Carrier ASPASICCA007 User's Manual
Contents
1. Owner s Manual Air cooled Prepackaged Automatic Standby Generators C UL US Models ASPAS1CCA007 6 kW NG 7 kW LP LISTED ASPAS1CCA012 12 kW NG 12 kW LP ASPAS1CCA015 13 kW NG 15 kW LP AAAAAA ARARAN A Not intended for use as Primary Power in place of utility or in A life support applications A Es A DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model of the Carrier product line This model is a compact high performance air cooled engine driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure This unit is factory installed in an all weather metal enclosure that is intended exclusively for outdoor installation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Carrier Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows2. A EG A After this heading read instructions that if not strictly complied with will result in serious personal injury including death in addition to property damage warninc 4 amp After this heading read instructions that if not strictly complied with may result in serious personal injury or property damage A caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows A This symbol points out important safety information that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard A This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard Carrier The operator is responsible for proper and safe use of the equipment Carrier strongly recommends that the operator read this Owners Manual and thoroughly understand all instructions before using this equipment Carrier also
3. 8 Tttt The 8 Section 2 Operation 2 1 Break in 9 2 2 Using the Auto Off Manual Switch 9 2 3 Automatic Transfer Operation 10 2 4 Sequence of Automatic Operation 10 2 5 Manual Transfer cee 11 2 6 Setting the Exercise 11 2 7 Protection Systems 12 Table of Contents SOE CONTENTS Section 3 Maintenance 12 St aes ae Ae ais 12 3 2 Checking the Engine Oil 6 13 33 Changing the Engine 13 3 4 Changing the Oil Filter eee 14 3 5 Changing the Engine Air 14 3 6 Spark Plug S oo 14 3 7 Battery 15 3 8 Cooling Systemin eeens 15 3 9 Corrosion 16 3 10 Attention After 16 3 11 Out of
4. The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touching the battery by first touching a grounded metal surface A Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected A Be sure the utility power supply is turned off and the 7 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as the cables are attached and cause an explosion OPERATION Section 2 Operation Carrier Air cooled 7 kW 12 kW and 15 kW Generators J Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries When replacing the battery use the following type of battery Group 26 12 volt DC negative ground battery with a rating of 350 cold cranking amps minimum for 7 kW 525 cold cranking amps minimum for 12 and 15 kW at 17 8 C 0 F mi
5. 0 030 inch for 7 kW and 0 50 mm 0 020 inch for 12 kW and 15 kW by carefully bending the ground electrode Figure 3 7 Carrier Air cooled 7 kW 12 kW and 15 kW Generators Figure 3 7 Setting the Spark Plug Gap SET PLUG GAP AT 0 76 mm 030 inch 7 kW 0 508 mm 020 inch 12 kW amp 15 kW 3 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 1 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 Have the state of charge and condition checked This should be done with an automotive type battery hydrometer A EX A A Do not dispose of the battery in a fire The battery is capable of exploding A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove the 7 5A and 15A fuses from the generator control panel Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots e Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or disconnecting battery terminals warninc 4 amp Do not
6. 1 9 LOCATION 1 9 1 LIFTING THE GENERATOR To lift the generator insert pipe having sufficient strength and diameter through the lifting holes which are located near the unit s base see Figure 1 1 and 1 2 page 5 You may also lift the unit using a hook and hoist method provided you utilize a spreader bar to ensure that the lifting lines clear the roof panel A A When lifting or hoisting equipment is used be careful not to contact overhead power lines At generators weight of more than 300 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking Section 1 General Information Carrier Air cooled 7 kW 12 kW and 15 kW Generators GENERAL INFORMATION 1 9 2 GENERATOR h Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drifting consider using a windbreak to protect the unit e Install the generator on high ground where water levels will not rise and endanger it e Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow three feet of space on all sides Where strong prevailing winds blow from one direction face the gen
7. A Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure 3 3 2 OIL CHANGE PROCEDURE To change the oil proceed as follows 1 Run the engine until it is thoroughly warmed up then shut OFF the engine 2 Immediately after the engine shuts OFF pull the oil drain hose Figure 3 4 free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 Refill with the proper recommended oil see Section 3 3 1 See Section 1 5 2 for oil capacities Carrier 13 MAINTENENANCE 28 Section 3 Maintenance Figure 3 4 Oil Drain Hose and Filter Low Oil Switch High Temp Switch 3 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean engine oil to the gasket of the new filter See Section 1 5 2 for recommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 3 4 4 Refill with the proper recommended oil see Section 3 3 1 See Section 1 5 2 for oil capacities 5 Start the engine and check for leaks 3 5
8. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Carrier will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If during such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty p
9. CHANGING THE ENGINE AIR CLEANER 3 5 1 7 KW 12 KW AND 15 KW GENERATORS See Figures 1 1 and 1 2 for the location of the air cleaner Use the following procedure Figures 3 5 amp 3 6 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box 5 Install the cover Turn the two cover screws clockwise to tighten See the Service Schedule Section 4 1 for air cleaner maintenance See Section 1 5 1 for air filter replacement part number 14 Carrier Carrier Air cooled 7 kW 12 kW and 15 kW Generators Figure 3 5 7 kW Engine Air Cleaner Location Fuel Air Cleaner Regulator 3 4 Hole Figure 3 6 12 kW and 15 kW Engine Air Cleaner 3 6 SPARK PLUG S Reset the spark plug s gap or replace the spark plug s as necessary See Section 4 1 for maintenance requirements 1 Clean the area around the base of the spark plug s to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug s to clean 2 Remove the spark plug s and check the condition Replace the spark plug s if worn or if reuse is questionable See Section 4 1 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm
10. Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturers application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be
11. Service Procedure 16 Section 4 5 17 4 1 Service Schedule cerot iea 17 Section 5 Troubleshooting 18 5 1 Troubleshooting 18 Section 6 1 19 Carrier 1 f SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment WARNING A The engine exhaust from this product contains chemicals known to the state e For safety reasons Carrier recommends that the of California to cause cancer birth installation initial start up and maintenance of this defects or other reproductive harm equipment is carried out by a Carrier Dealer e The engine exhaust fumes contain carbon monoxide Al which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict compliance with applicable codes and standards Following installation do nothing that might render the system Study these SAFETY RULES carefully before installing unsafe or in noncompliance with such codes and operating or servicing this equipment Become
12. Standby system the decision is made to provide back up power to a bedroom branch circuit then the circuit breaker in the Carrier Transfer Switch should be replaced with an Arc Fault Circuit Interrupter It is most important that breakers only be switched like for like For instance if replacing a 15A breaker it MUST be replaced with a 15A breaker Likewise a 20A breaker MUST be replaced with a 20A These AFCI breakers are available at the nearest electrical wholesaler or hardware store Description 15A Single Pole 20A Single Pole AFCI Siemens Item Q115AF Q120AF 1 4 THE GENERATOR Section 1 General Information Carrier Air cooled 7 kW 12 kW and 15 kW Generators Figure 1 1 7 kW Single Cylinder GH 410 Engine Exhaust Enclosure Figure 1 2 12 kW and 15 kW V twin GT 990 Engine Exhaust Enclosure FLES ammm Y aee Control Data Panel 7 Dipstick Decal X 7 Outlet BAD os 3 Fuel 4 Regulator wa 4 ak ie Fuel 3 9 gt al KO E lo OL
13. Stop the unit by setting the AUTO OFF MANUAL switch to OFF 9 Turn on the utility power to the transfer switch 10 Set the AUTO OFF MANUAL switch to AUTO 11 The generator is now ready for service NOTE If the battery was dead or disconnected the exercise timer must be reset Section 4 Service Schedule Carrier Air cooled 7 kW 12 kW and 15 kW Generators SERVICE 2D 4 1 SERVICE SCHEDULE ATTENTION It is recommended that all service work be performed by the nearest Carrier Dealer SYSTEM COMPONENT PROCEDURE FREQUENCY X Action inspect Change Clean W Weekly R Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections LUBRICATION Oil level AFTER BREAK IN Oil filter AFTER BREAK IN COOLING Enciosure louvers BATTERY Remove corrosion ensure dryness Clean and tighten battery terminals Check charge state Electrolyte level unsealed batteries only ENGINE AND MOUNTING Air cleaner Spark plug s GENERAL CONDITION Vibration Noise Leakage Temperature COMPLETE TUNE UP TO BE COMPLETED BY A CARRIER DEALER Carrier 17 TROUBLESHOOTING Section 5 Troubleshooting Carrier Air cooled 7 kW 12 kW and 15 kW Generators 5 1 TROUBLESHOOTING GUIDE CAUSE PROBLEM The engine will not crank The engine cranks but will not start 1 Fuse blown Loose corroded or defective battery cables Defective start
14. automatic transfer switches Any Carrier generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustmenis installation and start up Steel enclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to accident misuse abuse negligence or improper installation As with all mechanical devices the Carrier engines need periodic part s service and replacement to perform well Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Carrier in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication exp
15. circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Section 2 4 Sequence of Automatic Operation 2 3 1 12 VDC ACCESSORY OUTLET Your generator is equipped with a 12 VDC accessory outlet in the Generator Control Panel Figure 2 1 With the generator running or in standby mode this outlet may be used to temporarily power low power accessories such as a work light cell phone radio or any other automotive style accessory This outlet is capable of delivering a MAXIMUM of 7 5 Amps If the accessory to be used through this circuit demands too much power the fuse that protects this circuit will melt open and the circuit will not be functional WARNING amp This 12 VDC outlet draws power from the generator s starting battery and extended use of this outlet may drain the battery and the engine may not start This outlet should NOT be used for battery charging 2 3 2 120 VAC GFCI OUTLET Your generator is equipped with an external 15 amp 120 volt GFCI convenience outlet that is located in the right rear of the generator enclosure Figures 1 1 and 1 2 page 5 When the generator is running in the absence of utility power this outlet may be used to power items outside your home such as lights or power to
16. i J i ta vA Eihar Battery Composite Base Oil Fiter Compartment ries Sa 1 Control 8 Data Panel 4 i e Dipstick N Decal N Ne N N N N N 7 7 Outlet Fuel 3 Regulator 4 4 R Fuel 4 p Inlet s 5 3 4 4 old BE E O Oil Filter Battery vA Compartment Composite Base GENERAL INFORMATION Carrier 5 GENERAL Section 1 General Information INFORMATION Carrier Air cooled 7 kW 12 kW and 15 kW Generators 1 5 SPECIFICATIONS 1 5 1 GENERATOR Model ASPAS1CCA007 ASPAS1CCA012 ASPAS1CCA015 Rated Max Continuous Power Capacity Watts 6 000 NG 7 000 LP 12 000 NG 12 000 LP 13 000 NG 15 000 LP Rated Voltage 120 240 120 240 120 240 Rated Max Continuous Load Current Amps 120 Volts 50 0 NG 58 3 LP 100 0 NG 100 0 LP 108 3 NG 125 0 LP 240 Volts 25 0 NG 29 2 LP 50 0 NG 50 0 LP 54 2 NG 62 5 LP Main Line Circuit Breaker 30 Amp 50 Amp 65 Amp Phase 1 1 1 Number of Rotor Poles 2 2 2 Rated AC Frequency 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 Recommended Air Filter Carrier Part 008127 Carrier Part 008127 Carrier Part 0C8127 Battery Requirement At 0 F 17 8 C Group 26 12 Volts and 350 Cold cranking Amperes Minimum Group 26 12 Volts and 525 Cold cranking Amperes Minimum Gro
17. of the oil in the crankcase 8 Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s 9 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 10 Clean and wipe the entire generator 3 11 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Verify that utility power is turned off and that the AUTO OFF MANUAL switch is set to OFF 2 Check the tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in the engine see Section 3 3 1 if necessary drain and refill with the proper oil 3 Check the state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery See Specifications Section 1 5 for type and size 4 Clean and wipe the entire generator 5 Remove the 7 5A and 15A fuses from the generator control panel Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 6 Open the fuel shutoff valve 7 insert the 7 5A and 15A fuses into the generator control panel Start the unit by moving the AUTO OFF MANUAL switch to MANUAL Allow the unit to warm up thoroughly 8
18. start and run for approximately 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week Carrier 11 OPERATION Section 2 Operation ips Carrier Air cooled 7 kW 12 kW and 15 kW Generators NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is performed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected A caution amp A The exerciser WILL NOT work if dip switch 2 on the controller printed circuit board Remote Not Auto is ON NOTE Damage will result if battery connections are made in reverse 2 7 PROTECTION SYSTEMS 2 7 1 LOW OIL PRESSURE SWITCH This switch Figure 2 3 has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi limit switch contacts close and the engine shuts down The Low Oil LED will light The unit should not be restarted until oil is added The AUTO OFF MANUAL switch must then be turned to OFF and then back to AUTO to reset 2 7 2 HIGH TEMPERATURE SWITCH This switch s contacts Figure 2 3 close if the temperature should exceed approximately 1405 C 2845 F initiating an engine shutdown The High Temp LED will light The generator will automatically restart and the LED on the generator control panel will reset once the temperature has retur
19. strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views a lists of repair parts for three different Carrier models ASPAS1CCA007 6 kW NG 7 kW LP single cylinder GH 410 Engine e ASPAS1CCA012 12 kW NG 12 kW LP V twin GT 990 Engine e ASPAS1CCA015 13 kW NG 15 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE it is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Carrier Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See a Carrier Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact a Carrier Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contactin
20. RCUIT INTERRUPTION BREAKER FOR BEDROOMS In 2001 the National Electric Code NEC introduced a requirement for new construction This new requirement indicates the need for Arc Fault Circuit Interrupters to be used to protect the complete branch circuit that feeds a dwelling bedroom The actual NEC requirement is indicated below 1 3 1 SECTION 210 12 ARC FAULT CIRCUIT INTERRUPTER PROTECTION 1 Definition An arc fault circuit interrupter is a device intended to provide protection from the effects of arc faults by recognizing characteristics unique to arcing and by functioning to de energize the circuit when an arc fault is detected 2 Dwelling Unit Bedrooms All branch circuits that supply 125 volt single phase 15 and 20 ampere outlets installed in dwelling unit bedrooms shall be protected by an arc fault circuit interrupter listed to provide protection of the entire branch circuit Section 210 12 requires that protection be provided on branch circuits that supply outlets receptacle lighting etc in dwelling bedrooms The requirement is limited to 15 and 20 ampere 125 volt circuits There is no prohibition against providing AFCi protection on other circuits or in locations other than bedrooms Because circuits are often shared between a bedroom and other areas such as closets and hallways providing protection on the complete circuit would comply with 210 12 if during the installation of the Carrier Home
21. Starter 12 Vde 12 Vde 12Vde Oil Capacity Including Filter Approx 1 5 Qts Approx 1 7 Qts Approx 1 7 Qts Recommended Oil Filter Carrier Part 70185D Carrier Part 70185D Carrier Part 70185D Recommended Air Filter Carrier Part 0C8127 Carrier Part 008127 Carrier Part 0C8127 Operating RPM 1 6 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true 3 600 3 600 3 600 4 No alarms are present for example low oil pressure high temperature etc 1 7 FUEL REQUIREMENTS 1 The AUTO OFF MANUAL switch is set to the AUTO position 2 The utility voltage being supplied to the unit is being sensed by the PCB If the utility sense voltage is not connected to the unit or if it is below 168 volts AC then the system set light will flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto position the generator will start 3 The Not in Auto dip switch is set to the OFF position on the control board 6 Carrier AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has
22. T 12 LOW OIL HIGH TEMP p OVER SPEED q i we OVER CRANK i 4 mat i eA 154 SET A f FLASHING GREG w EXERCISE ACCESSORY JOOOO FLASHKG KED LEDS TIME OUTLET 7 5A MAX EXERCISE 2 2 3 MANUAL POSITION Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure warninc amp A With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a preset level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuses before working on or around the generator or transfer switch Then place a DO NOT OPERATE tag on the generator panel and on the transfer switch Carrier 9 OPERATION Section 2 Operation ID Carrier Air cooled 7 kW 12 kW and 15 kW Generators 2 3 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their UTILITY position i e loads connected to the utility power source Figure 2 2 2 Be sure that normal UTILITY power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generators AUTO OFF MANUAL switch to AUTO 4 Set the generator s main
23. Y A NE A A Do not dispose of the battery in a fire The battery is capable of exploding 8 Carrier Section 1 General Information Carrier Air cooled 7 kW 12 kW and 15 kW Generators A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove the 7 5A and 15A fuses from the generator control panel Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or disconnecting battery terminals WARNING 4 amp Do not open or mutilate the battery Released A electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water
24. been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section 1 9 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water colum 0 18 to 0 25 psi and for liquid propane 11 inches to 14 inches of water column 0 4 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges 1 8 FUEL CONSUMPTION Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour Values given are approximate Nat Gas LP Vapor 1 2 Load 1 2 Load erkw 66 0 82 30 T 4754 12 kw 1 53 56 T3A5kWw 220 1 5858 2 40 88 A NN A A Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas
25. cious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regulations Keep a fire extinguisher near the generator at all times IMPORTANT SAFETY INSTRUCTIONS Carrier Air cooled 7 kW 12 kW and 15 kW Generators SAFETY RULES AN Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extinguisher properly charged and be familiar with its use Consult the local fire department with any questions pertaining to fire extinguishers EXPLOSION HAZARDS 44 Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible material
26. d Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Carrier 3 GENERAL INFORMATION A DE A A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage This standby generator set has been factory supplied with a weather protective enclosure that is intended for outdoor installation only This UL listed standby generator set is packaged with an automatic transfer switch with built in load center The combination transfer switch and load center is pre wired with a two foot and 30 foot conduit Circuit breakers for emergency circuit connections are included e This UL listed 2 pole switch is rated at 100 AC amperes at 250 volts maximum This transfer switch is for indoor use only warninc amp A If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a transfer switch The transfer switch must effectively isolate the electrical system from the utility distribution s
27. e fluid if necessary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Set the generators AUTO OFF MANUAL switch to OFF 2 Turn off utility power supply to the transfer switch 3 Remove the 7 5A and 15A fuses from the generator control panel Battery cables were factory connected at the generator Figure 1 5 Connect cables to battery posts as follows Figure 1 5 Battery Cable Connections BLACK LEAD FROM FRAME RED LEAD FROM STARTER CONTACTOR Wee RED BATTERY BLACK 4 Connect the red battery cable from starter contactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a negative NEG or NOTE Damage will result if battery connections are made in reverse NOTE The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation With the battery installed and utility power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charger is designed to help extend the life of the battery by maintaining the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 11 THE BATTER
28. ealer for assistance Section 6 Warranty Carrier Air cooled 7 kW 12 kW and 15 kW Generators WARBANTY CARRIER TWO YEAR LIMITED WARRANTY FOR PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale warrants that its generator will be free from defects in material and workmanship for the items and period set forth below Carrier will at its option repair or replace any part which upon examination inspection and testing by a Carrier Dealer is found to be defective All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Carrier prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS AND TWO 100 one hundred percent transferable coverage on Labor and Part s listed ENGINE All Components ALTERNATOR All Components TRANSFER SYSTEM All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks scrapes dents or scratches the painted enclosure should be repaired promptly by the owner THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Carrier generators that utilize non Carrier replacement parts Carrier generators utilizing non Carrier
29. ed as follows Figures 3 2 and 3 3 1 Start the generator by moving the AUTO OFF MANUAL switch to the MANUAL position Allow it to run for a shor while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth 3 Install the dipstick then remove it again The oil level should be at the dipstick Full mark If necessary add oil to the Full mark only DO NOT FILL ABOVE THE FULL MARK A caution A Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 4 Install the dipstick 5 Reset the AUTO OFF MANUAL switch to its original position NOTE If the generator is to operate continuously for several days the oil level should be monitored frequently A low oil shutdown can occur Section 2 7 1 causing loss of generator power to emergency circuits Figure 3 2 Oil Dipstick and Fill 7 kw Figure 3 3 Oil Dipstick and Fill 12 kW and 15 kW Oil Dipstick 3 3 CHANGING THE ENGINE OIL 3 3 1 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 Synthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with organic break in oil See the Break in Procedure Section 2 1 for the first required oil change Aa caution amp
30. enses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY CARRIER MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you CARRIER S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL CARRIER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CARRIER S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state Revision 1 20 05 Carrier 19 Section 6 Warranty WARRANTY Carrier Air cooled 7 kW 12 kW and 15 kW Generators
31. er contactor 7 kW Defective starter motor Dead Battery Out of fuel Defective fuel solenoid FS Open 14 wire from engine control board Defective spark plug s Valve lash out of adjustment CORRECTION 1 Replace 15A fuse in generator control panel Tighten clean or replace as necessary Charge or replace battery Replenish fuel Clean re gap or replace plug s The engine starts hard and runs rough The Auto Off Manual switch is set to OFF but the engine continues to run There is no AC output from the generator Air cleaner plugged or damaged Defective spark plug s Fuel Regulator not set Fuel Pressure incorrect Defective switch Auto Off Manual switch wired incorrectly Defective control board Main line circuit breaker open Generator internal failure Check replace air cleaner Clean re gap or replace plug s Set Fuel Regulator Confirm fuel pressure to regulator is 11 14 water column 0 4 0 5 psi for LP and 5 7 water colum 0 18 0 25 psi for natural gas Reset circuit breaker to ON or closed There is no transfer to standby after utility source failure Defective transfer switch coil Defective transfer relay Transfer relay circuit open Defective control logic board Unit consumes large amounts of oil 18 Carrier Break in procedure not followed see Section 2 1 Contact the nearest Carrier D
32. erator air inlet openings to the prevailing winds e Install the generator as close as possible to the fuel supply to reduce the length of piping e Install the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE The genset must be installed on a level surface The base frame must be level within two 2 inches all around 1 9 3 TRANSFER SWITCH 1 9 3 1 7 kW 12 kW and 15 kW Units The transfer switch shipped with this generator is enclosed in a NEMA 1 enclosure This type of enclosure is intended for indoor use only Follow these rules Install the transfer switch indoors on a firm sturdy supporting structure To prevent switch distortion level the switch if necessary This can be done by placing washers between the switch enclosure and mounting surface e Never install the switch where water or any corrosive substance might drip onto the enclosure e Protect the switch at all times against excessive moisture dust dirt lint construction grit and corrosive vapors warning amp If the AUTO OFF MANUAL switch is not set to its OFF position the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off sparking can occur at the battery posts and cause an explosion Carrier 7 GENERAL INFORMATION 1 10 BATTERY INSTALLATION Fill the battery with the proper electrolyt
33. familiar standards with this Owner s Manual and with the unit The generator Keep hands feet clothing ete away from drive belts can operate safely efficiently and reliably only if it is fans and other moving or hot parts Never remove any properly installed operated and maintained Many drive belt or fan guard while the unit is operating accidents are caused by failing to follow simple and e Adequate unobstructed flow of cooling and ventilating fundamental rules or precautions air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe IMPORTANT SAFETY INSTRUCTIONS Carrier Air cooled 7 kW 12 kW and 15 kW Generators GENERAL HAZARDS WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Carrier cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit operation of the generator The generator MUST be are therefore not all inclusive If using a procedure installed outdoors work method or operating technique Carrier does not 5 When working on this equipment remain alert at all specifically recommend ensure that it is safe for others times Never work on the equipment when physically Also make sure the procedure work method or operati
34. g a Carrier Dealer about parts and service always supply the complete model number and serial number of the unit as given on its data decal which is located on the generator See Figure 1 1 or Figure 1 2 in Section 1 4 for decal location Model No Serial No Carrier Air cooled 7 kW 12 kW and 15 kW Generators Introduction Inside Front Cover Read This Manual Thoroughly IFC IFC Operation and Maintenance IFC How to Obtain Service ooo ccecccccccecccececeecceceeeeeeeees IFC Safety Rules siei ieun i 2 Standards INGOxX rica aa a a aaraa 3 Section 1 General Information 4 1 14 Unpacking inspection 4 1 2 Protection Systems 4 1 3 Requirement for Arc Fault Circuit Interruption Breaker for Bedrooms 4 1 4 Whe 5 1 5 Specifications cee cee ridek 6 1 6 System Set LED 6 1 7 Fuel Requirements and Recommendations 6 1 8 Fuel 7 1 8 nee RRA eA 7 1 10 Battery installation
35. ircuit and the battery charge circuit against overload This fuse is wired in series with the battery output lead to the panel if this fuse element has melted open the engine will not be able to crank or start The generator will also lose all battery charge capabilities Replace this fuse using only an identical 15 amp replacement fuse To replace the fuse push the fuse holder cap down and rotate it counterclockwise The generator panel s 7 5 amp fuse protects the 12 VDC accessory socket If the fuse element has melted open the 12 VDC socket will not be able to provide power to any accessories Replace this fuse using only an identical 7 5 amp replacement fuse To replace the fuse push the fuse holder cap down and rotate it counterclockwise Section 3 Maintenance post zar Aj INSTALLATION Carrier Air cooled 7 kW 12 kW and 15 kW Generators STARTUP ADJUSTMENTS Figure 3 1 Generator Control Panel f EXTERNAL OUTLET FUSE GFCI a Need CIRCUIT 5 BREAKER mnane SYSTEM SET LOW CHL HIGH TEMP OVER SPEED ZF OVER CRANK FLASH 7 5A AUTO OFF MAN a GREEN L ACCESSORY OUTLET 7 54 MAX Eg NO UTHATY CXC 4 FLASHNG E Y SEN 4 RED LED EXERCISER NOT SET EXERCISE TIME 3 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 For engine oil recommendations see Section 3 3 1 To check the engine oil level proce
36. kets with corrosion inhibiting spray such as WD 40 or a comparable product 3 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it must not be started and operated Following any submersion in water have a Carrier Dealer thoroughly clean and dry the generator 3 11 OUT OF SERVICE PROCEDURE 3 11 1 REMOVAL FROM SERVICE if the generator cannot be exercised every seven days and will be out of service longer than 90 days prepare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 Once the unit has shut down it will signal a low oil fault 4 Set the generator s main circuit breaker to its OFF or open position 1G Carrier Carrier Air cooled 7 kW 12 kW and 15 kW Generators 5 Set the AUTO OFF MANUAL switch to OFF and turn off the utility power to the transfer switch Remove the 7 5A and 15A fuses from the generator control panel Disconnect the battery cables as outlined in General Hazards page 2 Turn on the utility power supply to the transfer switch in order to power the emergency load centers circuits while utility power is available 6 While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations Section 3 3 1 7 Attach a tag to the engine indicating the viscosity and classification
37. ned to a safe operating level Figure 2 3 Oil Pressure and High Temperature Switches Low Oil Switch High Temp Switch Ses le Hose A ee T C i Oil Filter 12 Carrier 2 7 3 OVER CRANK This feature prevents the generator from damaging itself when it continually attempts to start and another problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the Over Crank LED on the generator control panel will light indicating an over crank failure The AUTO OFF MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the over crank feature will continue to activate 2 7 3 1 Approximate Crank Cycle Times 15 seconds ON e 7 seconds OFF 7 seconds ON e 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 2 74 OVER SPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the generator from supplying an output that could potentially damage appliances connected to the generator circuit If this protective shutdown should occur the Over Speed LED will light Contact the nearest Carrier Dealer if this failure occurs 3 1 FUSES The generator panel s 15 amp fuse Figure 2 1 protects the DC control c
38. ng or mentally fatigued technique chosen does not render the generator unsafe e Inspect the generator regularly and contact the nearest Carrier Dealer for parts needing repair or replacement Despite the safe design of this generator Before performing any maintenance on the generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators Carrier disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in operation Avoid co
39. nimum When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service Schedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly connected and terminals are tight Observe battery polarity when connecting the battery to the generator set 2 1 BREAK IN PROCEDURE Once the unit has been installed and all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Set the generator s AUTO OFF MANUAL switch to AUTO 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker 3 The unit will start and the transfer switch will transfer to standby 4 Using the transfer switch s built in emergency load center turn on circuits to load the generator to approximately 25 rated load and run the unit for one hour Run the unit for one hour at 50 rated load Run the unit for one hour at 75 rated load Run the unit for one hour at 100 rated load Turn ON the utility power supply to the transfer switch which will allow the transfer switch to transfer back to utility power The unit will continue to run for one minute and then shut down Allow the uni
40. ntact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical system After installing this home standby electrical system the generator may crank and start at any time without warning When this occurs load circuits are transferred to the STANDBY generator power source To prevent possible injury if such a start and transfer occur always set the generators Auto Off Manual switch to its OFF position before working on equipment and remove the 7 5A and 15A fuses from the generator control panel In case of accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is uncons
41. ols This outlet may also be used when utility power is present by running the generator in manual mode This oultlet does not provide power if the generator is not running This outlet is protected by a 15 amp circuit breaker located in the generator control panel Figure 3 1 10 Carrier 2 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors utility power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility power supply generator circuit board action signals the transfer switch to transfer loads back to the utility power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 70 percent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 second
42. open or mutilate the battery Released A electrolyte has been known to be harmful to the skin and eyes and to be toxic A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed MAINTENENANCE 2D Section 3 Maintenance Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touching the battery by first touching a grounded metal surface A Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and s
43. rier 21 PART NO 0F6902 CATALOG 2 REV 6 01 05 PRINTED IN U S A
44. s are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applicable fuel gas codes Before placing the home standby electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation inspect the fuel system periodically for leaks No leakage is permitted STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be used as installation guide for this equipment 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food an
45. s before the load is transferred to the standby source C Standby Voltage Sensor This sensor monitors generator AC output voltage When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor e This sensor monitors utility power supply voltage When that voltage is restored above 70 percent of the nominal source voltage a retransfer time delay starts timing E Retransfer Time Delay This timer runs for about 15 seconds At end of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs F Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down OPERATION Section 2 Operation Carrier Air cooled 7 kW 12 kW and 15 kW Generators ofp 2 5 MANUAL TRANSFER OPERATION 2 5 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generators AUTO OFF MANUAL switch to OFF 2 Set the generator s main circuit breaker to its OFF or open position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A DIG A A Do not attempt to activate the transfer
46. switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 4 Use the manual transfer handle inside the transfer switch to move the main contacts to their Standby position i e loads connected to the standby power source Figure 2 2 Figure 2 2 Manual Transfer Switch Operation t LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 5 To crank and start the engine set the AUTO OFF MANUAL switch to MANUAL 6 Let the engine stabilize and warm up for a few minutes 7 Set the generators main circuit breaker to its ON or closed position The standby power source now powers the loads 2 5 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generators main circuit breaker to its OFF or open position 2 Let the engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generators AUTO OFF MANUAL switch to its OFF or open position The engine should shut down 4 Check that utility power supply to the transfer switch is turned OFF A Pia A A Do not attempt to activate
47. t to cool 10 Set the generator s main circuit breaker to its OFF or OPEN position 11 Set the generators AUTO OFF MANUAL switch to OFF Remove the 7 5A and 15A fuses from the generator control panel Disconnect the battery cables as outlined in General Hazards page 2 12 Drain the oil and remove the oil filter Replace the oil filter according to Section 3 4 Changing the Oil Filter Replace the oil with synthetic oil as recommended in Section 3 3 Changing the Engine Oil 13 Reconnect the battery cables as outlined in General Hazards page 2 and insert the 7 5A and 15A fuses into the generator control panel The generator is now ready for service 22 USING THE AUTO OFF MANUAL SWITCH FIGURE 2 1 2 2 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also allows personnel to start and exercise the engine every seven days with the setting of the exercise timer see Section 2 6 This position also is used for remote starting when it is set up 2 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation Figure 2 1 Generator Control Panel f ou EXTERNAL OUTLET FUSE ERM pte oo booste your nearest servicing dealer st i Op if i OFF BREAKER SYSTEM SE
48. tart as soon as the battery cables are connected A Be sure the utility power supply is turned off and the 7 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as the cables are attached and cause an explosion 3 8 COOLING SYSTEM Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 3 8 for vent locations Carrier 15 MAINTENENANCE 29 Section 3 Maintenance Figure 3 8 Cooling Vent Locations AIR OUTLET warninc 4 amp A The exhaust from this product gets extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system caution A A The maximum ambient temperature for the generator is 40 C 104 F 3 9 CORROSION PROTECTION Periodically wash and wax the enclosure using automotive type products Frequent washing is recommended in salt water coastal areas Periodically spray all engine linkage parts and brac
49. the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 5 Use the manual transfer handle inside the transfer switch to move the main contacts back to their UTILITY position i e loads connected to the utility power source Figure 2 2 6 Turn ON the utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 2 3 2 6 SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day the following sequence is completed During this exercise period the unit runs for approximately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 2 1 permits selection of the day and time for the system to exercise At the chosen time perform the following sequence to select the desired day and time of day the system will exercise 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Hold down the Set Exercise Time switch until the generator starts approximately 10 seconds and then release 3 The generator will
50. there is any conflict in terms between the ECS Warranty and the Carrier Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty service evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at one of the following addresses For Air cooled Product For Liquid cooled Product ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC GENERAC POWER SYSTEMS INC P O BOX 297 211 MURPHY DRIVE WHITEWATER WI 53190 EAGLE WI 53119 Part 1 20 Carrier Section 6 Warran Carrier Air cooled 7 kW 12 kW and 15 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty
51. up 26 12 Volts and 525 Cold cranking Amperes Minimum Weight 375 Pounds 470 Pounds 487 Pounds Output Sound Level 23 ft 7m at full load Normal Operating Range 68 db A 70 5 db A 71 5 db A 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition ete Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature Load current values shown for 120 volts are maximum TOTAL values for two separate circuits The maximum current in each circuit must not exceed the value stated for 240 volts 1 5 2 ENGINE ASPAS1CCA007 ASPAS1CCA012 ASPAS1CCA015 Type of Engine GH 410 GT 990 GT 990 Number of Cylinders 1 2 2 Rated Horsepower 14 5 3 600 rpm 30 3 600 rpm 30 3 600 rpm Displacement 410cc 992cc 992cc Cylinder Block Aluminum w Cast Aluminum w Cast Aluminum w Cast lron Sieeve lron Sieeve lron Sieeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Ignition System Solid state w Magneto Solid state w Magneto Solid state w Magneto Recommended Spark Plug RC14YC RC12YC RC12YC Spark Plug Gap 0 76 mm 0 030 inch 0 508 mm 0 020 inch 0 508 mm 0 020 inch Compression Ratio 8 6 1 9 5 1 9 5 1
52. urposes Generac recommends that you retain all receipts covering maintenance on your engine However Carrier cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If
53. warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part ma
54. y be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shail be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Carrier engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Car
55. ystem when the generator is operating NEC 700 701 amp 702 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy if any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix their signature under the consignors memo of loss or damage if a loss or damage is noted after delivery separate the damaged materials and contact the Carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is discovered later 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator present to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 3 Overcrank 4 Overspeed 1 Low Oil Pressure Sensor 2 High Temperature Sensor 4 Carrier Section 1 General Information Carrier Air cooled 7 kW 12 kW and 15 kW Generators There are LED readouts on the control panel to notify personnel that one of these faults has occurred There is also a System Set LED that is lit when all of the conditions describe in Section 1 3 are true 1 5 NEC REQUIREMENT FOR ARC FAULT CI
Download Pdf Manuals
Related Search