S)

0.75“ 0.75” 0.25”

Ford WSG1068 CHGEN 55000(S)CHGEN 75000(S)

1.25“ 1.25” 0.75”




9.10.1 Natural Gas Fuel SystemFigure 43 illustrates a typical NG fuel supply system.

Figure 43. Typical NG Fuel Supply System.

Note: Other NG components or system layouts may be required for compli-ance with local gas codes and regulations.

NG is usually piped from the main distribution system to the gen-erator set site by the local distribution company. The supply pres-sure in this piped supply will vary from area to area and from distribution system to distribution system and may be legislated by local gas codes. A primary regulator is typically required to reduce this piped gas supply pressure to a safe working level before it enters the generator set site. This primary regulator can usually be obtained from the local gas distribution company.The primary regulator should be sized correctly to give a maxi-mum outlet pressure of 13.5 in. (342.9 mm) water column and be of sufficient size to flow the specified maximum gas volume required by a particular gas generator at the required minimum dynamic pressure (typically 4 in. [101.6 mm] water column). The optimum NG supply pressure at the generator fuel connection point (at the edge of the base frame) is 11 in. (279.2 mm) water column. An approved flexible gas fuel line should be used for tak-

ing the fuel supply to the generator set’s fuel connection point. Manual shut-off valves should be fitted at appropriate points in the system and as specified by local gas codes and regulations.A solenoid shut-off valve controls the flow of gas supplied to the generator fuel connection point. At generator startup, the sole-noid shut-off valve allows fuel to flow through the generator mounted secondary regulator to the generator throttle body. The solenoid shut-off valve automatically cuts-off fuel flow during generator set shutdown.

9.10.2 LP Vapor Fuel SystemA schematic indicating the typical main components of an LP vapor fuel system is shown in Figure 44. An expansion section of the LP storage tank allows the LP fuel to expand from the liquid to the vapor state. The expansion section of the tank typically rep-resents 10 to 20% of the total storage tank volume. Expanded LP vapors are then withdrawn from this section of the storage tank and are supplied to the generator set.

Figure 44. Typical LP Vapor Fuel Supply System.




Ambient temperatures must be high enough to provide adequate vaporization to sustain the draw-off rate. If the draw-off rate is high and ambient temperatures are low, the vaporization rate may not be sufficient to sustain the fuel flow required. LP vapor with-drawal systems are therefore typically suited for use with smaller engines. As a result, care should be taken in matching LP storage tank size for vapor withdrawal systems and generator set size.As with the NG system, the flow of LP vapor supplied to the gen-erator set fuel connection point is controlled by a solenoid shut-off valve. At generator set start-up, this allows fuel to flow through the generator mounted secondary regulator to the generator throt-tle body. The solenoid shut-off valve automatically cuts-off fuel flow during generator set shutdown. The fuel supply is also sealed off within the throttle body when the generator is stopped.

9.10.3 LP Liquid Fuel SystemAn LP liquid fuel system again utilizes LP fuel, but with liquid with-drawal instead of vapor withdrawal as previously discussed. Liq-uid LP is delivered directly to the generator set where it passes through a fuel shutoff valve (typically operated via the engine manifold vacuum) to a ‘vaporizer-regulator’. The vaporizer-regula-tor vaporizes the LP liquid fuel (using engine coolant as the heat source) and provides a regulated LP vapor supply to the generator set’s throttle body. A typical system is illustrated in Figure 45.

Figure 45. Typical LP Liquid Gas Fuel Supply System.

9.10.4 Dual Fuel SystemsDual fuel systems allow operation on either NG and LP vapor or NG and LP liquid. Such systems are useful where there is a possi-bility of failure of the piped NG supply or where focused gas tariffs make generator set operation on NG excessively costly during peak tariff periods. These dual fuel systems are factory fitted and provide for automatic changeover from NG operation to LP vapor or LP liquid operation.

Figure 46 shows a typical natural gas / LP vapor dual fuel system. A low-pressure switch monitors the NG supply pressure. When this supply pressure drops below an adjustable threshold level, the LP vapor solenoid shut-off valve is opened and the NG solenoid shut-off is closed. The LP vapor then flows through a dedicated regulator to the engine throttle body.

Figure 46. NG/LP Vapor Dual Fuel System.

LC50 GOVERNOR

ENGINE

AIR FILTER

PRESSURE SWITCH

LPG VAPOURREGULATOR

LPG VAPOURSOLENOID SHUT-OFF

NATURAL GAS SOLENOID SHUT-OFF

BALANCE LINENATURAL GAS

REGULATOR

LPG VAPOUR

BASEFRAME SIDE BEAM

NATURAL GAS

CLOSED CRANKCASEBREATHING LINE




Figure 47 shows a typical NG / LP liquid dual fuel system. Its operation is similar to the dual fuel system already discussed. A low-pressure switch monitors the NG supply pressure. When this supply pressure drops below an adjustable threshold level, the NG solenoid shut-off is closed. The loss in pressure in the NG line

causes the vaporizer-regulator to open, permitting regulated LP vapor to flow to the engine throttle body. LP liquid flow to the vaporizer-regulator is controlled by a vacuum operated shut-off valve.

Figure 47. NG/LP Liquid Dual Fuel System.

9.10.5 Gas PipelinesGaseous fuel lines should meet all Federal, State, and local codes. They should be made of black iron (Schedule 40), should be rig-idly mounted, and provide for protection against vibration. An approved flexible gas fuel line should be used for connecting between rigid gas pipe work and the generator set gas connection point (typically at the edge of the generator set base frame). Every effort should be made to ensure that the pipe work is sized correctly to provide an adequate gas supply for the generator under all loading conditions.

9.10.6 Leak TestingThe complete fuel system must be purged and leak tested before being put into service, with further checks for leaks to be con-ducted thereafter on a regular basis. Any leaks found must be corrected immediately.

9.11 Fire PrecautionsWhen designing the generator set installation, the following points should be considered:• The installation area should provide an easy escape for operat-

ing personnel in the event of fire.• Supply a Class BC or Class ABC fire extinguisher and/or fire

extinguishing system.• Gravity operated fire valves released by temperature operated

fusible links mounted above the engine can be installed in the fuel lines.

9.12 Starting Batteries

The starting batteries should be located as close as possible to the generator set while still being accessible for servicing. This will prevent electrical losses from long cables that could impact on the engine starting capability of the batteries. See Section 14.4.2, Battery, for minimum battery specifications and more details.To install the starting battery, proceed with the following steps.

9.12.1 ProcedureTools and Materials Required:• Battery (customer supplied);• Supplied Battery Cables; and• Appropriately Sized Wrenches.Step 1: Ensure that the battery hold-downs on the generator set

frame are loose enough to allow the battery to be set between them.

LC50 GOVERNOR

BALANCE LINE

ENGINE

AIR FILTERNATURAL GAS

SOLENOID SHUT-OFF

NATURAL GAS

FUEL FILTER LOCK-OFF

COOLANT SUPPLY

VACUUM SIGNAL LINE

COOLANT RETURN

BALANCE LINEPRESSURE SWITCH

NATURAL GASREGULATOR

LPG LIQUID

CLOSED CRANKCASE SUCTION LINE

CLOSED CRANKCASEBREATHING LINE

WARNINGFOR STATIONARY GENERATOR SETS WITH GAS TANK STORAGE SYSTEMS, MAKE SURE SUCH SYSTEMS ARE INSTALLED IN COM-PLIANCE WITH ALL RELEVANT CODES, STANDARDS, OR OTHER REQUIREMENTS.

WARNINGDO NOT SMOKE OR ALLOW SPARKS, FLAMES, OR OTHER SOURCES OF IGNITION NEAR THE GENERATOR SET AND ASSOCI-ATED FUEL SUPPLY SYSTEM AS FUEL AND OIL VAPORS ARE HIGHLY EXPLOSIVE.

WARNINGDO NOT SMOKE OR ALLOW SPARKS, FLAMES, OR OTHER SOURCES OF IGNITION AROUND BATTERIES. HYDROGEN GAS GENERATED BY CHARGING BATTERIES IS EXPLOSIVE.




Note: The generator set is shipped with the positive battery cable con-nected to the starter. However, neither end of the negative battery cable is connected. When setting the battery in place, ensure that it is positioned so the positive battery cable can be properly connected to the positive ter-minal of the battery.

Figure 48. Battery Cable Connectors and Hold-downs.Step 2: Place the battery in the proper position so the negative

battery cable connector can be connected later in this process. Tighten the battery hold-down hardware to secure the battery to the generator set frame.

Step 3: Connect the positive battery cable connector to the posi-tive terminal of the battery. Tighten the connector securely to the terminal.

Step 4: Using the existing hardware on one of the generator alter-nator frame studs, connect the flat connector on the neg-ative battery cable to one of the alternator frame studs.

Step 5: Connect the other negative battery cable connector to the negative terminal of the battery. Tighten the connector securely to the terminal.

Figure 49. Typical Cable Connectors.

Note: A 120 V receptacle (from the Utility power source) to power any generator set accessories such as the heater blanket, battery charger, etc. is needed. See Section 9.4.

9.13 Electrical ConnectionOn-site electrical installation will generally consist only of connect-ing the site load to the generator set output terminals.Note: Only fully qualified and experienced electrical technicians should carry out electrical installation, service, and repair work. Contact the Eaton Cutler-Hammer Standby Generator Support Line at 800-975-8331 to locate a recommended contractor near you.

9.13.1 CablingNote: The installation of all cables MUST follow all national, state, and local regulations.

Due to movement of generator sets on their vibration mounts, the electrical connection to the generator set should be made with flexible cable. This will prevent transmission of vibrations and possible damage to the alternator or circuit breaker terminals. If flexible cabling cannot be used throughout the installation, then a link box should be installed close to the set with a flexible connec-tion to the set.Note: Knockouts are NOT provided in the generator set breaker enclosure.Note: The generator load cables shall NOT be run in the same conduit as the remote start control wires.

The cable should be protected by laying it in a duct or cable tray. However, the duct or tray should never be rigidly connected to the generator set. When bending cable, reference must be made to the recommended minimum-bending radius.The cable must be suitable for the output voltage and the rated current of the generator set. In determining the size, allowances should be made for ambient temperature, method of installation, proximity of other cables, etc. When single core cables are used, the gland plates must be of non-ferrous material such as alumi-num, brass, or a nonmetallic material such as Tufnol. As an alter-native, slots can be cut between gland holes of cables to prevent circulating (eddy) currents in magnetic gland plates.All connections should be carefully checked for integrity. All cov-ers and shields must be installed prior to energizing of cables.

9.13.1.1 ProcedureTools and Materials Required:• Flat-blade Screwdriver;• Appropriately Sized Knock-out Punch;• Appropriately Sized Wire Strippers and Cutters; and• Appropriately Sized Conduit and Shielding.

Step 1: Remove the cover from generator set breaker.

Step 2: Using an appropriately sized knock-out punch, cut out the required size conduit hole in the bottom of the breaker enclosure.

Step 3: Connect the phase wires, neutral wire, and ground wire to appropriate terminals.

Step 4: Reinstall cover on the generator breaker.

Step 5: Open the generator set control panel.

Step 6: Using an appropriately sized knock-out punch, cut out the required size control wire conduit hole in the bottom of enclosure.

Positive

Negative

AlternatorFrame Stud

BatteryHold-down

WARNINGMAKE ELECTRICAL CONNECTIONS IN COMPLIANCE WITH RELE-VANT ELECTRICAL CODES, STANDARDS, OR OTHER REQUIRE-MENTS. THIS INCLUDES REQUIREMENTS ABOUT GROUNDING AND GROUND/EARTH FAULTS.




Step 7: Ensure that the generator controller is NOT in the “AUTO” mode. The LED located next to the “AUTO” push button should NOT be illuminated. Pressing the EMERGENCY STOP button will also ensure that the gen-erator will NOT automatically start.

Step 8: Connect the remote start wires to terminals #1 and #2 on the back of the DSE 703 Control Module.

Figure 50. Wires Connected to the Remote Start Terminals.

Step 9: Close the generator set control panel.

Step 10: Install the cable conduit shield on frame of the generator set.

9.13.2 ProtectionThe cables connecting the generator set with the distribution sys-tem are protected by means of a circuit breaker to automatically disconnect the generator set in case of overload or short circuit.

9.13.3 LoadingWhen planning the electrical distribution system, it is important to ensure that a balanced load is presented to the generator set. If loading on one phase is substantially higher than the other phase, it will cause overheating in the alternator windings, imbalance in the phase-to-phase output voltage.Ensure that no individual phase current exceeds the current rating of the generator set. For connection to an existing distribution system, it may be necessary to reorganize the distribution system to ensure these loading factors are met. See Appendix F, Tables F-2 through F-4 for information on typical residential loads.

9.13.4 Power FactorThe power factor (cos) of the connected load should be deter-mined. Power factors below 0.8 lagging (inductive) can overload the generator. The generator set will provide its kilowatt rating and operate satisfactorily from 0.8 lagging to unity power factor (1.0).Particular attention must be given to installations with automatic or manual power factor correction equipment, such as capacitors, to ensure that a leading power factor is never present. This will lead to voltage instability and may result in damaging over-volt-ages. Generally, whenever the generator set is supplying the load, any power factor correction equipment should be switched off.

9.13.5 Grounding RequirementsRegulations vary for different locations. The frame of the genera-tor set must be positively connected to an earth ground. Since the generator set is mounted on vibration isolators, the ground connection must be flexible to avoid possible breakage due to vibration. On the majority of self-contained generator sets, the ground connection is located inside the circuit breaker box.

Figure 51. Ground Connection Inside the Circuit Breaker Box.

Ground connection cables or straps should have at least full load current carrying capacity and meet applicable regulations.

9.13.6 Insulation TestBefore starting the generator set after installation, test the insula-tion resistance of the windings. The Automatic Voltage Regulator (AVR) should be disconnected and the rotating diodes either shorted out with temporary links or disconnected. Any control wiring must also be disconnected.A 500 V Megger or similar instrument should be used. Discon-nect any earthing conductor connected between neutral and earth and Megger an output terminal to earth. The insulation resistance should be in excess of 5 M to earth. Should the insulation resis-tance be less than 5 M, the winding must be dried out. See Sec-tion 14.5 for the applicable for procedures.

9.14 Acoustic SilencingControl of generator set noise is becoming very important in most installations. There is a range of options available to control the noise level. Contact your Eaton Electrical Representative for details on the available options.

9.14.1 Exhaust SilencersAs discussed in Section 9.9, the exhaust silencer will decrease sound levels from the engine. Varying degrees of sound attenua-tion are available from different types of silencers. These levels are often described by terms such as industrial, residential, criti-cal, or supercritical.

9.14.2 EnclosuresSection 9.2 discusses enclosures that are available in either weatherproof or sound attenuating versions. These enclosures can be designed to meet a specific sound level requirement.

WARNINGEAR PROTECTION MUST BE WORN WHEN OPERATING OR WORK-ING AROUND AN OPERATING GENERATOR SET.




10 Storage10.1 Generator Set StorageIf the generator set is not going to be immediately installed, or if it will be removed from service for an extended period of time, cer-tain storage precautions MUST be taken to protect the compo-nents of the generator set. Long-term storage can have detrimental effects on both the engine and alternator. These effects can be minimized by properly preparing and storing the generator set.

10.1.1 Engine StorageThe engine should be put through an engine "preservation" proce-dure that includes cleaning the engine and replacing all the fluids with new or preserving fluids. See Section 14.4 for the proper procedure.

10.1.2 Alternator StorageWhen an alternator is in storage, moisture tends to condense in the windings. To minimize condensation, store the generator set in a dry storage area. If possible, use space heaters to keep the windings dry.After removing the generator set from storage, perform an insula-tion check as discussed in Section 9.13.6. If the readings are lower than prior to storage, it may be necessary to dry out the windings.If the Megger reading is below 1 M after drying, the insulation has deteriorated and should be reconditioned.

10.1.3 Battery StorageWhile the battery is stored, it should receive a refreshing charge every 12 weeks (8 weeks in a tropical climate) up to a fully charged condition. Harsher climates may require more frequent charging.

11 Engine Preparation and Operation11.1 General InformationEaton Electrical liquid cooled standby generator sets utilizing Ford or Isuzu engines are tested and inspected before leaving the fac-tory. However, certain checks should be made before putting them into regular operation.

11.1.1 How To Use This SectionThis section should be read in conjunction with the Installation, Control, and Alternator sections in this manual prior to operation of the unit. This will allow you to become familiar with the vari-ous controls and instruments, how to maintain your engine, and what services need to be performed to keep it in excellent running condition.This section does not identify equipment as standard or optional. Therefore, some of the equipment described in this section may not be found on your engine or generator set.

11.2 Fuel SystemsThe positive pressure of both NG and LPG to the generator set should be in the range 10 to 34 mBar (4 to 13.5 in. H2O).• If the pressure is less than 10 mBAR (4 in. H2O), the generator

set may not be able to achieve 100% load.• If the pressure is greater than 34 mBAR (13.5 in. H2O), the

solenoid valve may not be able to open causing the generator not to start.

• The calorific value of natural gas should be above a minimum of 34 MJ/m3 (913 BTU/ft3). If it is below this, a de-rate may need to be applied to certain generator sets.

Impurities in the fuel should be kept to a minimum as they can have a detrimental effect on engine durability. If quality of the fuel is poor, a fuel protection option is available.

11.2.1 What is LPG?LPG is "liquefied petroleum gas", commonly known as propane (C3H8), a combustible hydrocarbon based fuel. It comes from the refining of crude oil and natural gas. At normal pressure (29.92 in. HG) and temperatures above -44°F /- 45°C, propane remains in its gaseous form. At lower temperatures and/or higher pres-sures, propane will become a liquid. Propane is colorless and odorless. For safety reasons, propane is required to be odorized to indicate, by distinct odor, the presence of LPG in air down to a concentration of over 1/5th the lower level of flammability (0.4% in air). This is achieved by adding 1.0 #s of ethyl mercaptan, or 1.0 #s of thiophane, or 1.4 #s of amyl mercaptan per 10,000 gal-lons of LPG. There are currently three grades of propane avail-able:• HD5 for internal combustion engines;• Commercial propane; and• Commercial propane/butane mix for other uses.The exact composition of propane varies slightly between differ-ent parts of the country and different refineries. Compared to gasoline, the energy content of LPG is 74%.The Table 5 shows approximate composition of HD5.

Table 5. Approximate Composition of HD5 Propane.HD5 PROPANE

PROPANE (C3H8)

PROPYLENE BUTANE (C4H10)

ISO-BUTANE METHANE (CH4)

TOTAL

90.0% min. Up to 5% 2.0% 1.5% 1.5% 100%




Figure 52. Composition of HD5 Propane.

11.2.2 What is NG?NG is "compressed natural gas". Natural gas (CH4) is a naturally occurring mixture of combustible hydrocarbon gases found in porous formations beneath the earth's surface. Natural gas is cre-ated by the decomposition of plant and animal remains, under great heat and pressure, over very long periods of time. Natural gas can be found as:• Non-associated gas - free gas not in contact with significant

amounts of crude oil in the reservoir;• Associated gas - free gas in contact with crude oil in the reser-

voir; and• Dissolved gas - gas in solution with crude oil in the reservoir.For safety reasons, natural gas is required to be odorized to indi-cate, by distinct odor, the presence of the natural gas in air down to a concentration of not over 1/5th the lower level of flammabil-ity (1.0% in air). This is achieved by adding ethyl mercaptan, thiophane, or amyl mercaptan to the natural gas. Compared to gasoline, the energy content on NG is 25%.The exact composition of natural gas varies between different parts of the country and different refineries. Table 6 shows the approximate composition of natural gas.

Table 6. Approximate Composition of Natural Gas.

Figure 53. Approximate Composition of NG.

11.3 OPERATING INSTRUCTIONS

11.3.1 Set-up Procedure

The generator set will have been tested at full load for the speci-fied fuel in the factory. Adjustments are not normally required on site. Refer to the User’s Section of this manual for normal start-ing, stopping, and control instructions. However, in certain cir-cumstances (for example if a generator set is converted from one fuel to another, or a major component is replaced) some set-up will be required. Before beginning the set-up procedures, refer to Section 13.2 and perform the recommended pre-start checks.

11.3.2 Tools Required• 2 Manometers capable of reading between 0 to 20 in. H2O (50

mBar) for natural gas or LP vapor sets or 0 to 200 psi (14 Bar) for LP liquid sets.

• Lambda sensor (for example part number 622-643) or Exhaust Gas Analyzer capable of reading % CO.

• Steel rule or Vernier gauge with mm scale.

11.3.3 Pre-Start ChecksCheck the fuel pressure at the inlet to the unit is within the speci-fied pressure range (see below):• NG or LPG vapor: 4 in. H2O (10 mBar) to 13.5 in. H2O (34

mBar)• LPG liquid: 58 psi (4 Bar) to 180 psi (12 Bar)If a new regulator or LC50 fuel control have been installed, or if the generator set is being converted from NG to LP vapor or vice versa, set the regulator main adjustment screw (MAS) and ignition timing according to specifications contained in Tables 7 and 8. For detailed information and instructions for changing from one fuel type to another, see Section 11.3.3.1.

NATURAL GAS

COMPONENT VOLUME = %

Methane CH4 92.3

Ethane C2H6 3.6

Propane C3H8 1.0

Butanes C4H10 0.3

Pentanes C5H12 0.1

Hexanes C6H14 0.1

Carbon Dioxide C02 1.0

Nitrogen N2 1.6

Total Natural Gas 100

PROPANEPropane(C3H8)

Propylene Butane(C4H10)

Iso-Butane Methane(CH4)

Total

90.0% min. Up to 5% 2.0% 1.5% 1.5% 100%

90

5 2 1.5 1.5

0

20

40

60

80

100

%

Propane Propylene Butane Iso-butane Methane

HD5


92.3

3.6 1.6 1 1 0.40

20

40

60

80

100

%

Methane Ethane Nitrogen Propane C02 Butane,Hexane,Pentane

Natural Gas




Figure 54. Location of the MAS.

Install the Lambda sensor in the port provided in the exhaust pipe work (or insert an exhaust gas analyzer probe into the exhaust outlet).

Figure 55. Lambda Sensor Installed in the Exhaust Port.

If using the Lambda sensor, connect as follows:• Black wire (signal positive): Digital voltmeter (positive lead)• Gray wire (signal negative): Digital voltmeter (negative lead)• White wires (heater): Fused 12 Vdc supply

Note: It is important to use a digital meter because an analog meter typi-cally has a low input impedance that can distort the signal.

The Lambda sensor gives an output as shown in Figure 56.

Figure 56. Typical Lambda Output.

11.3.3.1 Changing Fuel TypesIf the fuel used to run the generator set is switched from one fuel type to another (NG to LP or LP to NG), changes to the settings for the fuel regulator, MAS, and ignition timing will be necessary (depending on the engine powering the generator set). Refer to Tables 7 and 8 while following the instructions in the following sections.Adjusting the Fuel RegulatorThe fuel regulator is adjusted by turning the adjustment screw at the top of the spring tower. The fuel regulator specifications given in Tables 7 and 8 give the distance between the top of the adjustment screw and the top of the spring tower.

Table 7. Natural Gas Specification

Table 8. LP Vapor Specifications

MAS

0.00.10.20.3

0.40.50.60.70.80.91.0

0.86 0.88 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06 1.08 1.10 1.12 1.14

LambdaLa

mbd

a Se

nsor

VRich Lean

NATURAL GAS 50/60 HZ

ISUZU LOW SPEED

ISUZU HIGH SPEED

FORD 425 FORD 642 FORD 1068

Regulator Setting– in. (mm) down from top edge

0.55 (14) 0.63 (16) 0.55 (14) 0.61 (15.5) 0.63 (16)

MAS Setting – in. (mm) out from body

0.39 (10) 0.43 (11) 0.43 (11) 0.59 (15) 0.75 (19)

Ignition Timing (DBTDC) 24 (60 Hz)19 (50 Hz)

25 Ground - Ground Wire 674 to wire 53A Wire 674 to wire 53A

LPG 50/60 HZ ISUZU LOW SPEED

ISUZU HIGH SPEED

FORD 425 FORD 642 FORD 1068

Regulator Setting– in. (mm) down from top edge

0.55 (14) 0.55 (14) 0.55 (14) 0.49 (12.5) 0.55 (14)

MAS Setting– in. (mm) out from body

0.32 (8) 0.37 (9.5) 0.35 (9) 0.47 (12) 0.63 (16)

Ignition Timing (DBTDC) 18 25 Ground – Ground Wire 674 to wire 5 Wire 674 to wire 5




Figure 57. Adjusting the Fuel Regulator.

Turn the adjusting screw either in or out until the specifications given in Table 7 and 8 are achieved.Adjusting the MASThe MAS is adjusted by turning it in or out. The MAS specifica-tions given in Tables 7 and 8 give the distance between the top of the MAS and the main body of the MAS connection.

Figure 58. Adjusting the MAS.

Turn the MAS screw either in or out until the specifications given in Table 7 and 8 are achieved.Adjusting the Ignition TimingIsuzu 4ZB1 Engine (Low Speed)Connect the timing light’s battery leads to the positive and nega-tive terminals of the generator set battery. Connect the timing light’s ignition lead to the high-tension plug wire for the number 1 cylinder (closest to the front of the engine).The timing marks are located on the front engine case and the timing notch for top dead center (TDC) is located on the crank-shaft pulley.

Figure 59. Location of the Timing Marks and Notch.Start the engine and allow it to run until it is warm. Using the tim-ing light verify the timing setting on the engine.

To adjust the engine timing to the specifications for the fuel being used (see Tables 7 and 8), loosen the nut securing the base of the distributor. Turn the body of the distributor until the desired tim-ing is achieved. Once the timing is set, tighten the nut to lock the distributor in position.

Screw

Spring Tower

Distance

MAS

Main Body

Distance

WARNINGKEEP HANDS, CLOTHING, TOOLS, TIMING LIGHT, AND TIMING LIGHT LEADS AWAY FROM THE MOVING PARTS ON THE FRONT OF THE MOTOR. FAILURE TO DO SO COULD RESULT IN SERIOUS PER-SONAL INJURY AND/OR DAMAGE TO THE ENGINE.

Timing Marks

Timing Marks

20° 0°




Figure 60. Location of the Distributor Nut.

Isuzu 4ZB1 Engine (Low Speed)No adjustment is necessary.

Ford LRG425 EngineNo adjustment is necessary.

Ford ESG642 and WSG1068 EnginesThe ignition timing is adjusted by means of the wiring harness located beneath the generator set alternator.

Note: The default generator set configuration from the factory is for NG (Plug# 653-446).

Figure 61. Wiring Harness to Adjust the Ignition Timing.To adjust the ignition timing for LP fuel, the link on the plug from wire 674 to 53A must be moved to link wires 674 and 5. The link can be moved on the existing plug, or it can be changed by simply replacing the plug with one that has these links already estab-lished for LP (Plug # 653-003).

11.3.4 Engine Running AdjustmentsWhen using a Lambda sensor, correct Lambda is achieved when the voltage is between 0.2 V and 0.7 V. Due to the characteris-tics of the sensor, the voltage will be unstable and fluctuate ran-domly between the two points. When Lambda is rich, the voltage remains constant above 0.8 V. When Lambda is lean, the voltage remains constant below 0.1 V.When using a CO meter, correct Lambda is when 0.7%<CO<1.2%. Below 0.7%, Lambda is too lean; above 1.2%, Lambda is too rich.

11.3.4.1 1800 RPM Sets (Isuzu & Ford)Step 1: Start the generator set and adjust for correct Lambda at

no load. If Lambda is rich (Lambda sensor >0.7 V, or CO >1.2%), the regulator outlet pressure is set too high. Adjust the regulator to reduce the outlet pressure.

If Lambda is lean (Lambda sensor <0.2 V or CO <0.7%), the regulator outlet pressure is set too low. Adjust the regulator to increase the outlet pressure.

Step 2: Increase the load to around 60% of nameplate rating using a load bank, or available building load. Allow the engine time to reach normal operating temperature.

Step 3: Adjust the MAS on the mixer for correct Lambda.

Step 4: Increase the load to 100% of nameplate rating using a load bank (if a load bank is available).

Step 5: If required, adjust the MAS for correct Lambda. If the screw has been opened completely and Lambda is still too high, either the fuel inlet pressure is too low or the fuel quality is too poor. It may not be possible to achieve full load in this case.

Step 6: Remove all load from the generator set. Adjust the regu-lator again for correct Lambda at no load.

Step 7: Repeat Steps 2 through 6 until the generating set oper-ates at correct Lambda at all loads.

Step 8: Stop the generator set and check that it can re-start with the new MAS and regulator settings.

11.3.4.2 3600 RPM Sets (Isuzu)Step 1: Start the generator set.

Step 2: Increase the load to around 60% of nameplate rating using a load bank, or available building load. Allow the engine time to reach normal operating temperature.

Step 3: Adjust the MAS on the mixer for correct Lambda.

Step 4: Increase the load to 100% of nameplate rating using a load bank (if a load bank is available).

Step 5: If required, adjust the MAS for correct Lambda. If the screw has been opened completely and Lambda is still too high, either the fuel inlet pressure is too low or the fuel quality is too poor. It may not be possible to achieve full load in this case.

Step 6: Remove all load from the generator set.

Step 7: Stop the generator set and check that it can re-start with the new MAS and regulator settings.

11.3.4.3 Problem DiagnosisMost operating troubles that might be encountered with a new or well-maintained generator set will be of a minor nature. There-fore, if you have troubles starting or operating your engine, look for some simple cause rather than failure of a major component.

Distributor Nut




For instance:• Loose or corroded battery connections are much more likely

than battery failure, or• A loose ignition wire is much more likely than distributor, coil,

or ignition system failure.In many cases, engine-operating troubles are coupled with outside factors, such as climatic conditions, operating conditions, change of servicing or fueling source, or change of operator.Engine troubles that occur as a result of normal use usually give plenty of advance warning. These troubles usually result from overlooking the Preventive Maintenance Schedule services.Whenever engine performance seems less than normal in any cat-egory, it is best to consult with your dealer at the first symptom rather than waiting until a serious problem develops. One of the aims of regular maintenance is to help you in just these circum-stances. See Section 14 for the suggested maintenance schedule and additional troubleshooting information.

11.3.4.4 Emergency StartingUse a booster battery and jumper cables in an emergency start sit-uation. Particular care should be taken when connecting to a booster battery in order to prevent sparks.To jump-start the engine (negative grounded battery) in an emer-gency start situation:Step 1: Shield your eyes with safety glasses or visor.

Step 2: Connect the ends of the positive cable to the positive (+) terminals of each battery.

Step 3: Connect one end of negative cable to negative (-) termi-nal of "good" battery.

Step 4: Connect other end of cable to engine block of unit being started (NOT to the negative (-) terminal of the battery).

Figure 62. Connecting the Booster Battery and Cables.

Step 5: To prevent damage to other electrical components on unit being started, make certain that engine is running at the rated speed and at no load before disconnecting jumper cables.

11.4 Carburetion

11.4.1 System Operation for Ford and Isuzu EnginesThe carburetion system starts with the fuel shut-off (vacuum operated lock-off with LP liquid systems and electric solenoid with NG and LP vapor systems). As the engine is cranked, the fuel shut-off is opened and allows fuel to flow through the gas regula-tor to the carburetor. When the engine is shut down, the fuel is shut off automatically.The LC-50 consists of a die-cast aluminum throttle body, inte-grated fuel mixer featuring a venturi style annular ring mixer with no moving parts for superior mixing, plus a fully programmable integrated digital speed control and bi-directional actuator.

Figure 63. The LC-50 Throttle Body.The actuator connects directly to the butterfly valve that regu-lates the amount of air/fuel mix being supplied to the engine. When the engine is cranked, the flow of air through the venturi ring mixer draws in fuel. As the airflow increases, more fuel is drawn in, maintaining the air/fuel ratio under all load conditions. This system requires that the pressure of the fuel be regulated to 0” pressure and that the flow of fuel can be metered as required. For this reason, a zero pressure regulator (ZPR) is incorporated between the fuel supply and the LC50 unit. While running, the fuel flow to the LC50 is metered by means of the MAS, which is adjusted to give good air / fuel ratio for all load conditions.The system operates using a tailored software configuration for the specific engine it is fitted to and can operate using both NG and LP liquid gas. When using LP liquid, the regulator is replaced with a vaporizer, which uses the heat from the engine coolant to assist in vaporizing the fuel before reaching the LC50 unit.

Positive Cable

Negative Cable




Figure 64. The Major Fuel System Components.

11.4.2 Problem Diagnosis for Ford and IsuzuStep 1: Fuel carburetion, because of its simplicity, is unlikely to

give any problems when properly installed with an ade-quate supply of fuel. It would be well to exhaust every other avenue of possible mechanical or electrical failure before tampering with fuel pressure or carburetor adjust-ments, particularly if the system has been functioning normally in the past.

Step 2: Check all air, coolant, fuel supply and vacuum hoses for deterioration.

Step 3: The first corrective step is to measure the fuel inlet pres-sure (before the shut-off) with a water manometer (do not attempt to measure fuel pressure with a mercury manom-eter). The fuel pressure should typically be between 4 and 13.5 in. (101.6 and 342.9 mm) water column. If the fuel pressure is too high, it will prevent the solenoid valve from opening; if the fuel pressure is too low, there will not be sufficient fuel for the engine to run. In both cases, the installation needs to be modified to bring the fuel pressure within acceptable limits.

Step 4: The fuel pressure downstream of the ZPR should be zero in. water column. Small changes in the fuel pressure can be affected by adjusting the ZPR. If zero pressure cannot be achieved, the ZPR is not functioning correctly and should be replaced.

Step 5: If conditions still indicate carburetor malfunction:

A. Switch off the fuel supply and remove the actuator cover plate.

B. Check that the butterfly is operating correctly during engine cranking (the butterfly should open, indicated by movement of the shaft).

C. Check the butterfly is free to move and does not bind. It should have a spring pressure that pushes it closed. If the butterfly is seized, binds, or has no spring pres-sure, then replace the LC50 unit.

D. Remove the deutch plug connector and test the supply voltage to the LC50 is within specifications as follows:

While cranking the engine, measure the dc voltage between Pins 1 and 2 of the Deutsch connector on the wiring loom. It should be >8 V. If the voltage is less than 8 V, investigate the reason and rectify.

E. Test the magnetic pick-up signal is within specifica-tions as follows:

While cranking the engine, measure the ac voltage between Pins 11 and 3. It should be >1.5 V. If the voltage is less than 1.5 V, investigate the reason and rectify (check the magnetic pick up has not been dam-aged and is correctly positioned ¼ turn out from the flywheel).

F. If there is still a problem, the LC50 has malfunctioned. If this is the case, remove and replace the complete unit.

LC-50Zero Pressure

MAS

Air Filter




12 Standby Generator Set Control12.1 General DescriptionEaton Electrical’s standby liquid cooled generator sets utilize Deep Sea Electronics PLC (DSE) 703 Control Modules. The 703 module is an engine automatic start and protection module. It utilizes advanced surface mount construction techniques to provide a compact, yet highly specified module.

Figure 65. The DSE 703 Control Module.The module is designed with DSE’s proven experience and uses modern construction to provide a high level of reliability and suit-ability for the intended operating environment. Issues such as environmental compliance and electromagnetic compatibility (EMC) have been carefully engineered into the design. Advanced features such as protected solid-state outputs mean that there are no moving parts or contacts to burn out.

12.2 Description of Operation

12.2.1 Manual Mode OperationTo initiate a start sequence in Manual Mode, press the Manual button and the start sequence is initiated. The Emergency Stop button must be in the full out position in order to start the engine.Note: There is no Start Delay in the Manual Mode of operation.

If the pre-heat output option is selected, the pre-heat timer is initi-ated and the auxiliary output selected is energized. After the above delay, the fuel solenoid is energized and then the starter motor is engaged.The engine is cranked for a ten-second period. If the engine fails to fire during this cranking attempt, the starter motor is disen-gaged for a ten-second period. Should this sequence continue beyond the three starting attempts, the start sequence will be ter-minated and Fail to Start fault will illuminate.When the engine fires, the starter motor is disengaged and locked out when 20 Hz is measured from the alternator output. Rising oil pressure can also be used to disconnect the starter motor, how-ever it cannot be used for under-speed or over-speed detection.After the starter motor has disengaged, the Safety On timer is activated (which is fixed at 12 seconds), allowing oil pressure, high engine temperature, under-speed, charge fail, and any delayed auxiliary fault inputs to stabilize without triggering the fault.

Pressing the STOP button on the generator controller de-energizes the fuel solenoid, bringing the engine to a stop. The Emergency STOP button can also be used to stop the engine.Note: The Safety On time (used for delayed alarms) is pre set to 12 sec-onds and cannot be changed.

12.2.2 Automatic Mode of OperationThe Automatic Mode is activated by pressing the Auto button. An LED indicator beside the Auto button confirms this action.The start sequence is initiated when the remote start input is acti-vated. To allow for false remote start signals, the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected, the pre-heat timer is initiated and the corresponding aux-iliary output (if configured) will energize.Note: If the remote start signal is removed during the Start Delay timer, the unit will return to a stand-by state.

After the above delays, the fuel solenoid is energized then the starter motor is engaged one second later. The engine is cranked for a ten-second period. If the engine fails to fire during this cranking attempt, the starter motor is disengaged for a ten-sec-ond rest period. Should this sequence continue beyond the three starting attempts, the start sequence will be terminated and Fail to Start fault will illuminate.When the engine fires, the starter motor is disengaged and locked out when 20 Hz is measured from the alternator output. Rising oil pressure can also be used to disconnect the starter motor, how-ever it cannot be used for under-speed or over-speed detection.After the starter motor has disengaged, the Safety On timer is activated, allowing oil pressure, high engine temperature, under-speed, charge fail, and any delayed auxiliary fault inputs to stabi-lize without triggering the fault.Once the engine is running, the output generator running is acti-vated if it has been configured. On removal of the remote start signal, the Stop Delay timer is initiated. Once this timer has expired, the fuel solenoid is de-energized, bringing the generator to a stop.Note: The Safety On time (used for delayed alarms) is pre set to 12 sec-onds and cannot be changed.

12.2.3 Control WarningsControl warnings are used to warn the operator of an impending fault.

Figure 66. Location of the Battery Charge Failure, !1, and !2 Icons.

Manual AutoStop

Battery !1 !2Charge Failure




Battery Charge Failure: If the module does not detect a voltage from the warning light terminal on the auxiliary charge alternator, the Battery Charge Failure icon will illuminate. (Either 8 volts or 16 volts, depending on the configuration of the nominal DC voltage.)Inputs !1 and !2: Inputs !1 and !2 can be configured as warnings or shutdowns. The relevant or icon will be illuminated when the input is active.Note: The !1 icon default setting is for the Emergency Stop Button.Note: The !2 icon default setting is for a Low Water Temperature situation.

12.2.4 ShutdownsShutdowns stop the engine and must be reset before the engine is allowed to restart. The alarm must be cleared and the fault removed to reset the module. In the event of a shutdown, the appropriate icon will be illuminated.Note: The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it will not be possible to reset the unit (the exception to this is the Low Oil Pressure alarm and similar ‘delayed alarms’, as the oil pressure will be low with the engine at rest). Any subsequent warnings or shutdowns that occur will cause a constant LED illumination, therefore only the first-up shutdown will appear flashing.Note: The Safety On time (used for delayed alarms) is preset to 12 seconds and cannot be changed.

Figure 67. Location of the Shutdown Icons.

Fail to Start: If the engine does not fire after the preset three attempts at starting, a shutdown will be initiated. The Fail to Start icon will illuminate.

Low Oil Pressure: If the module detects that the engine oil pres-sure has fallen below the low oil pressure switch after the Safety On timer has expired, a shutdown will occur. The Low Oil Pres-sure icon will illuminate.

High Engine Temperature: If the module detects that the engine coolant temperature has exceeded the high engine temperature switch after the Safety On timer has expired, a shutdown will occur. The High Engine Temperature icon will illuminate.

Over-speed: If the engine speed exceeds the preset trip (14% above the nominal frequency), a shutdown is initiated. Over-speed is not delayed, it is an immediate shutdown. The Over-speed icon will illuminate.

Note: During the start-up sequence, the over-speed trip level is extended to 24% above the normal frequency for the duration of the Safety On timer to allow an extra trip level margin. This is used to prevent nuisance tripping on start-up.

Under-speed: If the engine speed falls below the preset trip (20% of the nominal frequency) after the Safety On timer has expired, a shutdown is initiated. The Under-speed icon will illuminate.

Inputs !1 and !2 are configured as shutdowns. The relevant icon will be illuminated when the input is active

12.3 Control OperationOperation is via three buttons mounted on the front panel (refer to Figure 65). The buttons are Stop, Manual, and Auto.

Stop Button: This is used to stop the engine when it is running and to cancel the “Auto” mode. It is also used to reset any shut-down alarm conditions.

Manual Button: This is used to manually start and run the engine. The engine can be stopped at any time by pressing the “Stop” button.

Auto Button: This is used to select the automatic mode of opera-tion in which the module will await the remote start signal. Once received, the module will initiate its pre-configured “Start” sequence, observing the Start Delay time before starting the engine. When the remote start signal is removed, the module will initiate its pre-configured “Stop” sequence.

The module monitors the engine and provides the following func-tions:• Automatic Start with three attempts and Automatic Crank Dis-

connect – with adjustable Start and Stop timers and Fail to Start indication.

• Configurable Pre-heat and Energize to Stop functions.• Low Oil Pressure and High Engine Temperature Shutdown.• Over-speed and Under-Speed (frequency) protection.• Charge Fail Alarm.• Two fully configurable auxiliary inputs.

All alarms are indicated by high-visibility, red LED’s.

The module’s microprocessor provides a comprehensive list of timers and configurable functions. Parameter settings can be adjusted using the front panel buttons once in the Configuration Mode. Access to the settings is via a small Configuration Switch located on the rear of the module (see Figure 68) and enables changes to be made in the field. Selection of the Configuration Mode is indicated by rapid flashing of the Auto LED.

Fail to Start

Low Oil PressureHigh Engine Temperature

OverspeedUnderspeed




Figure 68. Location of the Configuration Switch.

12.4 Control Features• Micro-processor based design• Automatic engine starting and stopping• Automatic shutdown on fault condition• Configurable via the front panel• Simple, button controlled operation• Configurable digital inputs• Configurable solid-state outputs• Configurable timer settings• Solid-state fuel and crank outputs• External remote start input• LED alarm indication• Start delay timer• Stop delay timer• Energize to Stop timer• Pre-heat timer• Over-speed shutdown• Under-speed protection• Low oil pressure shutdown• High engine temperature shutdown• Optional crank disconnect from oil pressure

12.5 ConfigurationStep 1: With the control module in the Stop Mode , the Con-

figuration Mode is selected by operation of a small switch on the rear, left-hand edge of the 703 Control Module (see Figure 68). This is partially hidden to prevent acci-dental operation.

Step 2: Once the Configuration Mode is selected, the “Auto” LED will start to flash rapidly. When in the Configuration Mode, all normal operation is suspended.

Step 3: The Stop button can be used to select the LED “code” that corresponds to the required function. The five left-hand LED’s will form the code (see Figure 69.

Figure 69. LEDs During the Configuration Sequence.

A key to all configuration options is provided in Table C-1 in Appendix C.

The Manual button allows the user to change the function parameters. The three right-hand LED’s inform the user of the current value for the chosen function (see Figure 67 and Table C-1 in Appendix C).

Step 4: When the required parameters are displayed, pressing the “Auto” button will save the new setting. The process is repeated for each function change.

Step 5: When configuration is complete, the Configuration Mode selector switch should be returned to the “Normal” posi-tion.

Configuration Switch

Fail to Start

Low Oil PressureHigh Engine Temperature

OverspeedUnderspeed

Battery Charge Failure

Emergency Stop

Low WaterTemp




12.6 Terminal Description

See Table 9 for a complete description of the terminals.

Table 9. Terminal Description.

Note: All the outputs are solid state, rated at 1.2 A, 8 to 35 Vdc, and switch to battery negative when active.

12.7 Specification• DC Supply:

8 to 35 V continuous.• Cranking Dropouts:

Able to survive 0 V for 50 mS, providing supply was at least 10 V before the dropout and supply recovers to at least 5 V.Note: This is achieved without the need for internal batteries.

• Maximum Current:Operating 50 mAStandby 10 mA

• Alternator Input Range:75 (ph-N) to 277 (ph-N) 3-Phase, 4 wire AC (+20%)

• Alternator Input Frequency:50 - 60 Hz at rated engine speed (Minimum: 75 Vac Ph-N)(Crank Disconnect from 15V Ph-N @ 20 Hz)Over-speed +14% (+24% overshoot)Under-speed -20%

• Start Output:1.2 Amp DC at supply voltage

• Fuel Output:1.2 Amp DC at supply voltage

• Auxiliary Outputs:1.2 Amp DC at supply voltage

• Dimensions:4.9 × 6.5 × 1.1 in. (125 × 165 × 28 mm)

• Charge Fail:12 V = 8 V CF, 24 V = 16 V CF

• Operating Temperature Range:-30 to +70°F (-34.4 to +21.2°C)

• Compliant with BS EN 60950Low Voltage Directive

• Compliant with BS EN 50081-2EMC Directive

• Compliant with BS EN 50082-2EMC Directive

• Compliant with BS EN 61000-6-4EMC Directive

• Compliance to European Legislation

• Registered Component for USA and Canada

PIN # DESCRIPTION RATING CABLE SIZEIN. (MM)

NOTES

1 DC Plant Supply Input – Negative 12 volts DC 0.04 (1.0) Connected to plant battery negative.

2 DC Plant Supply Input – Positive 12 volts DC 0.04 (1.0) Connected to plant battery positive (recommended fuse 2 A).

3 Fuel Relay Output 1.2 amps @ 12 volts DC 0.04 (1.0) Used to operate the fuel relay.

4 Start Relay Output 1.2 amps @ 12 volts DC 0.04 (1.0) Used to operate the cranking relay.

5 Auxiliary Output Relay 1 (!1) 1.2 amps @ 12 volts DC 0.04 (1.0) Configurable output.

6 Auxiliary Output Relay 2 (!2) 1.2 amps @ 12 volts DC 0.04 (1.0) Configurable output.

7 Charge Fail Input/ Excitation Output 8 volts @ 12 volts DC 0.04 (1.0) Must NOT be connected to plant supply negative if not used.

8 Low Oil Pressure Input 12 volts DC 0.02 (0.5) Switch to negative.

9 High Engine Temp Input 12 volts DC 0.02 (0.5) Switch to negative.

10 Auxiliary Input 1 (!1) 12 volts DC 0.02 (0.5) Switch to negative. Used for Emergency Stop Button

11 Auxiliary Input 2 (!2) 12 volts DC 0.02 (0.5) Switch to negative. Used for Low Water Temp Sensing

12 Remote Start Input 12 volts DC 0.02 (0.5) Switch to negative. Used for Auto Start

13 Not Used

14 Not Used

15 Functional Earth 0.04 (1.0) Connect to a good clean earth point.

16 Not Used

17 Not Used

18 Not Used

19 Not Used

20 Alternator Input L1 120 volts Vac 0.04 (1.0) Do not connect if not used (2 A fuse).

21 Alternator Input N 120 volts Vac 0.04 (1.0) Do not connect if not used.




12.8 Solid State OutputsThe DSE 703 Control Module utilizes solid-state outputs, located on the controller itself, that provide many advantages including:• No moving parts;• Fully overload / short circuit protected;• Smaller dimensions making it lighter, thinner, and less costly

than conventional relays; and• Less power required making it far more reliable.The main difference from conventional outputs is that solid-state outputs switch to negative when active. This type of output is normally used with an automotive or plug-in relay.

12.8.1 Typical ConnectionsFigure 70 provides an example of relay pins connected to the DSE 703 module solid-state output to drive a fuel solenoid.

Figure 70. DSE 703 Module Typical Connections.

See Section 12.10 - Typical Connections, for an overall typical wiring diagram.

Battery positive (+)

Solid state output from DSE module

eg. Terminal 3 of 703/4 - FUELFuel Solenoid (+ terminal)

* Observe polarity when usingrelays fitted with integral diodes!

*

A D

B C

Solid State Outputfrom DSE Module Pin

Automotiverelay Pin

8 Pin Plugin relay Function

3 86 7 Fuel Output85 2 To Positive supply via fuse 30 1 To Positive supply via fuse

ABCD 87 3 To Fuel Solenoid




12.9 DimensionsFigure 71 gives the dimensions for the DSE 703 module.

Figure 71. Dimensions of the DSE 703 Module.

12.10 Typical ConnectionsSee Figure 72 for a detailed, typical wiring diagram for the DSE 703 module.

Figure 72. Typical Wiring Diagram for the DSE 703 Module.

Dimensions:165mm x 125mm x 29mm (6.5” x 4.9” x 1.2”)

Panel cut out:149mm x 109mm(5.9” x 4.3”)

Mounting Method:4 x 4.2mm diameter holes suitable for M4screws.

F 2A

SSOSSOSSOSSO

SSO = Solid state outputs

= External 'Automotive' or 'Plug-in' type relays

41 2 3 5 6 7

2021

Auxiliary Outputs

++

8 9 10 11 12

Auxiliary AlarmInputs

+Battery

F2A F

Crank

Fuel Startermotor

Chargealt

+ +

Fuel o/p Start o/p

15

Terminals suitable for 22-16 awg (0.6mm2-1.3mm2 ) field wiring Tightening Torque = 0.8N-m (7lb-in)

Emer

genc

y Sto

p

Low

wat

er t

emp.




13 Operation of the Standby Generator Set13.1 Control SystemThe Eaton Electrical liquid cooled standby generator set is equipped with an advanced electronic control system. It is con-trolled by the DSE 703 Module.This control system allows the user to manually or automatically control the generator set. The control system has protection cir-cuits to sound an optional alarm and even shutdown the set if problems occur.The procedures detailed in this section are required to prepare the generator set for operation; both starting and stopping it for the first time after installation and starting and stopping it normally. Note that Section 13.2, Pre-Start Checks are applicable with all control systems. Sections 13.3, and 13.4 cover operation of the Auto-start Control Systems.

13.2 Pre-Start Checks (Applicable to All Control Systems)The following checks should be performed prior to starting the generator set.

Step 1: Ensure the control panel is in the “Stop” Mode. The “Auto” LED will not be illuminated.


Step 2: Check the engine oil and coolant levels. Replenish the engine oil (see Tables 1 and 2 in Section 5 of the Owner’s manual) and coolant, as needed, using the rec-ommended fluids.

Figure 74. Typical Location of the Oil Dip Stick and Radiator Cap.

Note: When adding coolant to the radiator system, always pour slowly to help prevent air from becoming trapped in the engine.

Step 3: Check for any fuel, oil, or coolant leaks. If any are found, contact a trained, qualified technician to make the neces-sary repairs.


Stop

WARNINGDO NOT REMOVE THE RADIATOR CAP WHEN THE COOLANT IS HOT. DO NOT ADD LARGE AMOUNTS OF COLD COOLANT TO A HOT SYSTEM AS SERIOUS DAMAGE COULD RESULT.

WARNINGDO NOT SMOKE OR USE AN OPEN FLAME IN THE VICINITY OF ANY FUEL SUPPLY OR STORAGE SYSTEM.

Radiator Cap

Oil Dipstick




Step 4: Check the condition and tension of the fan and engine alternator belts. Tighten the belts if necessary.

Figure 75. Typical Location of the Fan and Engine Alternator Belts.

Step 5: Check all hoses for loose connections or deterioration. Tighten all connections or replace hoses as necessary.

Step 6: Check the battery terminals and cables for corrosion. Clean the terminals and cables as necessary.

Figure 76. Example of a Corrosion Free Battery Terminal and Connector.

Step 7: Check the control panel and the overall generator set for heavy accumulation of dust and/or dirt. If found, clean the control panel and/or generator set as necessary. An accumulation of dust and/or dirt can pose an electrical hazard or give rise to cooling problems.

Step 8: Clear the area around the generator set of any insecure items that could inhibit operation or cause injury. Ensure the cooling air ventilation screens are clear.

Figure 77. Cooling Air Ventilation Screens.Step 9: Regularly check the entire generator set for signs of

leaks from the fuel system, cooling system, or lubrica-tion seals.

Step 10: Periodically drain the exhaust system condensate traps, if equipped.

Figure 78. Exhaust System Condensate Traps.

WARNINGBEFORE TIGHTENING THE FAN OR ENGINE BELTS, DISCONNECT THE BATTERY NEGATIVE (-) LEAD TO ENSURE THE ENGINE CAN-NOT BE ACCIDENTALLY STARTED.

FanBelt

WARNINGDO NOT SHORT THE POSITIVE AND NEGATIVE TERMINALS TOGETHER.

Condensate Trap




Step 11: Ensure the alternator output circuit breaker is in the "OFF" (handle down) position.

Figure 79. Alternator Output Circuit Breaker in the “Off” Position.

13.3 Normal Manual Startup/ShutdownThe following procedure should be used for manual starts and shutdowns of the generator set.Note: The generator set may be stopped at any time by pushing the “Stop” button on the DSE 703 control panel.

Figure 80. The “Stop” and “Manual Buttons on the Control Panel.


Note: The engine will not start if any fault indicators are illuminated. Ensure the faults have been corrected prior to attempting to start the gen-erator set.

13.3.1 Manual StartStep 2: Press the “Manual” button on the DSE control panel. The

engine will automatically crank up to three (3) times or until the engine fires. If the engine does not fire, the con-trol system locks-out on "Fail to Start" and illuminates a fault lamp on the control panel. If this happens, refer to the Troubleshooting Guide in Section 14.6.

13.3.2 When the Engine Has StartedStep 3: Check for any abnormal noise or vibration.

Step 4: Check for fluid leakage or leaks in the exhaust system.

Step 5: Check the control panel for indications of abnormal oper-ation, particularly abnormally high temperature or abnor-mally low oil pressure. The oil pressure should be in the normal range within about ten seconds of starting.

Figure 81. The “High Temperature” and “Low Oil Pressure” Icons on the Control Panel.

Step 6: Switch the Alternator Output Circuit Breaker to "ON" (handle up).

Stop Manual

WARNINGUNBURNED FUEL GASES CAN BUILD-UP IN THE EXHAUST SYSTEM AFTER MULTIPLE FAILED ATTEMPTED STARTS. UNSCREW THE PLUGS ON THE EXHAUST OUTLET ELBOWS OR STUB PIPES AND ALLOW THE UNBURNED FUEL TO DISSIPATE. ONCE ALL SIGNS OF UNBURNED FUEL HAVE DISAPPEARED AND ANY OTHER PROBLEMS CAUSING THE FAILURE TO START HAVE BEEN RECTIFIED, REPLACE THE PLUGS AND REPEAT THE CRANKING PROCEDURE.

Low

High Temperature

Oil Pressure




Figure 82. Alternator Output Circuit Breaker in the “On” Position.Note: Load can now be applied to the generator set. However, the maxi-mum step load that can be accepted in any one step is dependent on the operating temperature of the set. With the generator cold (not more than 20°C [68°F]), the maximum step load acceptance is approximately 50% of rated output. However, with the generator set at the normal operating temperature (approximately 80°C [176°F]), the maximum step load can be 70-100% of the rated power depending on the generator set model. All Eaton Electrical generator sets up to 75 kVA can accept a 100% load as listed on the nameplate on the control panel door.

13.3.3 ShutdownStep 1: To shutdown the generator set, turn the load off by

switching the Alternator Output Circuit Breaker to "Off" (handle down). Allow the generator set to run without load for a few minutes to cool. Then press the “Stop” button on the DSE 703 control panel. The generator set will shutdown.

13.4 Automatic Startup/ShutdownThe following procedure should be used for preparing a generator set to be started from a remote location.Note: The generator set may be stopped at any time by pressing the “Stop” button on the DSE 703 control panel or the Emergency Stop button.

Pressing the Emergency Stop button also illuminates the !1 LED.


Note: The engine will not be able to start if any fault indicators are illumi-nated. Ensure the faults have been corrected prior to attempting to start the generator set.

13.4.1 Automatic StartStep 2: Ensure that any remote Stop buttons are released. Set

the DSE control panel to the “Auto” position by pressing the “Auto” button.

Step 3: Switch the Alternator Output Circuit Breaker to "On" (handle up – see Figure 82). The generator set is now ready to automatically start when it receives a remote start signal. When the start signal is removed, it will automatically stop.

Note: If the Run On timer was configured during setup, the DSE 703 con-trol module will allow the generator set to run for a short duration to cool prior to stopping automatically.

WARNINGIN CASE OF AN EMERGENCY WHERE IMMEDIATE SHUTDOWN IS NECESSARY, THE “STOP” BUTTON SHOULD BE PUSHED IMMEDI-ATELY WITHOUT DISCONNECTING THE LOAD.




14 Generator Set Maintenance and Troubleshooting14.1 GeneralA good maintenance program is the key to long generator set life.Preventative (non-routine) maintenance and service should only be carried out by trained, qualified technicians. Records of this work should be kept to aid in developing an efficient overall mainte-nance program.In general, the standby liquid cooled generator set should be kept clean. Do not permit liquids, such as oil film, to accumulate on any internal or external surfaces or on, under, or around any acoustic material, if fitted. Wipe down surfaces using a water-based industrial cleaner. Do not use flammable solvents for clean-ing purposes.Any acoustic material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or oil film within the material.

14.2 Routine MaintenanceDepending on the application of the standby liquid cooled genera-tor set, requirements for routine maintenance will vary. See Table B-1 in Appendix B for the complete routine and preventative main-tenance schedules broken down by engine type.Note: Maintenance intervals for the engine may be more frequent than those shown in this section depending on operating conditions.

Refer to Section 5.2 in the Owner’s Manual portion of this manual for routine maintenance procedures

14.2.5 Alternator Routine MaintenanceThere is no routine maintenance required on the alternator. How-ever, periodic inspection of the alternator winding condition and periodic cleaning by a trained, qualified technician is recom-mended. See the Alternator Preventative Maintenance section of this manual for more detailed information.

14.3 Engine Routine Maintenance

14.3.1 Checking the Oil LevelFor details on how to check the engine oil level, see Section 5.3.1 in the Owner’s Manual portion of this manual.

14.3.2 Changing the Engine OilFor details on how to change the engine oil, see Section 5.3.2 in the Owner’s Manual portion of this manual.

14.3.3 Changing the Engine Oil FilterFor details on how to change the engine oil filter, see Section 5.3.3 in the Owner’s Manual portion of this manual.

14.3.4 Changing the Air FilterFor details on how to change the air filter, see Section 5.3.4 in the Owner’s Manual portion of this manual.

14.3.5 Checking the Coolant Level and RadiatorFor details on how to check the coolant level in the radiator, see Section 5.3.5 in the Owner’s Manual portion of this manual.

14.4 Engine Preventative MaintenanceHave a trained, qualified technician perform the preventative maintenance required to keep your generator set operating effi-ciently. See Table B-1 in Appendix B for a complete maintenance schedule broken down by engine type.

14.4.1 Drive BeltsDrive belt(s) are used for driving such items as the water pump, battery-charging alternator, and cooling fan. The belt(s) should be properly adjusted at all times. A loose drive belt causes improper alternator, fan, and water pump operation. This can lead to over-heating or improper battery charging.Over-tightening the belt(s) may result in excessive wear on the alternator and water pump bearings, as well as premature wear on the belt itself. Therefore, it is recommended that a belt tension gauge be used to check and adjust the belt tension. Before beginning the process to replace or adjust the drive belt(s), ensure that the following tools and materials are available.

Needed Tools and Materials:• Replacement Drive Belt (If replacing the belt[s]);• Belt Tension Gauge;• Pry Bar;• Appropriately Sized Wrenches; and• Shop Rags or Paper Towels.

14.4.1.1 Procedure

If the Belt(s) Is to Be Replaced

Step 1: Note the path of the belt to be replaced. The new belt MUST be installed following the same path.

Step 2: Loosen the hardware securing the tensioning component. On Ford engines, this will be the tensioner arm/pulley assembly; on Isuzu engines, it will be the battery-charg-ing alternator adjusting bolt.

Step 3: With the tension relieved on the belt, remove the belt from its pulleys and guides.

WARNINGDO NOT ATTEMPT TO CHANGE THE DRIVE BELT(S) WHILE THE ENGINE IS HOT. SERIOUS PERSONAL INJURY COULD OCCUR.




Figure 83. Typical Serpentine Belt Configuration.

Step 4: Install the replacement belt following the same path as the original belt.

Tensioning the Belt(s)Step 5: Install the belt tension tool on the drive belt and check the

tension following the instructions of the tool manufac-turer.

Figure 84. Belt Tension Gauge Installed on the Typical Drive Belt.

Step 6: If the tension is not adequate, move the tensioner arm/pulley assembly or battery charging alternator until the correct tension is achieved.

Step 7: Tighten the hardware securing the tensioner arm/pulley assembly or battery-charging alternator. Check the belt tension gauge again to make sure the tension is correct.

Step 8: If the tension is not correct, repeat the procedure. If the tension is correct, remove the belt tension gauge.

14.4.2 BatteryIf there is any corrosion on the cables and terminals, remove it with a wire brush and neutralize the acid with a solution of baking soda or ammonia with water. After cleaning, flush the top of the battery with clean water, install the terminal clamps on the bat-tery posts, and coat the parts with grease to retard further corro-sion.Check the battery charge regularly during extreme cold weather. Make sure the cables are clean and tightly clamped to the battery terminals. Keep the top of the battery clean and dry.

14.4.2.1 Fluid LevelIf a non-maintenance free battery has been installed in the genera-tor set, periodically check the electrolyte fluid level.

14.4.2.2 Minimum Battery SpecificationsIf the generator set battery must be replaced, the replacement bat-tery MUST meet the minimum specifications listed in Table 10

Table 10. Replacement Battery Specifications.

14.4.3 Closed Circuit Breathing SystemClean air is supplied to the crankcase via an opening in the rocker cover. The fumes are vented out of another opening in the rocker cover through a PCV Valve and into the intake manifold.Check the PCV Valve on a regular basis to make sure it is not clogged. If it is clogged, either clean or replace the PCV Valve.

14.4.4 Ignition SystemTwo types of ignition systems are used on Eaton Electrical standby liquid cooled generator sets. A breakerless, solid-state type ignition system is used on the HM 4ZB1 engine. A distribu-torless ignition system is used on the Ford LRG425, ESG642, and WSG1068 engines. Use the appropriate maintenance procedures for the system in use on your engine.

Belt

BELT TENSION TOOL

952-227

MINIMUM RATINGS

Voltage 12 V

Cold Cranking Amperes 440 A

MAXIMUM DIMENSIONS – INCHES (MM)

Length 13.90 (353.1)

Width 6.90 (175.3)

Height 7.50 (190.5)




Figure 85. Typical “Breakerless” Ignition System.

Figure 86. Typical “Distributorless” Ignition System.

The spark plug wires are inserted in the distributor cap in the firing order of the engine (1-3-4-2 for the HM 4ZB1 and Ford LRG425, 1-4-2-5-3-6 for the ESG642, and 1-6-5-10-2-7-3-8-4-9 for WSG1068). The number one socket is identified by the number one (1) on the cap. The cylinders are numbered from front to rear, 1-2-3-4 for the HM 4ZB1 and LRG425, 1-2-3 right side and 4-5-6 left side for the ESG642, and 1-2-3-4-5 right side and 6-7-8-9-10 left side for the WSG1068 as viewed from the rear of the engine).

14.4.4.1 Breakerless Solid-state Ignition SystemsWhen installing a new distributor cap or rotor, coat the brass rotor electrode surfaces on all sides outboard of the plastic, including the outer edge, with silicone dielectric compound (GENPART part number 952-228), or equivalent to approximately 0.03-in. (0.79-mm) thickness. Do not reapply or attempt to remove any silicone coating from the distributor cap electrodes. As this compound ages, it has the appearance of being a contaminant of the cap and rotor electrode. This condition is normal and causes no perfor-mance loss.Coat the inside of each spark plug boot with silicone dielectric compound (GENPART part number 952-228), or equivalent, using a small screwdriver blade. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully seated on each plug and molded boot is firmly in place.At the intervals listed in Table B-1 in Appendix B, apply a few drops of engine oil to the distributor oil felt (where applicable) and apply an appropriate lubricant at the pivot points of the throttle and governor.The ignition timing should be checked and adjusted at the recom-mended intervals shown in Table B-1 in Appendix B. Proper adjustment of ignition timing must be maintained to provide maxi-mum engine power output and best possible fuel economy.

14.4.4.2 Distributorless Ignition SystemsAs with the solid-state ignition systems, coat the inside of each spark plug boot with silicone dielectric compound (GENPART part number 952-228), or equivalent, using a small screwdriver blade. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully seated on each plug and molded boot is firmly in place.The ignition timing on distributorless ignition systems is factory set and cannot be manually adjusted.

14.4.4.3 Spark PlugsThe spark plugs should be cleaned, tested, and gapped at the rec-ommended intervals shown in Table B-1 in Appendix B. Remove the wires from each spark plug by grasping, twisting, and then pulling the molded cap of the wire only. Do not pull directly on the wire because the wire connection inside the cap may become separated.After loosening each spark plug one or two turns, clean the area around each spark plug port with compressed air, then remove the spark plugs.

Distributorless SystemIgnition

CAUTIONWHEN USING COMPRESSED AIR TO CLEAN THE AREA AROUND THE SPARK PLUGS, WEAR SAFETY GLASSES TO PREVENT EYE INJURY.




After cleaning, examine each spark plug carefully for cracked or broken insulators, badly pitted electrodes, and other signs of mal-function. Replace the spark plugs as required.After cleaning, dress the electrodes with a small file to obtain flat parallel surfaces on the electrodes. Set the spark plug gap to specifications by bending the ground electrode. All spark plugs, new or used, should have the gap checked as required. The rec-ommended spark plug gap for the HM 4ZB1, LRG425, ESG642, and WSG1068 is 0.044 in. (1.12 mm).Install the spark plugs and torque each plug to (7 to 10 lb.ft (9 to 13 Nm). Connect the spark plug wires.Note: Do not over-tighten spark plugs. The gap may change considerably due to distortion of the plug outer shell.

14.5 Alternator Preventative MaintenanceThis section applies to 1000 and 2000/3000 Series alternators used in Eaton Electrical liquid cooled standby generator sets.

14.5.1 Safety Measures

Before attempting to perform maintenance on the alternator or troubleshoot any problems, ensure that the generator set cannot be started manually or automatically. This is accomplished by pressing the “Stop” button on the DSE 703 control module. Also be sure to read all information provided about the alternator and understand the operating principles of the alternator and generator set.

14.5.2 General Preventative Maintenance

9.5.2.1 Checks After Start-upAfter approximately 20 hours of operation, check that all mount-ing hardware and connections on the alternator are secure. Also check the overall general state of the alternator and the various electrical connections in the generator set.

14.5.2.2 Cooling CircuitOn a regular basis, depending on the environment in which the generator set is installed, check to ensure that the circulation air that cools the alternator is not restricted by full or partial blockage of the air intake or discharge areas. Make sure they are free of debris such as leaves, paper, mud, grease, etc.

14.5.2.3 BearingsThe bearings in the 1000 and 2000/3000 Series alternators are “greased for life” (approximate life of the grease [depending on environment and use] = 20,000 hours or 3 years. Note that harsh environments or extreme operating conditions can reduce the bearing life.To ensure the condition of the bearings, monitor the temperature rise in the bearings. The temperature rise should NOT exceed 60°C (140°F) above the ambient temperature. Should this value be exceeded, the alternator must be stopped and the condition of the bearings examined.

14.5.2.4 Electrical Cleaning/Servicing

Cleaning Products for the Windings

Certain strictly defined, pure volatile degreasing products can be used to clean the windings of the alternator. These include:• Normal petrol (without additives);• Toluene (slightly toxic); flammable;• Benzene or benzine (toxic); flammable; and• Ciclohexare (non-toxic); flammable.

Cleaning the Stator, Rotor, Exciter, and Diode BridgeThe isolating components and the impregnation system are not at risk of damage from certain solvents (see the list of authorized products above). Avoid letting the cleaning product run into the slots. Apply the product with a brush, sponging frequently to avoid accumulation in the housing. Dry the winding with a dry cloth. Let any traces of cleaning solvent evaporate before reas-sembling the alternator.Note: After cleaning the alternator, it is essential to check the isolation of the windings (see Section 14.5.4).

14.5.2.5 Mechanical Maintenance

Degreasing: Use a brush and detergent (specifically adapted to paint).

Dusting: Use an air gun to blow dust from the alternator.

If the alternator is fitted with air inlet and outlet filters, in order to ensure correct ventilation, a regular cleaning of the filters must be done according to the environmental conditions.Note: After cleaning the alternator, it is essential to check the insulation of the windings (see Section 14.5.4).

14.5.3 Fault DetectionIf, when first commissioned, the alternator does not work prop-erly, the source of the malfunction must be identified. To identify the problem, check that:• The protective devices are fitted correctly;• All connections comply with the diagrams in the manual sup-

plied with the alternator; and• The speed of the unit is correct (see Table A-1 in Appendix A).

14.5.4 Checking the Winding InsulationYou can check the winding insulation by performing a -Hi Pot test. In this case, you MUST disconnect all automatic voltage regulator (AVR) wires.

WARNINGSERVICING OR TROUBLESHOOTING MUST BE CARRIED OUT STRICTLY IN ACCORDANCE WITH THESE INSTRUCTIONS TO AVOID THE RISK OF ACCIDENTS AND TO MAINTAIN THE ALTERNATOR IN ITS ORIGINAL STATE.

THE MAINTENANCE AND TROUBLESHOOTING OF THE GENERATOR SET ALTERNATOR MUST BE PERFORMED BY AUTHORIZED, TRAINED, AND CERTIFIED TECHNICIANS. INCORRECT MAINTE-NANCE OR TROUBLESHOOTING CAN CAUSE DEATH, SERIOUS PER-SONAL INJURY, AND / OR PROPERTY DAMAGE.

CAUTIONDO NOT USE TRICHLORETHYLENE, PERCHLORETHYLENE, TRICHLO-ROETHANE, OR ANY ALKALINE PRODUCTS TO CLEAN THE WIND-INGS OF THE ALTERNATOR. THESE AGENTS WILL DAMAGE THE WINDINGS.

CAUTIONWATER AND/OR PRESSURE WASHING ARE STRICTLY PROHIBITED BECAUSE THEY WILL DAMAGE THE COMPONENTS OF THE ALTER-NATOR. ANY PROBLEMS CAUSED BY SUCH TREATMENT ARE NOT COVERED BY THE WARRANTY.

CAUTIONIF ALL THE AVR WIRES ARE NOT DISCONNECTED BEFORE PER-FORMING A HIGH VOLTAGE TEST, DAMAGES WILL OCCUR TO AVR. DAMAGE CAUSED BY NOT DISCONNECTING THE AVR WIRES IS NOT COVERED UNDER THE GENERATOR SET WARRANTY.




14.5.5 Checking the Diode BridgeThe diagrams in Figure 87 illustrate and give complete directions for conducting a diode bridge test.

Figure 87. Testing the Diode Bridges.

Figure 88. Separate Excitation Methods “A” and “B”.

14.5.6 Checking the Windings and Rotating DiodesThis section gives directions on how to test the windings and rotating diodes using separate excitation sources.

14.5.6.1 ProcedureStep 1: Stop the generator set and allow the unit to cool to

approximately ambient temperature. Disconnect and iso-late the AVR wires.

Step 2: There are two methods to carry out a separate excitation test (see Figure 88).

Method A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode on both exciter field wires (5+) and (6-).

Method B: Connect a "Variac" variable power supply and a diode bridge on both exciter field wires (5+) and (6-).

These two systems should have characteristics that are compatible with the exciter field excitation power of the alternator (see the nameplate).

Diode bridge - -C C C

A A A

+

C C C

A A A+~ ~ ~ ~ ~ ~ ~

~

~

+ -or

CAA n o d e C a t h o d e

A diode in good condition enables the current to flow in only one direction from Anode to Cathode

- -C C C

A A A

+

C C C

A A A

+

~ ~ ~

~ ~ ~

- Fig 23 -

DIODE BRIDGE

CAA n o d e C a t h o d e

-CA

+

-C A

+A diode in a good condition enables the current to flow in only one direction, from anode to cathode.

6 - 5 +

Diode 1A

12V battery

Rh. 50Ω -300W

-

-

+

+

6 - 5 +Variac

AC220V

DC12V

50 60

7080

90

100

40

3020

10

0

Exciter fieldExciter field

METHOD A METHOD B

WARNINGDURING THIS PROCEDURE, MAKE SURE THAT THE ALTERNATOR IS DISCONNECTED FROM ANY EXTERNAL LOAD. INSPECT THE TER-MINAL BOX TO CHECK THAT THE CONNECTIONS ARE FULLY TIGHTENED.




Step 3: Run the unit at its rated speed.

Step 4: Gradually increase the exciter field current by adjusting the rheostat or the Variac and measure the output volt-ages on L1 - L2 - L3, checking the excitation voltage and current at no load and at full load (see the alternator nameplate or ask for the factory test report).

When the output voltage is at its rated value and bal-anced within 1%, for the rated excitation level and rated speed, then the alternator is in good working order. The fault must therefore come from the AVR or its associated wiring (i.e.: sensing, auxiliary windings, etc.).

14.5.7 Disassembly and ReassemblyThroughout the disassembly and reassembly procedures, refer to the exploded views in Figures 90 through 94.Note: During the warranty period, these operations should be carried out only in an approved repair workshop or by the manufacturer. If they are not, the warranty may be invalidated.

Figure 89. Lifting Bar Attached to the Alternator for Lifting/Moving.

14.5.7.1 Tools RequiredTo fully disassemble / reassembly the alternator, the following tools are required.• Ratchet wrench and extension;• Torque wrench;• 8 mm socket;• 10 mm socket;• 13 mm socket;• 16 mm socket (2000/3000 Series Only);• 18 mm socket (2000/3000 Series Only);• 21 mm socket (2000/3000 Series Only);• 22 mm socket (2000/3000 Series Only);• 24 mm socket (2000/3000 Series Only);• 7 mm wrench;• 8 mm wrench;• 10 mm wrench;• 12 mm wrench;• 5 mm Allen key;• 6 mm Allen key;• 10 mm Allen key (2000/3000 Series Only);• 12 mm Allen key (2000/3000 Series Only);• T20 TORX bit;• T30 TORX bit;• Puller (Part # U35); and• Puller (Part # U32/350).

14.5.7.2 Screw Tightening TorquesDuring reassembly, the torque values given in Table 11 should be followed.

Table 11. Torque Values for Reassembly of the Alternator.

CAUTIONTHE ALTERNATOR MUST BE HORIZONTAL FOR DISASSEMBLY (WHEN THE LIFTING BAR IS REMOVED). SEE FIGURE 90.

IDENTIFICATION SCREW Ø TORQUE N.M (IN./LB)

Field Term. Block Screw M4 4 (35.4)

Field Screw M6 10 (88.5)

Diode Bridge Screw M6 5 (44.3)

Diode Nut M5 4 (35.4)

Assembly Rod (1000) M8 20 (177.0)

Assembly Rod (2000) M12 57 (504.5)

Assembly Rod (3000) M14 90 (796.6)

Grounding (Earthing) Screw M6 5 (44.3)

Balancing Bolt (1000) M5 4 (35.4)

Discs/Shaft Screw (1000) M10 66 (584.2)

Discs/Shaft Screw (2000) M12 110 (991.3)

Discs/Shaft Screw (3000) M14 180(1593.0)

Fan Screw (3000) M6 5 (44.3)

Lifting Screw (1000) M8 4 (35.4)

Louver Screw M6 5 (44.3)

Cover Screw M6 5 (44.3)

Terminal Plate Screw (2000 & 3000) M10 20 (177.0)




14.5.7.3 Exploded ViewsWhile performing any maintenance or diagnostics on the 1000 or 2000/3000 Series alternators, please refer to the applicable exploded views and parts lists contained in the following figures.

Figure 90. 1000 Series, Single Bearing, with Terminal Box.

Table 12. 1000 Series, Single Bearing, with Terminal Box Parts List.NO. QTY. DESCRIPTION NO. QTY. DESCRIPTION

1 1 Stator Assembly 91 4 Field Fixing Screw

4 1 Rotor Assembly 100 1 Exciter Armature

15 1 Fan 120 1 Terminal Plate Support (Aux-iliary Winding Regulation Excitation Principle [AREP])

28 1 Ground (Earth) Terminal 124 1 Terminal Plate

30 1 DE Flange 132 1 Terminal Box

33 1 Air Outlet Louver 198 1 Regulator (AVR)

36 1 NDE Bracket 322 1 Coupling Disc

37 4 Tie Rod 323 6 Fixing Screw

48 1 Terminal Box Lid 324 1 Clamping Washer

49 20 Terminal Box Fixing Screw 343 1 Direct Diode Assembly

51 1 Air Intake Louver 344 1 Reverse Diode Assembly

70 1 NDE Bearing 347 1 Surge Suppressor

79 1 Preloading Wavy (Borelly) Washer

367 2 Inspection Door

90 1 Wound Exciter Field 349 1 O-ring Seal

344343

349

347

70

79

9036

51

48

367

1

124

120198

100

132

91

37

4

15

30

33

323324

322

28

i

49




Figure 91. 1000 Series, Two Bearing, with Terminal Box.

Table 13. 1000 Series, Two Bearing, with Terminal Box Parts List.NO. QTY. DESCRIPTION NO. QTY. DESCRIPTION

1 1 Stator Assembly 90 1 Wound Exciter Field

4 1 Rotor Assembly 91 4 Field Fixing Screw

15 1 Fan 100 1 Exciter Armature

28 1 Ground (Earth) Terminal 120 1 Terminal Plate Support (AREP)

30 1 DE Flange 124 1 Terminal Plate

33 1 Air Outlet Louver 132 1 Terminal Box

36 1 NDE Bracket 198 1 Regulator (AVR)

37 4 Tie Rod 343 1 Direct Diode Assembly

48 1 Terminal Box Lid 344 1 Reverse Diode Assembly

49 20 Terminal Box Fixing Screw 347 1 Surge Suppressor

51 1 Air Intake Louver 367 2 Inspection Door

60 1 DE Bearing 349 1 O-ring Seal

70 1 NDE Bearing 410 1 DE Flange


344343

349

347

70

79

9036

51

48

367

1

124

120198

100

132

91

37

415

30

33

410

60

28

Fi 28

49




Figure 92. 1000 Series, Single Bearing, without Terminal Box.

Table 14. 1000 Series, Single Bearing, without Terminal Box Parts List.NO. QTY. DESCRIPTION NO. QTY. DESCRIPTION

1 1 Stator Assembly 79 1 Preloading Wavy Washer

4 1 Rotor Assembly 90 1 Exciter Field

15 1 Turbine 91 4 Field Fixing Screw

28 1 Ground (Earth) Terminal 100 1 Exciter Armature

30 1 DE Flange 322 1 Coupling Plate

33 1 Air Outlet Grille 323 6 Fixing Screw

36 1 Exciter Flange 324 1 Clamping Washer

37 4 Fixing Rod 343 1 Direct Diode Crescent

42 1 Cable Gland Support 344 1 Reverse Diode Crescent

43 1 Cable Gland 347 1 Surge Suppressor

51 1 Air Intake Grille 349 1 O-ring Seal

70 1 NDE Bearing

344343

349

347

70

79

9036

51

1

100

91

37

4

15

30

33

4342

323324

322

28

Fi 29




Figure 93. 2000/3000 Series, Single Bearing.

Table 15. 2000/3000 Series, Single Bearing Parts List.NO. QTY. DESCRIPTION NO. QTY. DESCRIPTION

1 1 Stator Assembly 107 1 Support Diode Assembly

4 1 Rotor Assembly 124 1 Terminal Plate

15 1 Fan 198 1 Regulator (AVR)

16 6 Fan Fixing Screw 207 1 Rubber

28 1 Ground (Earth) Terminal 217 1 Auxiliary Terminal Plate

30 1 DE Flange 290 1 Housing

33 1 Air Outlet Louver 291 1 Adaptation Shaft

36 1 NDE Bracket 292 1 Rotor Magnets

37 4 Tie Rod 293 1 Stator

41 1 DE Terminal Box 294 2 Fixing Screw

47 1 NDE Terminal Box 295 1 Tie Rod

48 1 Terminal Box Lid 296 1 Washer and Nut

49 20 Terminal Box Fixing Screw 297 1 End Plate

51 1 Air Intake Louver 320 1 Hub

59 3 Inspection Door 322 1 Coupling Disc

70 1 NDE Bearing 323 - Fixing Screw


324 1 Clamping Washer

90 1 Wound Exciter Field 325 - Spacer Shim

91 4 Field Fixing Screw 343 1 Diode Bridge Assembly

98 3 Corner Plate 347 1 Surge Suppressor

100 1 Exciter Armature 349 1 O-ring Seal

343

349

347

70

79

90

36

51

48

98

59

1

124

41

47217

198

100107

91

374

1615

1530

33

325

320

322

49

28

- Fig 30 -

207

290291

292293

294295

296297323

324

3000 series coupling

PMG option




Figure 94. 2000/3000 Series, Two Bearing.

Table 16. 2000/3000 Series, Two Bearing Parts List. 14.5.7.4 Accessing Connections and the Regulation SystemThe terminals are accessed by removing the terminal box lid (48).To access the adjustment potentiometers on the AVR, the inspec-tion door (367) should be removed.

14.5.7.5 Accessing, Checking, and Replacing the DiodesNote: The numbers in “[ ]” reference the components in the applicable exploded views.

Dismantling (1000 Series)Step 1: Remove the terminal box lid [48].

Step 2: Remove the air intake louver [51].

Step 3: Unscrew the fixing clamps on the power output cables. Disconnect E+, E- on the exciter, and the R 791 module.

Step 4: Remove the four nuts on the tie rods.

Step 5: Remove the NDE bracket [36] using the U32/350 puller.

Step 6: Remove the surge suppressor [347].

Step 7: Remove the four fixing screws from the diode bridges on the armature.

Step 8: Disconnect the diodes.

Step 9: Check the six diodes using either an ohmmeter or a bat-tery lamp (see Figure 88).

343

349

347

70

79

90

36

51

98

59

1

124

41

48

49

47

198

320

100107

91

2837

4

1530

33

- Fig 31 -

207

1615

6862

290291

292293

294295

296297

217

410

6068

63

67


PMG option

NO. QTY. DESCRIPTION NO. QTY. DESCRIPTION

1 1 Stator Assembly 90 1 Wound Exciter Field

4 1 Rotor Assembly 91 4 Field Fixing Screw

15 1 Fan 100 1 Exciter Armature

16 6 Fan Fixing Screw 107 1 Support Diode Assembly

28 1 Ground (Earth) Terminal 124 1 Terminal Plate

30 1 DE Flange 198 1 Regulator (AVR)

33 1 Air Outlet Louver 207 1 Rubber

36 1 NDE Bracket 217 1 Auxiliary Terminal Plate

37 4 Tie Rod 290 1 Housing

41 1 DE Terminal Box 291 1 Adaptation Shaft

47 1 NDE Terminal Box 292 1 Rotor Magnets

48 1 Terminal Box Lid 293 1 Stator

49 20 Terminal Box Fixing Screw 294 2 Fixing Screw

51 1 Air Intake Louver 295 1 Tie Rod

59 3 Inspection Door 296 1 Washer and Nut

60 1 DE Bearing 297 1 End Plate

62 2 or 4 Cap Fixing Screw 320 1 Hub

63 1 Washer 343 1 Diode Bridge Assembly

67 1 Circlips 347 1 Surge Suppressor

68 1 Bearing Cap 349 1 O-ring Seal

70 1 NDE Bearing 410 1 DE Flange





Reassembly (1000 Series)Step 1: Replace the diodes, respecting the polarity (see Figure

84). Replace the surge suppressor [347].

Step 2: Insert a new O-ring in the bearing housing.

Step 3: Refit the NDE bracket (see Figure 95) and pass the bundle of wires between the top bars of the flange.

Figure 95. Replacing the NDE Bracket.Step 4: Replace the fixing clamps on the cables and the R 791

module.

Step 5: Refit the air intake louver [51].

Step 6: Replace the terminal box lid [48].

2000/3000 SeriesDismantling (2000/3000 Series)Step 1: Remove the air intake louver [51].

Step 2: Remove the surge suppressor [347].

Step 3: Remove the four fixing screws from the diode bridges on the armature.

Step 4: Disconnect the diodes.

Step 5: Check the six diodes using either an ohmmeter or a bat-tery lamp (see Figure 95).

Reassembly (2000/3000 Series)Step 1: Replace the diodes, respecting the polarity (see Figure

88). Replace the surge suppressor [347].



14.5.7.6 Replacing the NDE Bearing on a Single Bearing Alternator

Dismantling (1000 Series)Step 1: Dismantle the NDE bracket [36] (see Section 14.7.5.5 -

Dismantling).

Step 2: Remove the bearing [70] using a puller (see Figure 96).

Figure 96. Removing the NDE Bearing.

Reassembly (1000 Series)Step 1: Heat the inner slip ring of the new bearing by induction or

in a drying oven at 80°C (176°F) (do not use an oil bath) and fit it to the alternator.

Step 2: Place the preloading wavy washer [79] in the flange and fit a new O-ring seal [349].

Step 3: Replace the NDE bracket [36] (see Section 14.7.5.5 – Reassembly).

Dismantling (2000/3000 Series)Step 1: Remove the terminal box lid [48].

Step 2: Remove the air intake louver [51].

Step 3: Unscrew the fixing clamps on the power output cables. Disconnect E+, E- on the exciter, and R 791 module.

Step 4: Remove the four nuts on the tie rods.

Step 5: Remove the NDE bracket [36] using the U32/350 puller.

Step 6: Remove the bearing [70] using a puller (see Figure 96).

- Fig 23 -

Rotor

NDE bracket

M8Threaded bar

- Fig 24 -




Reassembly (2000/3000 Series)Step 1: Heat the inner slip ring of the new bearing by induction or

in a drying oven at 80°C (176°F) (do not use an oil bath) and fit it to the alternator.

Step 2: Place the preloading wavy washer [79] in the flange and fit a new O-ring seal [349]. Refit the NDE bracket (see Figure 97) and pass the bundle of wires between the top bars of the flange.

Figure 97. Installing the NDE Bracket.Step 3: Replace the fixing clamps on the cables and the R 791

module.



14.5.7.7 Replacing the Bearings on a Two Bearing Alternator

DismantlingStep 1: Uncouple the alternator from the engine.

Step 2: Remove the eight assembly screws.

Step 3: Remove the DE flange [30].

Step 4: Remove the NDE bracket (see Section 14.7.5.5 - Disman-tling).

Step 5: Remove both bearings [60] and [70] using a puller.

ReassemblyStep 1: Fit new bearings after heating them by induction or in a

drying oven at 80°C (176°F) (do not use an oil bath).

Step 2: Check that both the preloading wavy washer [79] and new O-ring seal have been fitted [349] on the NDE bracket [36].

Step 3: Replace the DE flange [30] and tighten the eight fixing screws.

Step 4: Check that the whole alternator is correctly assembled and that all screws are fully tightened.

14.5.7.8 Accessing the Main Field and Stator

DismantlingStep 1: Follow the procedure for dismantling bearings (see Sec-

tions 14.7.5.6 and 14.7.5.7).

Step 2: Remove the coupling discs (single bearing machine) or the DE flange (two bearing machine) and insert a tube of the corresponding diameter on the shaft end or a support made according to Figure 98.

Figure 98. Typical Support Made to Hold the Unit.

Step 3: Rest the rotor on one of its poles, and then slide it out. Use the tube as a lever arm to assist dismantling.

Step 4: After extraction, be careful with the fan. It is necessary to replace the fan in case of disassembling.

Note: If intervention is required on the main field (rewinding, replacement of components), the rotor assembly must be rebalanced.

ReassemblyStep 1: Follow the dismantling procedure in reverse order. Take

care not to damage the windings when refitting the rotor in the stator.

Step 2: If you replace the fan, make use of the assembly guide (see Figure 99). Use a tube and a screw to fully install the fan.

Figure 99. Using an Assembly Guide to Install the Fan.Step 3: Follow the procedure for reassembling the bearings (see

Sections 14.7.5.6 and 14.7.5.7).

- Fig 27 -

Rotor

NDE bracket

Threaded bar

- Fig 25 -

- Fig 26 -




14.5.7.9 Installation and Maintenance of the PMG (2000/3000 Series Only)The permanent magnet generator (PMG) reference for the 2000/3000 Series alternator is PMG 1.

Mechanical Fitting

The PMG consists of the following components.• An adaptation shaft (centering of the rotor PMG on alternator

shaft.• A tie rod with screw and washer.• A rotor with 16 magnets.• The housing stator set plus the plastic tube.• The end plate with four CBLXS M5 screws.• The mounting of this set with four HM6 screws.The PMG mechanical assembly procedure is as follows. During the process, refer to Figure 100.

Figure 100. Exploded View of the PMG.

WARNINGAFTER FINAL ADJUSTMENTS, THE ACCESS PANELS OR COVER MUST BE REFITTED TO AVOID THE POTENTIAL FOR ELECTRIC SHOCK.

343

349

347

70

79

90

36

51

48

98

59

1

124

41

47217

198

100107

91

374

1615

1530

33

325

320

322

49

28

- Fig 30 -

207

290291

292293

294295

296297323

324


PMG option




Step 1: Remove the end plate [297] and the plastic obturator of the bracket and top box.

Step 2: Assemble the housing stator set [290] by tightening the four HM6 screws to 8.3 N.m (73.5 in. lbs).

Step 3: Put "Loctite" on the screw [295] and then tighten it in the shaft.

Step 4: Put the rotor with magnets on the adaptation shaft and assemble the set using the two M10 holes to hold the two threaded rods that guide the rotor when inserting it into the stator (be aware of the magnetic attraction strength).

Step 5: Install the end washer [296].

Step 6: Block the set with the M10 nut tightened to 30 N.m (265.5 in. lbs).

Step 7: Install the end plate [297] and tighten the CBLX 5 M5 screws to 5 N.m (44.3 in. lbs).

Step 8: Link the plastic tube to the top box using the end link.

Step 9: Connect the PMG leads to the AVR (see the electrical connection information that follows).

Electrical ConnectionIf this is a new PMG connection to upgrade a shunt alternator, proceed with the following steps.Step 1: Disconnect the wires of R 230A.

Step 2: Remove the R 230 A.

Step 3: Remove the voltage sensing wires 2 and 3 from terminals T8 and T11 and connect them on terminal T2 (wire 2) and T3 (wire 3).

Step 4: Fit the AVR plate using two HM6 screws tightened to 10 N.m (88.5 in. lbs).

Step 5: Be sure that the ST9 strap is open.

Step 6: Connect the three PMG wires (14, 15, and 16), the two exciter field wires (5 and 6), and the two voltage sensing wires (2 and 3) into the AVR according the wiring dia-gram enclosed with the PMG. Change the exciter field connection on the connector located on the back panel of the terminal box (see Figure 101).

Figure 101. Changing the Exciter Field Connection.Typical electrical values of the PMG stator resistance phase to phase 20°C (68°F), 0.7 . The voltage at no load is 73 V.

Series connection (SHUNT) Parallel connection (AREP / PMG)

6-5+

6-

Black

White

Blue

Red

Black

White

Blue

Red+ +

- -

R 230R 448

6-5+

6-+ +

- -

R 438




14.5.8 Electrical Characteristics Tables

14.5.8.1 1000 Series AlternatorsAlternator: 2-/4-pole, 50/60 Hz, No. 6 standard winding (400 V for the excitation values).The voltage and current values are given for no-load operation and operation at rated load with separate field excitation. All values are given at ± 10% (for exact values, request the test report from the factory) and are subject to change without prior warning.

Table 17. 1000 Series Alternator: 2-Pole with Shunt Excitation Resistances at 20°C (68°F) (), 50 / 60 Hz.

Table 18. 1000 Series Alternator: 2-Pole with Shunt Excitation Field Excitation Current "i exc" (A), 400 V, 50 Hz.Symbols: "i exc" - Excitation Current of the Exciter Field.

For 60 Hz alternators, the "i exc" values are approximately 5 to 10 % less.

Table 19. 1000 Series Alternator: 4-Pole with Shunt ExcitationResistances at 20°C (68°F) (), 50/60 Hz

Table 20. 1000 Series Alternator: 4-Pole with Shunt Excitation Field Excitation Current “i exc” (A), 400 V, 50 Hz:Symbols: "i exc" - Excitation Current of the Exciter Field.


Table 21. 1000 Series Alternator: 4-Pole with AREP Excitation Resistances at 20°C (68°F) (), 50/60 Hz.

Table 22. 1000 Series Alternator: 4-Pole with AREP Excitation Field Excitation Current “i exc” (A), 400 V, 50 Hz.Symbols: "i exc" - Excitation Current of the Exciter Field.


14.5.8.2 2000/3000 Series AlternatorsAlternator: 4-pole, 50/60 Hz, No. 6 standard winding (400 V, 50 Hz for the excitation values).The voltage and current values are given for no-load operation and operation at rated load with separate field excitation. All values are given at ± 10% (for exact values, request the test report from the factory) and are subject to change without prior warning.

Table 23. Shunt 2000 Alternator: Resistances at 20°C (68°F) ()

Table 24. Shunt 2000 Alternator: Field Excitation Current “i exec” (A)Symbols: "i exc" - Excitation Current of the Exciter Field.


1012 D F J N P

L/N Stator 0,76 0,61 0,40 0,22 0,16

Rotor 3,13 3,27 3,53 4,06 4,66

Field 23,5 23,5 23,5 23,5 23,5

Armature 0,79 0,79 0,79 0,79 0,79

1012 D F J N P

No-load 0,4 0,4 0,4 0,45 0,4

At Rated Load 1,7 1,7 1,7 1,7 1,7

1014 H L N Q S

L/N Stator 0,70 0,56 0,32 0,21 0,191

Rotor 2,06 2,3 2,71 3,35 3,7

Field 23,5 23,5 23,5 23,5 23,5

Armature 0,51 0,51 0,51 0,51 0,51

1014 H L N Q S

No-load 0,6 0,55 0,6 0,55 0,5

At Rated Load 1,6 1,7 1,6 1,55 1,5

1024 N Q S

L/N Stator 0,35 0,22 0,2

Rotor 2,71 3,35 3,7

Auxiliary Windings, X1, X2 0,3 0,26 0,23

Auxiliary Windings, Z1, Z2 0,5 0,44 0,41

Field 6 6 6

Armature 0,5 0,5 0,5

1024 N Q S

No-load 0,9 0,8 0,75

At Rated Load 2,4 2,35 2,3

2014 B D H J

L/N Stator 0,155 0,128 0,0836 0,0631

Rotor 1,35 1,41 1,76 1,96

Field 19,5 19,5 19,5 19,5

Armature 0,23 0,23 0,23 0,23

2014 B D H J

No-load 0,5 0,5 0,4 0,5

At Rated Load 1,6 1,7 1,5 1,6




Table 25. AREP 2000 Alternator: Resistances at 20°C (68°F) ().

Table 26. AREP or PMG 2000 Alternator: Field Excitation Current “i exec” (A)Symbols: "i exc" - Excitation Current of the Exciter Field.


Table 27. Shunt 3000 Alternator: Resistances at 20°C (68°F) ().

Table 28. Shunt 3000 Alternator: Field Excitation Current “i exec” (A)Symbols: "i exc" - Excitation Current of the Exciter Field.


Table 29. AREP or PMG 3000 Alternator: Resistances at 20°C (68°F) ().

Table 30. AREP 3000 Alternator: Field Excitation Current “i exec” (A)Symbols: "i exc" - Excitation Current of the Exciter Field.


2024 B D H J

L/N Stator 0,155 0,128 0,0836 0,0631

Rotor 1,35 1,41 1,76 1,96

Auxiliary Windings X1, X2 0,32 0,29 0,26 0,21

Auxiliary Windings Z1, Z2 0,52 0,5 0,44 0,4

Field 4,9 4,9 4,9 4,9

Armature 0,23 0,23 0,23 0,23

2024 B D H J

No-load 1 1 0,9 1

At Rated Load 3,2 3,4 3 3,2

3014 B F H

L/N Stator 0,55 0,0235 0,0186

Rotor 2,37 3,32 3,66

Field 19,5 19,5 19,5


3014 B F H

No-load 0,5 0,6 0,6

At Rated Load 2 1,9 2

3024 B F H

L/N Stator 0,055 0,0235 0,0186

Rotor 2,37 3,32 3,66

Auxiliary Windings X1, X2 0,28 0,17 0,16

Auxiliary Windings Z1, Z2 0,44 0,28 0,21

Field 4,9 4,9 4,9


3024 B F H

No-load 1 1,15 1,2

At Rated Load 4 3,7 4




14.6 Troubleshooting

14.6.1 Engine TroubleshootingPROBLEM POSSIBLE CAUSE SOLUTION

The engine will not turn over (crank). Proper control function is not selected.

Loose, disconnected, or corroded electrical leads.

Battery is discharged.

Set the control to Manual or Auto function (see Section13 – Control).

Check all electrical connections at the battery and engine to ensure clean, tight connections.

Charge or replace the battery.

The engine turns over (cranks) but will not start. The fuel pressure is too low.

Fuel is not being delivered to the engine.

The engine ignition system is not working properly.

Ensure that proper fuel pressure is being delivered to the engine (see Section 6.3.3 - Pre-Start Checks).

Ensure that the fuel solenoid is functioning properly. Replace the solenoid if neces-sary.

Check for spark at the spark plugs. Replace the spark plugs and /or spark plug wires if necessary.

Check the electronic ignition module. Replace the ignition module if necessary.

The engine runs hot.

Low coolant level.

The fan belt is loose or broken.

The thermostat is not functioning properly.

Dirty cooling system.

Engine coolant frozen.

Head gasket leaking.

Overloading the generator set, especially in hot weather.

Hot radiator air being recycled within the generator set.

Note: All procedures in the section should be performed when the engine is at ambient temperature.

Add coolant to the radiator to bring the coolant level up to the proper level.

Tighten or replace the fan belt as necessary.

Replace the thermostat.

Clean the radiator fins of leaves, dirt, etc.

Flush and drain the cooling system then install new coolant to the proper level.

Allow the coolant to thaw. Add antifreeze to achieve the manufacturer recom-mended ratio of antifreeze to water.

Examine the head and block mounting surfaces for cracks or other problems. If the mounting surfaces are in good shape, replace the head gasket.

Reduce the load on the generator set to within it rated limits.

Ensure that all air inlets and vents are clear of all debris.




14.6.2 DSE 703 Control Module Troubleshooting

14.6.3 Alternator TroubleshootingFor 1000 Series 2- & 4-Pole and 2000-3000 Series 4-Pole

Mechanical

PROBLEM POSSIBLE CAUSE SOLUTIONS

Generator does not start with manual initiation. Battery is discharged.Emergency Stop button is pressed.An alarm is present.Bad wiring.DSE 703 controller is bad.

Charge or replace the battery.Reset the Emergency Stop Button.Clear the cause of the alarm and press the Stop button to reset the control.Check all electrical connections at back of the controller. Repair / replace as necessaryReplace the controller.

Generator does not start with Auto initiation. Emergency Stop button is pressed.An alarm is present.Automatic Transfer Switch (ATS) Failure.Bad wiring.DSE 703 controller is bad.

Reset the Emergency Stop Button.Clear the cause of the alarm and press the Stop button to reset the control.Verify engine start contact closure from the ATS.Check all electrical connections at back of controller. Repair / replace as necessary.Replace the controller.

Generator does NOT shut down after the Stop button is pushed.

Engine Cool Down time is counting down.Fuel cutoff valve is bad.DSE 703 controller is bad.

Wait for timer to time out.Replace the fuel cutoff valve.Replace the controller.

Generator does NOT shut down after Emergency Stop but-ton is pressed.

Loose wiring.Bad wiring.Bad Emergency Stop switch.DSE 703 controller is bad.

Check all electrical connections at back of controller. Tighten any loose connections.Check all electrical connections at back of controller. Repair / replace as necessary.Replace the Emergency Stop switch.Replace the controller.

Fault indications do NOT clear when the Stop button is pressed.

Fault is still present.DSE 703 controller is bad.

Repair the cause of the fault.Replace the controller.

Cannot program the DSE 703. Program switch not in the correct position.Battery is discharged.DSE 703 controller is bad.

Move the switch to the correct position.Charge or replace the battery.Replace the controller.

For any other problems or questions please contact our Eaton Cutler-Hammer Standby Generator Support Line at 800-975-8331.

PROBLEM POSSIBLE CAUSE SOLUTION

Bearing Defect Excessive overheating of one or both bearings (Temp. of the bearings over 176°F [80°C]) (With or without abnormal bearing noise).

• If the bearing has turned blue or if the grease has turned black, change the bearing.

• Bearing race is badly locked (moving in its housing).• Bracket misalignment.

Overheating Excessive overheating of alternator frame (Temp. rise of more than 219°F [104°C] above ambient).

• Airflow (inlet - outlet) partially clogged or hot air is being recycled either from alternator or prime mover.

• Alternator is functioning at too high a voltage (over 105 % of rated voltage on load).

• Alternator is overloaded.

Vibration Problem Too much vibration.

Excessive vibration and humming noise coming from the alternator

Misalignment (coupling):• Defective mounting or play in the coupling. • Incorrect balancing of the shaft (engine - alternator).

3-phase alternator is single phase loaded in excess of the acceptable level.• Short circuit in the alternator stator.

Abnormal Noises Alternator was damaged by a significant impact that is followed by hum-ming and vibration.

• System short circuit. • Miss paralleling. Possible consequences (according to the seriousness of the above faults):• Broken or damaged coupling. • Broken or bent shaft end. • Shifting and short circuit of main field rotor. • Fractured fan or the fan is coming loose on shaft.• Blown-up rotating diodes, or and AVR.




14.6.4 Electrical Troubleshooting

FAULT ACTION SYMPTOMS CAUSE

No voltage at no-load or start-up. Connect a battery of 4 to 12 V to terminals E+ or E- respecting the polarity on the AVR for 2 to 3 seconds.

The alternator builds up and voltage is correct when the battery is removed.

The alternator builds up but the voltage does not reach nominal value when the battery is removed.

The alternator builds up but the voltage col-lapses when the battery is removed.

• Lack of residual magnetism.

• Check the connection of the sensing leads to the AVR.

• Faulty rotating diode. • Short-circuit on rotor windings.

• Faulty AVR.• Exciter windings shorted or open circuit

(check winding).• Main field winding open circuit (check resis-

tance).

Voltage is too low. Check the prime mover speed. Correct the speed.

Speed is too low.

Check the AVR connections (possible AVR fail-ure):• Exciter field is short-circuited.• Rotating diode(s) is burnt out.• Main field rotor is short-circuited. Check

the resistance.

Increase the speed of prime mover. (Do not touch the AVR voltage pot (P2) before running at the correct speed).

Voltage is too high. Adjust potentiometer voltage. No adjustment of voltage. AVR faulty.

Voltage oscillations. Adjust the stability potentiometer on the AVR. If no effect, change the recovery mode normal / rapid (ST2).

• Check the speed for possible cyclic irregular-ity.

• Loose connections.• Faulty AVR.• Speed is below the nominal on load (or the

load adjustment module (LAM) is set too high).

Voltage is correct on no-load but too low on load (*).

Run on no-load and check voltage between E+ and E-.

1000 Series:Voltage between E+ and E- is< 6 Vdc.

2000/3000 Series:Voltage between E+ and E- is (DC) shunt < 20 V – AREP/PMG < 10 V.

• Check the speed (or the LAM on R 438 is set too high).

1000 Series:Voltage between E+ and E- is > 10 Vdc.

2000/3000 Series:Voltage between E+ and E- is shunt > 30 V – AREP/PMG > 15 V.

• Faulty rotating diodes.• Short circuit in the main field. Check the

resistance.• Faulty exciter armature. Check the resis-

tance.

Voltage collapses during normal operation (**)

Check the AVR, surge suppressor, and the rotat-ing diodes. Replace any defective part.

The output voltage does not return to the rated value.

• Exciter winding is open circuit.• Faulty exciter armature.• Faulty AVR.• Main field rotor winding is open circuit or

short circuit.

WARNING* DURING SINGLE-PHASE OPERATION, CHECK THAT THE SENS-

ING WIRES FROM THE AVR ARE CONNECTED TO THE CORRECT OUTPUT TERMINALS.

** THE AVR INTERNAL PROTECTION MAY CUT IN (OVERLOAD LOST CONNECTION, SHORT CIRCUIT).




15 Spare Parts15.1 Engine Spare PartsTable D-1 in Appendix D gives a list of recommended spare parts, divided by engine type, to keep on hand for liquid cooled standby generator set maintenance. For additional information or ques-tions, contact your Eaton Cutler-Hammer Standby Generator Sup-port LIne at 800-975-8331.

15.2 Alternator Spare PartsTables E-1 through E-3 in Appendix E give lists of recommended spare parts to keep on hand for the alternators used in Eaton Elec-trical liquid cooled standby generators. Table E-1 and E-2 gives information concerning the bearings used in the alternators.For additional information or questions, contact your Eaton Cutler-Hammer Standby Generator Support LIne at 800-975-8331.




Appendix A. Eaton Electrical Liquid Cooled Standby Generator Set Models and Accessories.

Table A-1. Eaton Electrical Liquid Cooled Standby Generator Sets.

Notes: LP = Liquid PropaneNG = Natural GasS = Sound Attenuated

Table A-2. Available Accessories for Eaton Electrical Standby Liquid Cooled Generator Sets.

Note: A 120 V receptacle (from the Utility power source) to power any generator set accessories such as the heater blanket, battery charger, etc. is needed. See Section 9.4.

MODEL # CHGEN10000I(S)

CHGEN15000I(S)

CHGEN17500I(S)

CHGEN20000(S)

CHGEN25000I(S)

CHGEN25000(S)

CHGEN30000(S)

CHGEN35000(S)

CHGEN45000(S)

CHGEN55000(S)

CHGEN75000(S)

Nominal Watts (LP)

10000 15000 17500 20000 25000 25000 30000 35000 45000 55000 75000

Nominal Watts (NG)

10000 15000 17500 20000 25000 22500 30000 35000 42500 55000 70000

Rated Amps (LP)

83.3/41.7 125.0/62.5 145.8/72.9 166.7/83.3 208.3/104.2 208.3/104.2 250.0/125.0 291.7/145.8 375.0/187.5 458.3/229.2 625.0/312.5

Rated Amps (NG)

83.3/41.7 125.0/62.5 145.8/72.9 166.7/83.3 208.3/104.2 188.0/94.0 250.0/125.0 291.7/145.8 354.0/177.0 458.3/229.2 583.0/292

Engine Brand Isuzu Isuzu Isuzu Ford Isuzu Ford Ford Ford Ford Ford Ford

Engine Type In-line 4 In-line 4 In-line 4 In-line 4 In-line 4 In-line 4 V-6 V-6 V-6 V-10 V-10

RPM 1800 1800 3600 1800 3600 1800 1800 1800 1800 1800 1800

Engine Cooling Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid

Non-Sound Attenuated dB 23 ft. (7m)

76.0 76.0 87.2 79.0 88.5 81.0 79.0 79.0 80.0 85.0 85.0

Sound Attenuated dB23 ft. (7m)Full Load

61.9 62.0 73.6 64.2 73.5 65.0 61.65 62.1 63.4 66.4 67.0

Dimensions - in(mm)

53 × 28 × 471346 × 711

× 1194

53 × 28 × 471346 × 711

× 1194

53 × 28 × 471346 × 711

× 1194

61 × 28 × 481549 × 711

× 1219

53 × 28 × 471346 × 711 ×

1194

61 × 28 × 481549 × 711

× 1219

85 × 35 × 612159 × 889

× 1549

85 × 35 × 612159 × 889

× 1549

85 × 35 × 612159 × 889

× 1549

95 × 36 × 612413 × 914

× 1549

95 × 36 × 612413 × 914

× 1549

Weight – lb(kg)

961435.9

994450.9

950430.9

1190539.8

994450.9

1219552.9

2042926.2

2042926.2

2152976.1

25861173.0

26961222.9

Warranty 1 Year 1 Year 1 Year 1 Year 1 Year 1 Year 1 Year 1 Year 1 Year 1 Year 1 Year

ACCESSORY DESCRIPTION

BCK-PBC3U12 Battery Charger, UL 3 A, 120 Vac

BHK-LRG12 Battery Heater, 110-120 Vac (45 kW and Below)

BHK-WSG12 Battery Heater, 110-120 Vac (55 kW and Above)

SHK-HMLRG12 Lube Oil Sump Heater, 120 Vac (25 kW and Below)

SHK-EWSG12 Lube Oil Sump Heater, 120 Vac (30 kW and Above)

AHK-100012 Anti-Condensation Heater, 120 Vac (25 kW and Below)

AHK-200012 Anti-Condensation Heater, 120 Vac (30 kW and Above)




Appendix B. Eaton Electrical Liquid Cooled Standby Generator Set Maintenance Schedules.

Table B-1. Routine and Preventative Maintenance Schedules.

Notes:F = Ford engine service intervals.Z = Isuzu 4ZB1 service intervals.1 = More frequent intervals may be required in dusty areas.2 = Seasonal or as required.* = Scheduled maintenance beyond 1000 hours should be continued at the same intervals as before.

Note: Preventative maintenance and service should ONLY be carried out by qualified technicians. Records of this work should be kept to aid in develop-ing an efficient maintenance program.

INITIAL STARTUP

SEQUENCEOPERATION 100 HRS 200 HRS 300 HRS 400 HRS 500 HRS 600 HRS 700 HRS 800 HRS 900 HRS 1000 HRS*

Routine Maintenance

1 Check Oil Level Weekly

2 Check Coolant Level in Radiator Weekly

3 Check for Fuel, Oil, and Coolant Leaks Weekly

Change Engine Oil1 F F/Z F F/Z F F/Z F F/Z F F/Z

Change Oil Filter1 F F F F/Z F F F F/Z F F

4 Inspect and Clean Air Filter Element Weekly

Replace Air Cleaner1 F/Z F/Z F/Z F/Z F/Z F/Z F/Z F/Z F/Z F/Z

Preventative Maintenance (Performed by Trained, Qualified Technician)

5 Check Battery Charge and Level F/Z F/Z F/Z F/Z F/Z F/Z F/Z F/Z/ F/Z F/Z

Inspect and Clean Radiator Exterior F/Z F/Z F/Z F/Z F/Z

Clean Battery Cables F/Z F/Z F/Z F/Z F/Z

Check and Adjust Valve Clearance (Cold) Z Z Z Z Z

6 Check and Adjust Fan and Battery Charging Alternator Drive Belts

F/Z F/Z F/Z F/Z F/Z

7 Check and/or Refill Cooling System F/Z F/Z

Clean, Adjust, and Test or Replace Spark Plugs

Z F/Z Z F/Z Z

Check and Adjust Ignition Timing Z F/Z Z F/Z Z

Replace PCV Valve (if so equipped) and Check Hoses/Tubes and Fittings

F

Replace Spark Plugs F Z

Replace Coolant2 F/Z

Replace Thermostat Z

Replace Timing Belt Z

Clean Oil Pump Strainer and Sump Z

Check All Bolts and Nuts for Tightness 2 As Needed




Appendix C. DSE 703 Control Module Configuration

Table C-1. Configuration and Functions.

FUNCTION VALUE(DEFAULT IN

BOLD)

Preheat Timer 0 Seconds

5 Seconds

10 Seconds

15 Seconds

20 Seconds

30 Seconds

60 Seconds

180 Seconds

Used to preheat the engine prior to cranking. The output is active for the duration of the setting, prior to cranking.

Start Delay 0 Seconds

5 Seconds

10 Seconds

15 Seconds

20 Seconds

30 Seconds

60 Seconds

180 Seconds

Used to give a delay between activating the remote start input and actually starting the engine.

Stop Delay 0 Seconds

5 Seconds

10 Seconds

15 Seconds

20 Seconds

30 Seconds

60 Seconds

180 Seconds

Used to give a delay between deactivating the remote start input and actually stopping the engine.

Energize to 0 Seconds

Hold Stop 5 Seconds

Timer 10 Seconds

15 Seconds

20 Seconds

30 Seconds

60 Seconds

180 Seconds

Used for the control of the engine stop solenoid. When the engine is to be stopped, the Energize To Stop output becomes active, closing the stop solenoid (fuel valve). When the engine comes to rest, the stop solenoid will remain energized for the period of the Energize To Stop Timer, to ensure the engine has come to a complete stop.

Nominal Frequency

50 Hz (O/S +14% / Overshoot +24%)

60 Hz (O/S +14% / Overshoot +24%)

The system’s nominal frequency. Either 50 or 60 Hz.




Table C-1. Configuration and Functions. (Cont.)


BOLD)

Nominal DC Voltage

12 Vdc (CF 8 V)

24 Vdc (CF 16 V)

The generator battery voltage (either 12 or 24 V. It is used for the Charge Alternator Failure level.

LOP Switch Contact

Close on Fault

Open on Fault

Configuration for the oil pressure switch. Either to close to battery negative on a fault, or open on a fault.

HET SwitchContact

Close on Fault

Open on Fault

Configuration for the coolant temperature switch. Either to close to battery negative on a fault, or open on a fault.

CrankDisconnect on Oil Pressure

Disabled

Enabled (2 Second Delay)

If this is enabled, the starter motor will disconnect 2 seconds after the oil pressure switch detects oil pressure.NOTE : Not suitable for all generators due to the different monitoring points on lubrication systems.

Under-speed Detection

Disabled

Enabled (U/S –20%)

If this is enabled, the unit will shut down the generator if the frequency falls below 20% of the nominal frequency.

Auxiliary Input 1 Function

Immediate WarningClose on Fault

Immediate WarningOpen on Fault

Immediate Shut-downClose on Fault

Immediate Shut-downOpen on Fault

Delayed WarningClose on Fault

Delayed WarningOpen on Fault

Delayed ShutdownClose on Fault

Delayed ShutdownOpen on Fault

Programmable input, can be configured to on of the following:• Immediate warning, close on fault. If the input is activated at any time, the unit will alarm and energize the common warning and common alarm output.• Immediate warning, open on fault. If the input is deactivated at any time, the unit will alarm and energize the common warning and common alarm output.• Immediate shutdown, close on fault. If the input is activated at any time, the generator will be shutdown and energize the common warning and common shutdown output. The generator can-

not be started.• Immediate shutdown, open on fault. If the input is deactivated at any time, the generator will be shutdown and energize the common warning and common shutdown output. The generator can-

not be started.• Delayed warning, close on fault. If the input is activated and the safety time has elapsed, the unit will alarm and energize the common warning and common alarm output.• Delayed warning, open on fault. If the input is deactivated and the safety time has elapsed, the unit will alarm and energize the common warning and common alarm output.• Delayed shutdown, close on fault. If the input is activated and the safety time has elapsed, the generator will be shutdown and energize the common warning and common shutdown output.• Delayed shutdown, open on fault. If the input is deactivated and the safety time has elapsed, the generator will be shutdown and energize the common warning and common shutdown output.






BOLD)

Auxiliary Input 2 Function

ImmediateWarningClose on Fault

Immediate WarningOpen on Fault

Immediate ShutdownClose on Fault

ImmediateShutdownOpen on Fault

Delayed WarningClose on Fault

Delayed WarningOpen on Fault

Delayed ShutdownClose on Fault

Delayed ShutdownOpen on Fault

Programmable input, can be configured to on of the following:• Immediate warning, close on fault. If the input is activated at any time, the unit will alarm and energize the common warning and common alarm output.• Immediate warning, open on fault. If the input is deactivated at any time, the unit will alarm and energize the common warning and common alarm output.• Immediate shutdown, close on fault. If the input is activated at any time, the generator will be shutdown and energize the common warning and common shutdown output. The generator can-

not be started.• Immediate shutdown, open on fault. If the input is deactivated at any time, the generator will be shutdown and energize the common warning and common shutdown output. The generator can-

not be started.• Delayed warning, close on fault. If the input is activated and the safety time has elapsed, the unit will alarm and energize the common warning and common alarm output.• Delayed warning, open on fault. If the input is deactivated and the safety time has elapsed, the unit will alarm and energize the common warning and common alarm output.• Delayed shutdown, close on fault. If the input is activated and the safety time has elapsed, the generator will be shutdown and energize the common warning and common shutdown output.• Delayed shutdown, open on fault. If the input is deactivated and the safety time has elapsed, the generator will be shutdown and energize the common warning and common shutdown output.

Auxiliary Output 1 Function

Not Used

Pre-heat

Engine Running

Common Warning

Common Shutdown

System in Auto

Common Alarm

Energize to Stop

Programmable output, can be configured to one of the following:• Pre-heat - The output is energized for the period of pre-heat time prior to cranking and between the cranking attempts.• Engine Running - The output is active after the safety timer has elapsed.• Common Warning - The output is active if there are any warning alarms active.• Common Shutdown - The output is active if there are any shutdown alarms active.• System in Auto - The output is active when the system is in automatic mode.• Common Alarm - The output is active if there is any alarm condition.• Energize to Stop - The output is energized when the engine is required to stop (normal or fault conditions) and will remain energized for the period of the Energize To Stop timer to ensure the

engine has come to a complete stop.




Abbreviations:LOP = Low Oil PressureHET = High Engine TemperatureU/S = Under-speedO/S = Over-speed



BOLD)

Auxiliary Output 2 Function

Not Used

Pre-heat

Engine Running

Common Warning

Common Shutdown

System in Auto

Common Alarm

Energize to Stop

Programmable output can be configured to one of the following:• Pre-heat - The output is energized for the period of pre-heat time prior to cranking and between the cranking attempts.• Engine Running - The output is active after the safety timer has elapsed.• Common Warning - The output is active if there are any warning alarms active.• Common Shutdown - The output is active if there are any shutdown alarms active.• System in Auto - The output is active when the system is in automatic mode.• Common Alarm - The output is active if there is any alarm condition.• Energize to Stop - The output is energized when the engine is required to stop (normal or fault conditions) and will remain energized for the period of the Energize To Stop timer to ensure the

engine has come to a complete stop.




Appendix D. Eaton Electrical Recommended Spare Generator Set PartsNote: Note: IF a part is needed that is not listed in this Appendix, contact Eaton Cutler-Hammer Standby Generator Support Line at 800-975-8331.

Table D-1. Recommended Spare Parts by Engine Model.

MODEL ENGINE MANUFACTURER

CHGEN10000I(S) 4ZB1

IsuzuCHGEN15000I(S) 4ZB1

CHGEN17500I(S) 4ZB1

CHGEN25000I(S) 4ZB1

CHGEN20000(S) LRG425Ford

CHGEN25000(S) LRG425

CHGEN30000(S) ESG642Ford

CHGEN35000(S) ESG642

CHGEN45000(S) ESG642

CHGEN55000(S) WSG1068Ford

CHGEN75000(S) WSG1068

ENGINE PART # DESCRIPTION ENGINE PART # DESCRIPTION

4ZB1 160-252 Air Filter Element LRG425 342-065 Radiator Hose, Top

4ZB1 951-179 Oil Filter Element LRG425 342-066 Radiator Hose, Bottom

4ZB1 951-231 Fan Belt LRG425 952-076 Front Oil Seal

4ZB1 951-899 Timing Belt LRG425 952-069 Rear Oil Seal

4ZB1 951-066 Cylinder Head Cover Gasket LRG425 952-123 Water Pump Gasket

4ZB1 951-079 Thermostat LRG425 952-107 Inlet Valve

4ZB1 951-102 Spark Plug LRG425 952-104 Exhaust Valve

4ZB1 951-098 Cable Kit HT LRG425 952-111 Valve Spring

4ZB1 951-106 Repair Kit, Cylinder Head Overhaul LRG425 622-333 LOP Switch Sender

4ZB1 342-060 Radiator Hose, Top LRG425 622-341 HWT Switch Sender

4ZB1 342-061 Radiator Hose, Bottom LRG425 596-795 Solenoid (Gas Train)

4ZB1 951-182 Front Oil Seal LRG425 116-009 Regulator (Gas Train)

4ZB1 951-075 Water Pump Gasket LRG425 922-192 Spartner Kit (Shunt)

4ZB1 951-210 Valve Spring LRG425 650-433 Deep Sea Electric 703 Control Module

4ZB1 622-333 LOP Switch Sender LRG425 160-252 Air Filter

4ZB1 171-234 HWT Switch Sender LRG425 952-229 Oil Filter

4ZB1 596-795 Solenoid (Gas Train) LRG425 952-030 Fan Belt

4ZB1 116-009 Regulator (Gas Train) LRG425 952-033 Timing Belt

4ZB1 922-192 Spartner Kit (Shunt) LRG425 952-038 Thermostat

4ZB1 650-433 Deep Sea Electric 703 Control Module LRG425 952-096 Cylinder Head Gasket

LRG425 952-035 Spark Plug




ENGINE PART # DESCRIPTION ENGINE PART # DESCRIPTION

ESG642 160-250 Air Filter Element WSG1068 160-146 Air Filter Element

ESG642 952-968 Oil Filter Element WSG1068 952-779 Oil Filter Element

ESG642 953-072 Belt WSG1068 952-887 Belt

ESG642 953-009 Rocker Cover Gasket WSG1068 952-825 Rocker Cover Gasket

ESG642 953-017 Thermostat WSG1068 952-743 Thermostat

ESG642 953-029 Spark Plug WSG1068 952-813 Spark Plug

ESG642 953-091 Cable Kit HT WSG1068 952-908 Cable Kit HT

ESG642 953-030 Ignition Coil WSG1068 952-857 Ignition Coil

ESG642 952-992 Cylinder Heat Gasket WSG1068 952-799 Gasket, Cylinder Head (R.H.)

ESG642 953-009 Rocker Cover Gasket WSG1068 952-800 Gasket , Cylinder Head (L.H.)

ESG642 342-213 Radiator Hose, Top WSG1068 342-205 Radiator Hose, Top

ESG642 342-214 Radiator Hose, Bottom WSG1068 342-206 Radiator Hose, Bottom

ESG642 952-939 Timing Chain WSG1068 952-837 Front Oil Seal, Front Entry

ESG642 952-967 Front Oil Seal, Front Entry WSG1068 952-766 Rear Oil Seal

ESG642 952-961 Rear Oil Seal WSG1068 952-738 Water Pump Gasket

ESG642 953-012 Water Pump Gasket WSG1068 952-807 Inlet/Exhaust Valve

ESG642 952-996 Inlet Valve WSG1068 952-809 Valve Spring, Intake/Exhaust

ESG642 952-995 Exhaust Valve WSG1068 622-333 LOP Switch Sender

ESG642 952-998 Valve Spring, Intake/Exhaust WSG1068 622-341 HWT Switch Sender

ESG642 622-333 LOP Switch Sender WSG1068 596-798 Solenoid (Gas Train)

ESG642 622-341 HWT Switch Sender WSG1068 116-006 Regulator (Gas Train)

ESG642 596-795 Solenoid (Gas Train) WSG1068 922-216 Spartner Kit (Shunt)

ESG642 116-009 Regulator (Gas Train) WSG1068 650-433 Deep Sea Electric 703 Control Module

ESG642 922-192 Spartner Kit (Shunt)

ESG642 650-433 Deep Sea Electric 703 Control Module




Appendix E. Recommended Alternator Spare Parts

Table E-1. Recommended Spare Parts for the 1000 Series Shunt Alternator.

Table E-2. Recommended Spare Parts for the 1000 Series AREP Alternator.

Table E-3. Recommended Spare Parts for the 2000/3000 Series Alternators.

NO. DESCRIPTION QTY. 1000 – SHUNT CODING PART #

198 Voltage Regulator (AVR) 1 R 230 B ESC 110 CU 003 922-197

343 Diode Bridge Assembly 1 LSA 411.1.59/60 ESC 025 MD 008 922-220

347 Surge Suppressor 1 LSA 411.1.17A CII 411 EQ 017 922-221

AVR Fuse 1 250 V - 8 A/Slow 922-222

OTHER PARTS

70 NDE Bearing 1 6305 2RS/C3 RLT 025 TN 030 922-234

Emergency Kits (Shunt) 1 922-192

NO. DESCRIPTION QTY. 1000 – AREP CODING PART #

198 Voltage Regulator (AVR) 1 R 438 LS ESC 220 CU 025 922-045

343 Diode Bridge Assembly 1 LSA 411.1.59/60 ESC 025 MD 008 922-220

347 Surge Suppressor 1 LSA 411.1.17A CII 411 EQ 017 922-221

AVR Fuse 2 250 V - 8 A/Fast 922-222

OTHER PARTS

70 NDE Bearing 1 6305 2RS/C3 RLT 025 TN 030 922-234

Emergency Kits (AREP) 1 922-196

NO. DESCRIPTION QTY. L 2000 PART # L 3000 PART #

Emergency Kit (Shunt) 1 922-216 922-218

198 Voltage Regulator (AVR) 1 R 230 922-197 R 230 922-197

343 Diode Bridge Assembly 1 LSA 432 9 03/04 922-230 LSA 432 9 03/04 922-230

347 Surge Suppressor 1 LSA 432 1 13 922-231 LSA 432 1 13 922-231

AVR Fuse 2 250 V, 8 A/Slow 922-222 250 V, 8 A/Slow 922-222

Emergency Kit (AREP/MPG) 922-217 922-219

198 Voltage Regulator (AVR) 1 R 438 922-197 R 438 922-197OTHER PARTS

70 NDE Bearing 1 6307 2RS/C3 954-039 6309 2RS/C3 954-232




Appendix F. Eaton Electrical Liquid Cooled Standby Generator Set Technical Data.F.1 Technical Data

Table F-1. Technical Data for Eaton Electrical Liquid Cooled Standby Generator Sets.

Note: * Estimate: Based on 1 gallon of LP producing 36.3 Cfm (1.03 M3/hr) of vapor. Dependent on the temperature and the amount of fuel in the fuel tank.

DESCRIPTION UNITS CHGEN10000I(S) CHGEN15000I(S) CHGEN17500I(S)

LP GAS NATURAL GAS LP GAS NATURAL GAS LP GAS NATURAL GAS

Ratings

Kilowatt Power kW (kVA) 10.0 (10.0) 10.0 (10.0) 15.0 (15.0) 15.0 (15.0) 17.5 (17.5) 17.5 (17.5)

Amperes @ 240 Volts

Amperes 42 42 63 63 73 73

Fuel System – Gen. Set Fuel Consumption

100% Load Cfh (M3/hr) 57.9 (1.64) 160.0 (4.5) 84.6 (2.4) 234.0 (6.6) 118.0 (3.3) 326.0 (9.2)

75% Load Cfh (M3/hr) 44.5 (1.3) 123.0 (3.5) 64.5 (1.8) 178.5 (5.1) 92.0 (2.6 255.0 (7.2)

50% Load Cfh (M3/hr) 31.1 (0.9) 86.0 (2.4) 44.5 (1.3) 123.) (3.5) 66.0 (1.9) 184.0 (5.2

100% Load gal/hr* 1.60 N.A. 2.33 N.A. 3.25 N.A.

75% Load gal/hr* 1.23 N.A 1.78 N.A 2.53 N.A


Air Requirements

Combustion Air Flow

Cfm (m3/min.) 35.3 (1.0) 35.3 (1.0) 57.2 (1.6) 57.2 (1.6) 77.8 (2.2 73.7 (2.1)

Max. Air Cleaner Restriction

In H2O (kPA) 5.9 (1.5) 5.9 (1.5) 5.9 (1.5) 5.9 (1.5) 5.9 (1.5) 5.9 (1.5)

Radiator Cooling Air (Zero Restricted)

Cfm (m3/min.) 2670.0 (75.6) 2670.0 (75.6) 2670.0 (75.6) 2670.0 (75.6) 4386.0 (124.2) 4386.0 (124.2)

Generator Cooling Air

Cfm (m3/min.) 381.0 (10.8) 381.0 (10.8) 381.0 (10.8) 381.0 (10.8) 551.0 (15.6) 551.0 (15.6)

Allowable Air Flow Restriction (After Radiator)

In H2O (kPA) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125) 1.0 (0.247) 1.0 (0.247)

Cooling Air Flow (at Rated Speed) Rate with Restriction

Cfm (m3/min.) 2224.0 (63.0) 2224.0 (63.0) 2224.0 (63.0) 2224.0 (63.0) 4237.0 (120.0) 4237.0 (120.0)

Exhaust System

Max. Allowable Backpressure

In Hg (kPA) 5.1 (17.3) 5.1 (17.3) 5.1 (17.3) 5.1 (17.3) 5.1 (17.3) 5.1 (17.3)

Exhaust Flow at Rated kW

Cfm (m3/min.) 101.5 (2.9) 110.0 (3.1) 170.5 (4.8) 170.5 (4.8) 367.0 (7.0) 367.0 (7.0)

Exhaust Temp. at Rated kW – Dry Exhaust

°F (°C) 1039.0 (559.0) 1062.0 (572.0) 1100.0 (593.0) 1133.0 (612.0) 1171.0 (633.0) 1171.0 (633.0)




Table F-1. Technical Data for Eaton Electrical Liquid Cooled Standby Generator Sets (Cont.).


DESCRIPTION UNITS CHGEN20000(S) CHGEN25000I(S) CHGEN25000(S)


Ratings


Amperes @ 240 Volts

Amperes 83 83 104 104 104 104


100% Load Cfh (M3/hr) 111.0 (3.1) 306.0 (8.7) 162.0 (4.6) 447.0 (12.7) 138.0 (3.9) 321.0 (9.1)

75% Load Cfh (M3/hr) 83.0 (2.4) 230.0 (6.5) 125.0 (3.6) 347.0 (9.8) 103.0 (2.9) 241.0 (6.8)

50% Load Cfh (M3/hr) 56.0 (1.6) 155.0 (4/4) 89.0 (2.5) 245.0 (6.9) 70.0 (2.0) 162.0 (4.6)




Air Requirements

Combustion Air Flow

Cfm (m3/min.) 79.5 (2.2) 79.5 (2.2) 113.0 (3.2) 106.0 (3.0) 79.5 (2.2) 79.5 (2.2)


In H2O (kPA) 10.0 (2.5) 10.0 (2.5) 5.9 (1.5) 5.9 (1.5) 10.0 (2.5) 10.0 (2.5)


Cfm (m3/min.) 2755.0 (78.0) 2755.0 (78.0) 4386.0 (124.2) 4386.0 (124.2) 2755.0 (78.0) 2755.0 (78.0)


Cfm (m3/min.) 382.0 (10.8) 382.0 (10.8) 551.0 (15.6) 551.0 (15.6) 382.0 (10.8) 382.0 (10.8)


In H2O (kPA) 0.5 (0.125) 0.5 (0.125) 1.0 (0.247) 1.0 (0.247) 0.5 (0.125) 0.5 (0.125)


Cfm (m3/min.) 1906.0 (54.0) 1906.0 (54.0) 4237.0 (120.0) 4237.0 (120.0) 1906.0 (54.0) 1906.0 (54.0)

Exhaust System


In Hg (kPA) 2.7 (9.1) 2.7 (9.1) 5.1 (17.3) 2.7 (9.1) 2.7 (9.1)


Cfm (m3/min.) 252.0 (7.1) 252.0 (7.1) 367.0 (10.4) 370.5 (10.5) 252.0 (7.1) 252.0 (7.1)


°F (°C) 1213.0 (656.0) 1213.0 (656.0) 1234.0 (668.0) 1247.0 (675.0) 1213.0 (656.0) 1198.0 (648.0)






DESCRIPTION UNITS CHGEN30000(S) CHGEN35000(S) CHGEN45000(S)


Ratings


Amperes @ 240 Volts

Amperes 125 125 146 146 188 177


100% Load Cfh (M3/hr) 167.0 (4.7) 462.0 (13.1) 190.0 (5.4) 526.0 (14.9) 243.0 (6.8) 635.0 (18.0)

75% Load Cfh (M3/hr) 127.0 (3.6) 351.0 (10.0) 144.0 (4.1) 400.0 (11.3) 183.0 (5.2) 481.0 (13.6)

50% Load Cfh (M3/hr) 87.0 (2.4) 240.0 (12.1) 98.0 (2.8) 272.0 (7.7) 124.0 (3.5) 327.0 (9.3)




Air Requirements

Combustion Air Flow

Cfm (m3/min.) 53.0 (1.5) 53.0 (1.5) 64.0 (1.8) 64.0 (1.8) 81.0 (2.3) 74.0 (2.1)


In H2O (kPA) 10.1 (2.5) 10.1 (2.5) 10.1 (2.5) 10.1 (2.5) 10.1 (2.5) 10.1 (2.5)


Cfm (m3/min.) 6356.0 (180.0) 6356.0 (180.0) 6356.0 (180.0) 6356.0 (180.0) 6356.0 (180.0) 6356.0 (180.0)


Cfm (m3/min.) 678.0 (19.2) 678.0 (19.2) 678.0 (19.2) 678.0 (19.2) 678.0 (19.2) 678.0 (19.2)


In H2O (kPA) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125)


Cfm (m3/min.) 4238.0 (120.0) 4238.0 (120.0) 4238.0 (120.0) 4238.0 (120.0) 4238.0 (120.0) 4238.0 (120.0)

Exhaust System


In Hg (kPA) 4.5 (15.3) 4.5 (15.3) 4.5 (15.3) 4.5 (15.3) 4.5 (15.3) 4.5 (15.3)


Cfm (m3/min.) 141.0 (4.0) 141.0 (4.0) 170.0 (4.8) 170.0 (4.8) 212.0 (6.0) 198.0 (5.6)


°F (°C) 1080.0 (584.0) 1080.0 (584.0) 1122.0 (607.0) 1122.0 (607.0) 1208.0 (653.0) 1187.0 (642.0)






F.2 Generator Sizing Information

Table F-2. Motor Load Reference (Amperes) – Air Conditioning and Heat Pumps.

Table F-3. Typical Residential Motor Loads (Amperes).

DESCRIPTION UNITS CHGEN55000(S) CHGEN75000(S)

LP GAS NATURAL GAS LP GAS NATURAL GAS

Ratings

Kilowatt Power kW (kVA) 55.0 (55.0) 55.0 (55.0) 75.0 (75.0) 70.0 (70.0)

Amperes @ 240 Volts Amperes 229 229 313 292


100% Load Cfh (M3/hr) 239.0 (6.8) 661.0 (18.7) 323.0 (9.2) 836.0 (23.6)

75% Load Cfh (M3/hr) 181.0 (5.1) 501.0 (14.2) 244.0 (6.9) 632.0 (17.9)

50% Load Cfh (M3/hr) 124.0 (3.5) 341.0 (9.7) 166.0 (4.7) 429.0 (12.1)

100% Load gal/hr* 6.58 N.A. 8.90 N.A.

75% Load gal/hr* 4.99 N.A 6.72 N.A

50% Load gal/hr* 3.42 N.A 4.57 N.A

Air Requirements

Combustion Air Flow Cfm (m3/min.) 111.0 (3.1) 106.0 (3.0) 142.0 (4.0) 127.0 (3.6)

Max. Air Cleaner Restriction In H2O (kPA) 10.1 (2.5) 10.1 (2.5) 10.1 (2.5) 10.1 (2.5)


Cfm (m3/min.) 8433.0 (239.0) 8433.0 (239.0) 8433.0 (239.0) 8433.0 (239.0)

Generator Cooling Air Cfm (m3/min.) 678.0 (19.2) 678.0 (19.2) 933.0 (26.4) 932.0 (26.4)

Allowable Air Flow Restric-tion (After Radiator)

In H2O (kPA) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125) 0.5 (0.125)


Cfm (m3/min.) 5721.0 (162.0) 5721.0 (162.0) 5721.0 (162.0) 5721.0 (162.0)

Exhaust System

Max. Allowable Backpres-sure

In Hg (kPA) 4.5 (15.3) 4.5 (15.3) 4.5 (15.3) 4.5 (15.3)

Exhaust Flow at Rated kW Cfm (m3/min.) 452.0 (12.8) 434.0 (12.3) 575.0 (16.3) 516.0 (14.6)


°F (°C) 1140.0 (616.0) 1127.0 (609.0) 1206.0 (652.0) 1173.0 (634.0)

CAPACITY HP RUNNING LOAD STARTING LOAD

1 Ø, 240 V 1 Ø, 240 V

1 Ton (12,000 BTU) 1 5 25

2 Ton (24,000 BTU) 2 10 50

3 Ton (36,000 BTU) 3 15 75

4 Ton (48,000 BTU) 4 20 100

5 Ton (60,000 BTU) 5 25 125

10 Ton (120,000 BTU) 10 49 250

DESCRIPTION HP RUNNING LOAD STARTING LOAD

1 Ø, 120 V 1 Ø, 240 V 1 Ø, 120 V 1 Ø, 240 V

Sump Pump, Furnace, Garage Door Opener, Washer

0.50 4.9 2.5 25 13

Septic Grinder 0.75 7.4 3.7 38 19

General 1 HP 1 9.8 4.9 50 25

Septic Lift Pump 2 19.6 9.8 100 50




Table F-4. Typical Residential Non-Motor Loads (Amperes).

Table F-5. Power Conversion Table.

DESCRIPTION RUNNING LOAD1 Ø, 120 V

DESCRIPTION STARTING LOAD1 Ø, 240 V

Receptacles (per 1000 ft2 [92.9 m2]) 8.3 Electric Heat (per 1000 ft2 [92.9 m2]) 50

Lighting (per 1000 ft2 [92.9 m2]) 6.3 Heat Pump (Elements per 1000 ft2 [92.9 m2]) 29

Blow Dryer 10.4 Gas Dryer 23

Dish Washer 12.5 Hot Tub 21

Microwave 8.3 Electric Oven 21

Toaster 8.3 Water Heater 19

Electric Stove (per Element) 6

KW RATED AMPERES(60 HZ @ SPECIFIED POWER FACTOR)

120/240 V1 Ø - 1 PF

10 42

15 63

17.5 73

20 83

25 104

30 125

35 146

45 188

55 229

75 313




Appendix G. Drawings and Schematics.Dimensional: WeatherproofEaton Catalog number: CHGEN10000I, CHGEN15000I, CHGEN175000I, and CHGEN25000I




Dimensional: Weatherproof (Cont.)Eaton Catalog Number: CHGEN20000 and CHGEN25000




Dimensional: Weatherproof (Cont.)Eaton Catalog number: CHGEN30000, CHGEN35000, and CHGEN45000




Dimensional: Weatherproof (Cont.)Eaton Catalog number: CHGEN55000 and CHGEN75000




Dimensional: Sound Attenuated EnclosersEaton Catalog number: CHGEN10000IS, CHGEN15000IS, CHGEN175000IS, and CHGEN25000IS




Dimensional: Sound Attenuated Enclosers (Cont.)Eaton Catalog number: CHGEN20000S and CHGEN25000S




Dimensional: Sound Attenuated Enclosers (Cont.)Eaton Catalog number: CHGEN30000S, CHGEN35000S and CHGEN45000S




Dimensional: Sound Attenuated Enclosers (Cont.)Eaton Catalog number: CHGEN55000S and CHGEN75000S




ElectricalEaton Catalog number: CHGEN10000I(S), CHGEN15000I(S), CHGEN175000I(S), and CHGEN25000I(S)




Electrical (Cont.)Eaton Catalog number: CHGEN20000(S) and CHGEN25000(S)




Electrical (Cont.)Eaton Catalog number: CHGEN30000(S), CHGEN35000(S), CHGEN45000(S), CHGEN55000(S) and CHGEN75000(S)




Electrical (Cont.)Optional Feature Wire Diagrams




Residential Standby Generator Set Warranty Information

Limited Warranty

Eaton Electrical Inc. warrants its Eaton Generator product to be free from failure due to defects in material and workmanship under normal care and proper usage for a period of 2 years or 500 hours of run time, whichever is shorter, from the date of pur-chase.

In the event the product fails to comply with this warranty, Eaton Electrical will, at its option, either repair or replace the product without charge. To obtain warranty service the purchaser should return the product to the place of purchase or deliver the product prepaid to Eaton Electrical at the address set forth below. Proof of purchase in the form of a receipt or invoice, which is evidence that the unit is within the warranty period, must be presented to obtain warranty service.

This warranty does not cover failure or damage due to improper storage, installation, operation, maintenance, accident, misuse, abuse or negligence. This warranty does not cover reimbursement for labor, connected loads, transportation, gaining access, removal, installation, temporary power, or any other expenses, which may be incurred in connection with repair or replacement. The warranty covers residential use of Eaton Generators and excludes any commercial application.

Repair or replacement as provided under this warranty is the exclusive remedy of the purchaser and the limit of the liability of Eaton Electrical Inc. with respect to this product, whether in con-tract, in tort (including negligence or strict liability) or otherwise. Eaton Electrical disclaims all other warranties, including without limitation any implied warranty of merchantability or of fitness for a particular purpose, and shall not be liable for any incidental or consequential damages.

With respect to products purchased by consumers of the United States for personal use, the implied warranties, including but not limited to the warranties of merchantability and of fitness for a particular purpose, are not excluded but are limited to the duration of the warranty period. Some states do not allow the exclusion or limitation of incidental or consequential damages or implied war-ranties, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

© 2006 Eaton CorporationAll Rights Reserved

Eaton Electrical Inc.Residential Products Division1000 Cherrington ParkwayMoon Township, PA 15108-4312USAtel: 1-800-525-2000www.eatonelectrical.com

Printed in USAPublication No. IB00407001E / TBG00125November 2006

Documents

O&M Manual for Eaton Standby Liquid Cooled …pub/@electrical/...IB00407001E For more information visit: O&M Manual for Eaton Standby Liquid Cooled Generator Sets Instructional Booklet