Home

Bryant ASPAS1BBL025 User's Manual

Contents

1. 120 240 No of Rotor Poles 4 Driven Speed of Rotor 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor Insulation Class F Stator Insulation Class H Section 1 General Information Bryant Liquid cooled 25 kW Generator Rated power of generator is subject to and limited by such factors as ambient temperature altitude engine condition and other factors Engine power will decrease about 2 5 for each 1000 feet above 500 feet and will decrease an addition al 2 5 for each 10 F above 104 F Maximum output power of the generator is limited by maximum engine power 1 11 FUEL CONSUMPTION 25 kW Models Using Natural Gas 441 cu ft per hour Using LP Gas 175 cubic ft 4 8 gal per hour Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE Fuel consumption i
2. 1 3 4 2 Number of Main Bearings 5 Compression Ratio 9 37 to 1 No of Teeth on Flywheel 164 Ignition Timing Waste Spark System at 1800 rpm 36 degrees BTDC Spark Plug Gap 0 044 inch Recommended Spark Plugs 0E96180241 Oil Pressure 30 50 psi Crankcase Oil Capacity 4 5 U S quarts 4 26 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery Cooling Fan Pusher Type Cooling System Capacity 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and deionized water Home standby control board assembly part number 0E9704 must be used on 1800 rpm gen erators 1 10 2 GENERATOR Model ASPAS1BBL025 Rated Max Cont AC Power Output kW 25 Rated Voltage volts
3. 8 Section 2 INSTALLATION 8 2 1 Standby Generator Installation 8 2 2 Generator Location 9 2 3 Generator Mounting and Support 9 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 9 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Signal Connections 10 2 10 Battery Installation 10 2 11 Preparation Before Start Up 11 Section 3 OPERATION 12 3 1 Engineered GTS Transfer Switch 12 3 2 Control Console Components 14 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustments 14 3 5 Retransfer and Shutdown 14 3 6 Automatic Operation 14 3 7 Weekly Exercise Cycle 15 Section 4 MAINTENANCE 16 4 1 Maintenance Performed by Authorized Service Fa
4. On the generator console set the Auto Off Manual switch to Off Wait for engine to come to a complete stop For transfer to utility position refer to the Owner s Manual of the particular transfer switch Turn on the utility power supply to the transfer switch using whatever means provided such as a utility main line circuit breaker The utility power source now powers the loads 3 5 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed as follows Check that load circuits are connected to the utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 6 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the gen erator to exercise set the weekly exercise cycle as fol lows 1 Place the AUTO OFF MANUAL switch in the auto position Figure 3 3 Section 3 Operation Bryant Liquid cooled 25 kW Generator Bryant 15 Section 3 Operation Bryant Liquid cooled 25 kW Generator 2 Press and hold the Set Exercise switch for five seconds then release At this time all five red LEDs w
5. 1 Move dip switch 8 to the test mode OFF posi tion 2 Set all three potentiometers pots fully counter clockwise 3 Under no load condition increase the GAIN pot as much as possible without causing instability 4 Apply 1 4 1 2 3 4 and full load to the unit Decrease the GAIN pot if there is instability at any load point 5 Under full load condition increase the stability pot until the unit returns to 60 Hertz or 50 Hertz in 50 Hertz applications Figure 3 2 Engine Governor Adjustment 6 Reduce load to 3 4 1 2 1 4 and no load Decrease the stability pot if there is instability at any load point 7 Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot If it is set too high it may introduce oscillations at some load It can be set to zero full CCW if a small amount causes oscillations at some load 3 4 RETRANSFER AND SHUTDOWN When utility power source voltage has been restored electrical loads may be transferred back to that source and the generator can be shut down as fol lows Verify that utility power supply voltage to the trans fer switch has been positively turned Off using whatever means provided such as utility main line circuit breaker Set the generator s main circuit breaker to its Off or Open position Let the generator engine run at no load for a few minutes to stabilize internal unit temperatures
6. 3 Flush cooling system D FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or six months whichever comes first 2 Retorque cylinder head see torque specs 3 Retorque intake and exhaust manifold see torque specs E EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator F EVERY 800 OPERATING HOURS 1 Retorque cylinder head see torque specs 2 Retorque intake and exhaust manifold see torque specs 3 Check engine compression 4 Check valve clearance 4 2 EXHAUST MANIFOLD PROCEDURE 1 If necessary clean gasket surfaces on exhaust manifold and cylinder head 2 Install exhaust manifold and exhaust manifold gasket 3 Install fasteners NOTE Exhaust manifold fasteners must be tightened in two stages 4 Tighten fasteners to 20 30 N m 15 22 lb ft dur ing the first stage 5 Retighten fasteners to 60 80 N m 44 59 lb ft during the second stage 4 3 INTAKE MANIFOLD PROCEDURE 1 Clean and inspect the mounting surfaces of the intake manifold and the cylinder head Both sur faces must be clean and flat Figure 4 1 2 Clean and lightly oil the manifold bolt stud threads 3 Install a new lower intake manifold gasket 4 Position the lower intake manifold to the cylinder head 5 Install retaining bolts studs finger tight 6 Tighten all bolts
7. 40 37 3 Bryant 39 ITEM PART NO QTY DESCRIPTION 1 0E9768 1 ROOF ACO amp STD ENCL 2 5L 2 0E9862 1 DUCT DISCHARGE MID 2 5L 3 0E9769 1 SUPPORT RADIATOR 2 5L FORD 4 0D8660 2 BRACE SIDE 1 5L MITSU 5 0A7568 2 DOORWELDMENT 1 5EPS 6 0E9771 1 CORNER POST REAR RH SIDE 2 5L 7 0E9773 1 DOOR REAR ENCL 2 5L FD 8 0E9772 1 BRACE REAR 2 5L FORD 9 0E9770 1 CORNER POST REAR LH SIDE 2 5L 10 067042 2 LATCH amp CAM 11 0C2454 34 SCREW TH FRM M6 1 X 16 N WA Z JS 12 033530 3 SCREW PHM 10 32 X 5 8 ZINC 13 051716 3 NUT HEX M5 0 8 G8 YEL CHR 14 022152 3 WASHER LOCK 10 15 0912970064 3 ASSEMBLY BASE DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT 10 STL 17 0912970063 3 GRD WIRE ASS Y 99HSB 18 022264 6 WASHER LOCK 8 M4 19 067035 6 SCREW PPHM 8 32 X 5 16 20 022127 1 NUT HEX 1 4 20 STEEL 21 0F4487A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1 4 ZINC 23 022097 1 WASHER LOCK M6 1 4 24 0D2023 2 GASKET CLIP ON SELF GRIPPING 89 LG 25 0F3390 1 LATCH AND CAM 26 037337 6 NUT HEX JAM 3 8 24 SS 27 0E0072G 2 ACSTC INSLTN 1 5L RR CRNR TOP 28 0E0072J 2 ACSTC INSLTN 1 5L RR CRNR BOTT 29 0E0072L 2 ACSTC INSLTN 1 5L SIDE BRC PNL 30 0E0072M 2 ACSTC INSLTN 1 5L SIDE DR PNL 31 0D2023 1 TRIM VINYL SELF GRIPPING 80 LG 32 0E0072P 2 ACSTC INSLTN 1 5L SIDE DR PNL 33 0E0072Q 2 ACSTC INSLTN 1 5L RAD SUPPORT 34 0E0072S 1 ACSTC INSLTN 2 5L ROOF 35 0E0072T
8. 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 0F0454 REF HARN GOV 2 5L FORD 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW PFHST 2 X 5 8 6 043146 3 SCREW HHC M6 1 0 X 10 G8 8 7 022097 5 WASHER LOCK M6 1 4 8 0E7358 REF SCREW PPPH HI LO 4 24 X 3 8 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 1 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 6 7 9 10 10 5 4 REF 6 12 A 7 2 3 1 INTAKE MANIFOLD 16 7 15 COATING WIRE HARNESS 14 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Stepper Motor Drawing No 0E9979 C Bryant 49 50 Bryant ITEM PART NO QTY DESCRIPTION 1 0E9769 REF SUPPORT RADIATOR 2 5L FORD 0F0779 REF SUPPORT RADIATOR 2 5L AL 2 0E9837 1 RADIATOR 2 5L FORD 3 0F0123 1 VENTURI 16 FAN 2 5L FORD 4 0F0118 1 GUARD FAN 2 5L FORD 5 099502 4 CLAMP HOSE 24 B1 06 2 00 6 0C2454 REF SCREW THF M6 1X16 N WA Z JS 7 052250 2 TAPE FOAM 1 X 1 17 LG 8 022097 8 WASHER LO
9. INTRODUCTION IFC Read this Manual Thoroughly IFC Operation and Maintenance IFC How to Obtain Service IFC SAFETY RULES 2 Section 1 GENERAL INFORMATION 4 1 1 Generator 4 1 2 Transfer Switch 4 1 3 Automatic System Operation 4 1 4 Generator AC Connection Systems 4 1 5 Main Circuit Breaker 4 1 6 Generator Fuel System 5 1 7 Engine Protective Devices 5 1 8 Unpacking 6 1 9 Lifting the Generator 6 1 10 Specifications 6 1 11 Fuel Consumption 7 1 12 Reconfiguring the Fuel System for LP Vapor 7 1 13 Engine Oil Recommendations 7 1 14 Coolant Recommendations 8 1 15 Before Installation
10. NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inches 10 to 16 mm 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console Figure 3 1 are as follows 3 1 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 5 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engin
11. 5L FORD 14 023897 19 WASHER FLAT 10 ZINC 15 036261 4 RIVET POP 125 X 275 AL 16 054450 1 CIRCT BRK 5 5 X 1 ETA 46 500 P 17 057073 1 JUNCTION BLOCK 3 8 16 18 067680 1 ASSY VOLTAGE REGULATOR 60HZ 19 082573 1 SWITCH ROC DPST 125V SPD 20 0C3910 1 TRANSFORMER 240 16V 1VA amp 56VA 21 029673 1 DIO BRIDGE 25A 600V 22 034616 1 FITTING STRAIGHT 3 4 23 0E2514 1 FITTING CONDUIT STR 1 1 2 24 0F0581 1 BRACKET FUSE HOLDER 2 5L FORD 25 040213 2 PCB SUPPORT SNAP IN 1 4 26 0F0558 1 BRACKET PCB SUPPORT 2 5L FORD 27 0F0598 1 DECAL FUSES 2 5L CNTRL PANEL 28 0F0599 1 DECAL TB1 2 5L CONTROL PANEL 29 0F0600 1 DECAL ICT 2 5L CONTROL PANEL 30 054199 1 DECAL DANGER HIGH VOLTAGE 31 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 32 0F0653 1 DECAL CONTROL HSB 2 5L FORD 33 022097 3 WASHER LOCK M6 1 4 34 0C2212 13 SCREW PHTT M4 0 7 X 16 ZYC 35 022264 20 WASHER LOCK 8 M4 36 0C2265 5 SCREW PHTT M4 0 7 X 12 ZYC ITEM PART NO QTY DESCRIPTION 37 023965 2 SCREW RHM 8 32 X 3 8 38 039782 1 BRKT MTG CB BQ 39 0A2077 1 CB 0125A 2P 240V S BQ2 LL 40 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 41 0A8955 2 SCREW PHM M6 1 0 X 20MM 42 022152 3 WASHER LOCK 10 43 051716 2 NUT HEX M5 0 8 G8 YEL CHR 44 023762 1 WASHER SHAKEPROOF EXT 10 STL 45 033121 1 SCREW HHC 10 32 X 1 2 46 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 47 0912970087 1 ASSY WIRE 14AWG 16 0 GRN YEL 48 022158 1 NUT HEX 10
12. 8 16 0536210261 1 ASSY WIRE 0 12 00 17 074906 1 SCREW HHTT M6 1 0 X 20 BP 18 077483 REF BATT 12VDC 75 AH 26 NOT SHOWN 19 0E9941 1 HOLD DOWN BATTERY 2 5L FORD 20 025507 3 WASHER SHAKEPROOF EXT 7 16 STL 21 059980 1 SCREW HHC M10 1 5 X 25 G10 9 22 046526 1 WASHER LOCK M10 23 022131 1 WASHER FLAT 3 8 M10 ZINC 24 021991 1 EARTH STRAP 25 038805J 1 CABLE BATT BLK 1 X 30 00 26 050331 REF BATTERY POST COVER BLACK 27 050331A REF BATTERY POST COVER RED 28 038804J 1 CABLE BATT RED 1 X 40 50 29 045771 REF NUT HEX M8 1 25 G8 YEL CHR 30 022129 REF WASHER LOCK M8 5 16 31 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 32 075763 1 BOOT BATTERY CABLE 33 0E9748 1 ASSY MTG BASE 2 5L FORD 34 0E9940 1 TRAY BATTERY 2 5L FORD 35 065852 1 SPRING CLIP HOLDER 37 62 36 024469 1 SCREW HHTT 10 32 X 3 8 CZ 38 Bryant Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Enclosure Drawing No 0F4568 B 35 NUTS ITEM 26 USE LOCTITE ON PANEL FOR ACCESS COVER CABLE WELD STUD UNDER ROOF 17 GROUND WIRE FASTENER TO SECURE USE DOOR LATCH NOTE 26 38 11 25 31 7 9 24 10 4 26 25 15 8 29 11 16 14 13 10 5 32 NOTE 30 11 4 19 26 6 10 18 10 26 Y 15 Y 17 19 18 33 3 11 17 29 2 15 1 34 21 36 24 3 20 11 35 3 41 2 11
13. BATTERY CABLE PRIOR TO SE LOW COOLANT LEVEL HI COOLANT TEMPERATURE FLASHING GREEN LED NO UTILITY SENSE 5 FLASHING RED LED S EXERCISER NOT SET IN AUTO MODE ONLY SOLID GREEN LED SYSTEM READY UTILITY POWER ON USE OF SYNTHETIC OIL IS RECOMMENDED SEE OWNER S MANUAL FOR COMPLETE DETAILS LED INDICATORS RED LED S INDIVIDUAL FAULT OVER CRANK SYSTEM READY LOW BATTERY LOW OIL PRESSURE OVER SPEED OFF MANUAL AUTO START RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN TIME SET EXERCISE TO AUTO POSITION SWITCH IN ON POSITION FOR 1 PLACE AUTO OFF MANUAL SWITCH 2 HOLD SET EXERCISE TIME TO SET EXERCISER TIME 10 SECONDS THEN THE UNIT WILL THE EXERCISER IS NOW SET ALL FIVE RED LED S WILL FLASH FOR THREE SECONDS AND RELEASE ON WARNING CAUTION WARNING 0F0653 OFF CAUTION Bryant 13 3 1 3 15 AMP FUSE This fuse protects the control console s DC control circuit against electrical overload and is located inside the control panel If the fuse has melted open because of an overload engine cranking and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacement fuse type ATO 3 1 4 5 AMP FUSE This fuse protects the battery charger against electri cal overload and is located inside the control panel If the fuse needs to be replaced use only an identical 5 amp replacement fuse type ATO NOTE This f
14. Figure 2 2 Generator Grounding Lug typical 2 8 GENERATOR AC NEUTRAL CONNECTIONS Bryant uses an UNGROUNDED AC neutral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the excessive current opens the load circuit breaker or collapses the generator field The actual result depends on the electrical characteristics of the particular installed generator Failure to connect the generator neutral prop erly will result in unbalanced line to neutral voltages Resulting high voltages will cause equipment damage 2 9 TRANSFER SWITCH SIGNAL CONNECTIONS It is necessary to connect the control wires between the generator and the transfer switch Control system interconnections consist of N1 N2 T1 T2 and leads 23 and 194 Control system inter connection leads must be run in a conduit that is sep arate from the AC power lead Recommended wire gauge sizes for this wiring depends on the length of the wire as recommended below 2 10 BATTERY INSTALLATION Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed int
15. cir cuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 10 1 VENTED BATTERIES The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures 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 thor oughly and immediately with water and seek med ical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbon ate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until 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 fol lowing procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel awa
16. codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serviced in accor dance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforemen tioned codes standards laws and regulations The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict com pliance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation
17. dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static elec tricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in haz ardous and possibly fatal electrical shock Connecting this unit to an electrical system normally sup plied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in dam age to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to per sonnel disable the generator s automatic start circuit bat tery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control p
18. diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY GENERATOR output are connected to an approved transfer switch The trans fer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System NOTE Bryant recommends the use of a Bryant transfer switch in conjunction with this generator 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within the wattage amperage capacity dur ing utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set The transfer switch must meet the following require ments It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit It must be installed bet
19. may occur at the battery posts as the cables are attached and cause an explosion DANGER Section 4 Maintenance Bryant Liquid cooled 25 kW Generator 20 Bryant 4 9 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows NOTE The BCI number should be located directly on the battery Section 4 Maintenance Bryant Liquid cooled 25 kW Generator BCI Group No CCA 26 525 0 deg F PERIODIC REPLACEMENT PARTS Part Name Part Number Oil Filter 0F4604A Radiator Cap 046627 Air Cleaner 059402 Spark Plug 0E96180241 Bryant 21 Section 4 Maintenance Bryant Liquid cooled 25 kW Generator 4 10 SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for small standby and residential generator sets The estab lished intervals in the schedule are the maximum recommended when the unit is used in an average service appli cation They will need to be decreased performed more frequently if the unit is used in a severe application Use the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to i
20. of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only fac tory approved parts Before performing any maintenance on the generator dis connect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous volt ages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in DANGER Important Safety Instructions Bryant Liquid cooled 25 kW Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for
21. safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING Bryant 3 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 If people must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent
22. studs to specifications in the tightening sequence shown First pass 7 10 N m 5 7 lb ft Final pass 26 38 N m 19 28 lb ft Figure 4 1 Intake Manifold Installation 4 4 CYLINDER HEAD PROCEDURE 1 Position head gasket on the block Figure 4 2 2 Position cylinder head to cylinder block 3 Install 10 cylinder head bolts in numerical sequence Tighten to 70 N m 52 lb ft in sequence Retighten to 70 N m 52 lb ft in sequence Then turn all head bolts an additional 90 100 degrees in sequence Figure 4 2 Cylinder Head Installation Bryant 17 4 5 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system 4 6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protec
23. 0 1 5 X 30 G12 9 31 060619 2 SCREW SHC M10 1 50 X 40 G12 9 32 0E8940 1 SPACER FLEXPLATE HSB 33 0E9680 1 GASKET 2 5L FORD EXHAUST MAN 34 0E9609 1 MANIFOLD EXHAUST MACHINED ITEM PART NO QTY DESCRIPTION 35 0E9930 1 HEAT SHIELD EXHAUST MANIFOLD 36 049821 3 SCREW SHC M8 1 25 X 30 G12 9 37 0E9747 1 STARTER 12 VOLT 38 043116 5 SCREW HHC M6 1 0 X 12 G8 8 39 022473 6 WASHER FLAT 1 4 M6 ZINC 40 045772 2 NUT HEX M10 1 5 G8 YEL CHR 41 064416 2 SCREW HHC M10 1 5 X 45 G8 8 42 0F0252 1 SPRING BUSHING 43 0E9868 1 ALTERNATOR D C 44 0F0035 1 BRKT D C ALTERNATOR MACHINED 45 026082 1 SCREW HHC 3 8 16 X 2 1 4 G5 46 0E9928 1 TENSIONER D C ALTERNATOR 47 0F0383 1 HOSE 2 5L FORD COOLANT BY PASS 48 057823 2 CLAMP HOSE 10 56 1 06 49 0E9737 1 LOWER HOSE ADAPTER 2 5L FORD 50 0F0393 1 O RING 1 3 16 X 1 7 16 X 1 8 51 045757 2 SCREW HHC M6 1 0 X 25 G8 8 52 069860C 1 HOSE OIL DRAIN ASSY 21 53 048031J REF HOSE CLAMP BAND 5 8 54 055596 1 BARBED STR 3 8NPT X 3 8 55 077456 1 ADAPTER M12 1 75 3 8NPT 56 052677 1 WASHER NYLON 50 X 87 X 06 57 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 58 0E9738A 1 DIPSTICK TUBE 2 5L FORD 59 0F1132 1 COVER R H SIDE ENGINE ADAPTOR 60 0F1133 1 COVER L H SIDE ENGINE ADAPTOR 61 059355 8 SCREW SHC M10 1 50 X 50 G12 9 62 076749 1 TANK COOLANT RECOVERY 63 029032 1 HOSE 9 32 ID 39 LG 64 0F1433 1 BRACKET 2 5L FORD WATER BOTTL
24. 2 ACSTC INSLTN 2 5L DUCT L amp RH SD 36 0E0072U 1 INSUL ACO 2 5L EXH ROOF PANEL 37 0E0072V 2 ACSTC INSLTN 2 5L DUCT FRNT SD 38 0E0072W 1 ACSTC INSLTN 2 5L REAR DOOR 39 0E0072X 2 ACSTC INSLTN 2 5 RR CRNR PNL S 40 0E9861 1 DUCT DISCHARGE RH SIDE 2 5L 41 0E9860 1 DUCT DISCHARGE LH SIDE 2 5L Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Enclosure Drawing No 0F4568 B 40 Bryant 6 TO A 15 4 19 5 32 44 40 14 1 14 26 10 14 1 24 29 33 31 50 52 41 33 4 48 13 27 36 54 A 23 65 37 35 2 7 3 35 9 34 43 34 21 35 17 30 34 22 3 35 16 36 34 0 56 5 12 14 11 64 54 38 18 39 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Control Panel Drawing No 0E9719 E Bryant 41 ITEM PART NO QTY DESCRIPTION 1 0C2267 16 SCREW HHTT M5 0 8 X 12 BP 3 0D5070A 1 ASSY 2A 12V UL BATTERY CHARGER 4 0D8671 1 HINGE CONTINUOUS 1 5L CTRL PNL 5 0E4494 1 SWITCH ROC DPDT ON OFF ON 6 0E6875A 2 RELAY 12VDC C FORM W DIODE 7 0E7358 4 SCREW PPPH HI LO 4 24 X 3 8 8 0E9704 1 ASSY PCB HSB CONTROLLER 2 5L 9 0E9934 1 CTRL PNL BACK amp BOTTOM 2 5L 10 0E9935 1 CTRL PNL LH SIDE 2 5L FORD 11 0E9936 1 CTRL PNL RH SIDE 2 5L FORD 12 0E9937 1 CTRL PNL TOP 2 5L FORD 13 0E9938 1 CTRL PNL FRONT 2
25. 32 STEEL 49 0E7403C 1 FUSE ATO TYPE 15 AMP BLUE 50 0E7403A 1 FUSE ATO TYPE 5 AMP TAN 51 0F0526 1 HARN CTRL PNL 2 5L FD NOT SHOWN 52 0A2115 2 WASHER NYLON 257 53 022473 2 WASHER FLAT 1 4 M6 ZINC 54 038150 5 WASHER FLAT 8 ZINC 55 0C2428 2 SCREW PHTT 6 32 X 1 2 ZYC 56 022155 2 WASHER LOCK 6 57 052619 2 SCREW HHC M5 0 8 X 20 G8 8 58 023897 4 WASHER FLAT 10 ZINC 59 049226 2 WASHER LOCK M5 60 051716 2 NUT HEX M5 0 8 G8 YEL CHR 61 046357 REF BLOCK TERM 20A 6 X 6 X 1100V 62 047822 REF BLOCK TERM 20A 7 X 6 X 1100V 63 0F1467 REF ASSY WIRE FUSE HOLDER 64 0E6881 REF SOCKET RELAY 65 0A9457 1 DECAL NEUTRAL NOT SHOWN HARDWARE FOR ATTACHING WIRES TO I N 39 PART OF I N 51 P N 0F0526 CONTROL PANEL HARNESS Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Control Panel Drawing No 0E9719 E 42 Bryant 8 15 66 16 14 19 41 30 20 27 60 20 30 29 28 59 39 52 19 38 39 20 40 2 25 4 17 13 15 19 FOR HARNESS GROUND 5 3 22 17 68 15 19 10 38 22 31 0 HSG 20 3 47 45 20 49 1 16 39 50 34 35 65 33 57 18 37 18 20 16 38 RADIATOR CAP 62 TO 58 39 STEPPER MOTOR UNITS ONLY 17 12 A 11 67 24 23 61 Section 8 Exploded Views and Parts Bryant Liqui
26. 4 Spark plugs defective 4 Clean regap or replace plugs Engine starts hard runs rough 1 Flame arrestor air cleaner plugged or 1 Clean or replace as needed damaged 2 Plugged fuel line 2 Unclog fuel line 3 Defective spark plugs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low Coolant Level Switch 7 Replace Switch AUTO OFF MANUAL Switch at OFF 1 Defective AUTO OFF MANUAL switch 1 Replace switch engine continues to run 2 Open disconnected wire 15A between 2 Reconnect close wire AUTO OFF MANUAL switch and Control Module circuit board 3 Defective Control Module circuit board 3 Replace board No AC output from generator 1 Check main line circuit breaker 1 Reset to ON or CLOSED 2 Check circuit breaker amp fuses 2 Reset and replace if necessary 3 Transfer switch set to NORMAL position 3 Set to GENERATOR position 4 Generator internal failure 4 Contact a dealer 5 Thermal circuit breaker open 5 Auto reset Wait 5 min and attempt restart NOTE Under normal operating conditions if repair of gen
27. 83 C Bryant 35 Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Electrical Schematic 2 5L 25kW unit Drawing No 0E9983 C 36 Bryant Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Mounting Base Drawing No 0E9964 E 28 ENGINE BLOCK 5 CARRIER REAR BEARING 14 15 13 3 BOTTOM PANEL 3 2 12 4 1 11 15 14 13 33 2 3 12 11 36 35 10 10 3 1 6 8 9 3 22 21 27 23 1 25 26 29 34 20 24 TO 19 3 30 HARNESS 6 17 16 MOUNT 2 WIRE O STARTER TO STARTER 29 BOLT TO 3 32 Bryant 37 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Mounting Base Drawing No 0E9964 E ITEM PART NO QTY DESCRIPTION 1 0D9336 3 PANEL BRACKET 2 0E9939 2 CTRL PNL SUPPORT 2 5L FORD 3 0C2454 24 SCREW TH FRM M6 1 X 16 N WA Z JS 4 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 5 022097 1 WASHER LOCK M6 1 4 6 026850 2 WASHER SHAKEPROOF EXT 1 4 STL 7 055414 1 LUG SLDLSS 2 8 X 17 64 CU 8 022473 1 WASHER FLAT 1 4 M6 ZINC 9 047411 1 SCREW HHC M6 1 0 X 16 G8 8 10 052860 4 NUT FLANGED HEX M12 1 75 11 052251 4 DAMPENER VIBRATION 40 BLUE 12 052257 4 SPACER 49 X 62 X 1 87 PWDR ZNC 13 052252 4 DAMPENER VIBRATION 14 052259 4 WASHER FLAT M12 15 052891 4 SCREW HHC M12 1 75 X 80 G8
28. AL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 7 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 8 ASAE EP 3634 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRICAL SYS TEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 9 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Important Safety Instructions Bryant Liquid cooled 25 kW Generator 4 Bryant 1 1 GENERATOR This equipment is a liquid cooled engine driven gen erator set The generator is designed to supply elec trical power that operates critical electrical loads during utility power failure The unit has been facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the oper ation of 120 and or 240VAC single phase loads This model is rated as follows Model ASPAS1BBL025 Provides 25 000 watts 25 kW of single phase power 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 trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating NEC 701 Failure to iso
29. ARRANTY SCHEDULE YEARS ONE 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 to the painted enclosure should be repaired promptly by the owner THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Bryant generators that utilize non Bryant replacement parts Bryant generators utilizing non Bryant automatic transfer switches Any Bryant 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 adjustments 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 Bryant engines need periodic part s service and replace
30. CK M6 1 4 9 022473 12 WASHER FLAT 1 4 ZINC 10 022127 8 NUT HEX 1 4 20 STEEL 11 046627 1 CAP RADIATOR 12 060035 4 SPACER 41 X 75 X 87 ST ZNC ITEM PART NO QTY DESCRIPTION 14 0F0127 1 HOSE UPPER RADIATOR 174MM TAL 15 0E9833 1 HOSE 2 5L FORD LOWER RADIATOR 16 035461 1 BARBED STR 1 4NPT X 3 8 17 069860C 1 HOSE OIL DRAIN ASSY 21 18 0A7275 4 FOAM 1 5 X 1 ADHESIVE BACKING 21 5 LG 19 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 20 065852 1 SPRING CLIP HOLDER 37 62 21 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 24 0C2454 6 SCREW TH FRM M6 1X16 N WA Z JS 25 022287 4 SCREW HHC 1 4 20 X 3 4 G5 25 6 19 16 17 9 10 8 12 7 9 18 18 1 7 11 2 WATERINLET TO BASE OF 15 5 10 5 14 24 4 24 3 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Radiator Drawing No 0E9965 D Bryant 51 Section 9 Installation Diagram Bryant Liquid cooled 25 kW Generator Installation Diagram Drawing No 0F1020 A 52 Bryant Section 10 Warranty Bryant Liquid cooled 25 kW Generator 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 des
31. E 65 070007 3 WASHER FLAT M6 SS 66 070005 3 WASHER LOCK M6 SS 67 080826 3 SCREW HHC M6 1 0 X 12 SS 68 045771 1 NUT HEX M8 1 25 G8 YEL CHR 69 048031C 2 CLAMP HOSE BAND 1 4 NOTE TORQUE TO 44 FT LBS Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Engine Drawing No 0E9918 F 44 Bryant PORT OUT 1 22 7 21 TO ENGINE 10 42 COVER TO VALVE 12 13 28 1 8 20 33 31 32 17 34 26 6 38 30 16 25 24 18 4 29 15 9 5 27 6 4 CARBURETOR ASSY 0E1028A I N 19 CONVERSION 35 41 OUT 2 PORT L P VAPOR 3 40 1 11 3 40 7 2 6 11 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Fuel System Drawing No 0E9980 D Bryant 45 ITEM PART NO QTY DESCRIPTION 1 0E8456 1 BRACKET FUEL REGULATOR 2 075580 1 FLANGE FUEL INLET 3 0E9967 1 ASSY FUEL REG 2 5L FRD N G L P 4 039253 4 SCREW HHC M8 1 25 X 20 G8 8 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 6 WASHER LOCK M8 5 16 7 045771 2 NUT HEX M8 1 25 G8 YEL CHR 8 0F1570 1 BODY CARBURETOR ASSEMBLY 9 0A6344 1 BARBED EL 90 1 8 NPT X 3 8 10 0F3994 REF PCV VALVE 2 5L FORD 11 0E1056 1 FUEL HOSE ASSM NAT GAS L P V 12 0F0397 1 HOSE CRANKCASE BREATHER 13 0A5547 1 COVER AIR CLEANER 14 048031C 2 CLAMP HOSE BAND 1 4 15 0D1509 1 DECAL INLET PRESSU
32. GH COOLANT TEMPERATURE SWITCH Normally open N O thermostatic switch has sens ing tip which is immersed in captive coolant Should coolant temperature exceed about 230 F 110 C the switch contacts close which causes the engine to shut down automatically Figure 1 5 Figure 1 5 High Coolant Temperature Switch 1 7 3 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shutdown To prevent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatical ly shuts down Figure 1 6 on page 6 Section 1 General Information Bryant Liquid cooled 25 kW Generator 6 Bryant Figure 1 6 Low Coolant Level Sensor 1 7 4 OVERSPEED SHUTDOWN Should AC frequency exceed about 72 Hz circuit board action will automatically shutdown the engine 1 7 5 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking process when attempting to start the engine The first crank cycle is a 15 second crank followed by a seven second rest This is followed by five more crank cycles each with a seven second crank followed by a seven second rest If the engine fails to start after all six attempts the start attempt is stopped and the overcrank LED turns on 1 7 6 LOW BATTERY The engine control board continually mo
33. L RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service SJ or latest available Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change NOTE Synthetic oil is highly recommended when the generator will be operating in ambient tempera tures which regularly exceed 90 F and or fall below 30 F Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure DANGER NG FUEL SYSTEM LP FUEL SYSTEM Port 1 Port 2 FUEL HOSE BRASS HOSE FITTING OUT PORT 2 PLUG FUEL HOSE BRASS HOSE FITTING FUEL INLET PLUG OUT PORT 1 Section 1 General Information Bryant Liquid cooled 25 kW Generator Bryant 7 Temperature Oil Grade Recommended Above 80 F 27 C SAE 30W or 15W 40 32 to 80 F 1 to 27 C SAE 20W 20 or 15W 40 Below 32 F 0 C SAE 10W or 15W 40 8 Bryant 1 14 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half deionized water Cooling system capacity is about 8 U S quarts 7 6 liters Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolan
34. MM 31 070892 1 SLIP RING MACHINED Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Alternator Drawing No 0F5092 ITEM PART NO QTY DESCRIPTION 1 0F2912 1 PIPE MUFFLER OUT 2 0F2869 1 PIPE EXHAUST 2 5L FORD 3 0F2823 1 MUFFLER 2 5L FORD 4 036434 2 BOLT U 5 16 18 X 2 09 5 036449 2 SADDLE 2 INCH 6 022129 6 WASHER LOCK M8 5 16 7 022259 4 NUT HEX 5 16 18 STEEL 8 0E0170A 1 EXHAUST BLANKET 938MM 9 044149 1 GASKET EXHAUST RING 10 0E8816 1 EXHAUST FLANGE 2 PIPE 11 0F2925 2 STRAP MUFFLER 12 0F2926 1 BRACKET MUFFLER ITEM PART NO QTY DESCRIPTION 13 047411 4 SCREW HHC M6 1 0 X 16 G8 8 14 022097 4 WASHER LOCK M6 1 4 15 022473 8 WASHER FLAT 1 4 M6 ZINC 16 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 17 039253 2 SCREW HHC M8 1 25 X 20 G8 8 18 045771 2 NUT HEX M8 1 25 G8 YEL CHR 19 0A4010 1 SCREW HHC M8 1 25 X 60 G8 8 FT 20 022145 5 WASHER FLAT 5 16 M8 ZINC 21 022131 2 WASHER FLAT 3 8 M10 ZINC 22 085917 2 WASHER LOCK 3 8 SS 23 0D2611 2 SCREW HHC 3 8 16 X 1 3 4 SS 24 052858 1 NUT TOP LOCK FL M8 1 25 48 Bryant 17 19 20 11 7 6 4 5 7 20 3 6 5 2 12 4 20 18 6 15 13 24 11 1 16 15 14 9 8 22 21 10 23 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Muffler Drawing No 0F2930 B ITEM PART NO QTY DESCRIPTION 1 098290
35. OFF OFF O in the MANUAL Mode Weekly Exerciser X Flashing Flashing Flashing Flashing Flashing O O O is not set 1 sec rate Battery Voltage lt 12V X ON O O O for gt 1 minute Non latching Battery Voltage lt 6V X ON O O Unit Shutdown due OFF X ON O O to Low Oil Pressure Unit Shutdown due OFF X ON O O to High Temperature Unit Shutdown due OFF X ON O O to Engine Overspeed Unit Failed to Start OFF X ON O O during it s Crank Cycle Utility Voltage is Flashing X O O lt 45 of Nominal 1 sec rate Engine Speed Signal Fault OFF X Flashing O O Control Board Dip Switch OFF X The five RED LED s will turn on one at a time O O O is in wrong position X indicates that the LED can be ON or OFF depending on the operating conditions 14 Bryant 3 2 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMER GENCY power source side and start the engine man ually refer to the Owner s Manual of the particular transfer switch 3 3 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board The engine governor has been set by the factory during final testing of the generator and should not be adjusted If however adjustments are necessary the following procedure should be followed Figure 3 2 and Section 3 8
36. OR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing Five feet allowance of space is recommended on all sides Local codes may supercede this recommendation Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE 2 3 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic
37. Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model No ASPAS1BBL025 25kW Bryant INTRODUCTION Thank you for purchasing a Bryant home standby generator system Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAU TION and NOTE blocks are used to alert personnel to special instructions about a particular service or oper ation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows After this heading read instructions that if not strictly complied with will result in serious person al injury including death or considerable property damage After this heading read instructions that if not strictly complied with may result in personal injury or property damage After this heading read instructions that if not strictly complied w
38. RE 16 0E0591 1 ADAPTER CARB TO AIR CLNR 17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 1 4 20 NYLK 19 0E1028A 1 CARBURETOR ASSY 2 5L FORD 20 059401 1 CARBURETOR GASKET 21 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 22 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0C2454 3 SCREW TH FRM M6 1 X 16 N WA Z JS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0E0590A 1 VENTURI 20MM 33 0C5133 1 0 RING 29 82 X 2 62 34 0E0665 1 SCREW THROTTLE PIN STOP 35 0E1108 1 THROTTLE ARM REWORK 36 033138 1 SCREW HHM 10 32 X 5 8 37 022152 1 WASHER LOCK 10 38 0E0645 1 LEVER THROTTLE STOP 39 034339 1 BARBED EL 90 3 8 NPT X 5 8 40 059194 1 HOSE 5 8 ID LPG amp NG 24 LG 41 057823 2 CLAMP HOSE 10 56 1 06 42 0F0382 1 HOSE 3 8 90 DEG 2 5L PVC INCLUDED IN ITEM 19 CARBURETOR ASSY Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW Generator Fuel System Drawing No 0E9980 D 46 Bryant 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 8 Exploded Views and Parts Bryant Liquid cooled 25 kW G
39. ace cap if necessary To have pressure cap tested contact a dealer Inspect cool ing system and coolant recovery system for leaks 4 8 MAINTENANCE OWNER OPERATOR CAN PERFORM 4 8 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels 4 8 2 CHECK BATTERY See Checking Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 4 8 3 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See Weekly Exercise Cycle 4 8 4 INSPECT COOLING SYSTEM Inspect engine cooling system See Maintenance Schedule Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness Oil Dipstick Oil Filter Oil Fill Cap Engine Air Cleaner Section 4 Maintenance Bryant Liquid cooled 25 kW Generator 18 Bryant 4 8 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels 4 8 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks 4 8 7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks sec
40. andby Generator Part 2 Section 10 Warranty Bryant Liquid cooled 25 kW Generator 1 Fuel Metering System 1 2 LPG Natural Gas carburetion assembly and its internal components a Fuel controller if so equipped b Mixer and its gaskets if so equipped c Carburetor and its gaskets if so equipped d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped 2 Air Induction System including a Intake pipe manifold b Air cleaner 3 Ignition System including a Spark plug b Ignition module 4 Catalytic Muffler Assembly if so equipped including a Muffler gasket b Exhaust manifold 5 Crankcase Breather Assembly including a Breather connection tube Section 10 Warranty Bryant Liquid cooled 25 kW Generator BRYANT TWO YEAR LIMITED WARRANTY FOR PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Bryant warrants that its generator will be free from defects in material and workmanship for the items and period set forth below Bryant will at its option repair or replace any part which upon examination inspection and testing by a Bryant 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 Bryant prepackaged emergency automatic standby generators sold and rated for use in Standby applications W
41. anel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insu lation Keep the extinguisher properly charged and be familiar with its use Consult the local fire department for any questions pertaining to fire extinguishers EXPLOSION HAZARDS Properly ventilate any room or building housing the gener ator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Bryant generator sets may operate using one of several types of fuels All fuel t
42. ation NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available NOTE It is essential to use the latest version of any stan dard to ensure correct and current information Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 DANGER Section 2 Installation Bryant Liquid cooled 25 kW Generator Bryant 9 AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available from the American National Standard Institute 1430 Broadway New York N Y 10018 2 2 GENERAT
43. atteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 4 9 3 BATTERY MAINTENANCE The battery should be inspected per Section 4 7 Scheduled Maintenance 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 batter
44. cilities 16 4 2 Exhaust Manifold Procedure 16 4 3 Intake Manifold Procedure 16 4 4 Cylinder Head Procedure 16 4 5 Cooling System 17 4 6 Overload Protection for Engine DC Electrical System 17 4 7 Checking Fluid Levels 17 4 8 Maintenance Owner Operator Can Perform 17 4 9 Miscellaneous Maintenance 19 4 10 Scheduled Maintenance 21 Section 5 TROUBLESHOOTING 24 Section 6 NOTES 25 Section 7 ELECTRICAL DATA 28 Section 8 EXPLODED VIEWS AND PARTS LISTS 36 Section 9 INSTALLATION DIAGRAM 51 Section 10 WARRANTY 52 2 Bryant Study these SAFETY RULES carefully before installing operat ing or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed oper ated and maintained Many accidents are caused by failing to fol low simple and fun
45. d cooled 25 kW Generator Engine Drawing No 0E9918 F Bryant 43 ITEM PART NO QTY DESCRIPTION 1 0E9909 REF ENGINE 2 5L FORD 2 0E9739 1 PULLEY 2 5L FORD WATER PUMP 3 049814 8 SCREW HHC M10 1 5 X 25 G8 8 4 0F0001 1 CLUTCH COOLING FAN 2 5L FORD 5 0D3488B 1 SERPENTINE BELT 40 85 LENGTH 6 0A8584 1 SWITCH OIL PRESSURE 10PSI 2POL 7 0E0561 1 ASSY WATER LEVEL SENSOR C E PL 8 0A6751 1 SW TMP 245DEG 3 8NPT 9 035579 1 BUSHING REDUCER 1 4 TO 1 8 10 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 11 0E9611 1 MANIFOLD INTAKE MACHINED STEPPER MOTOR 0E9611A 1 MANIFOLD INTAKE MACH BOSCH32 BOSCH GOV NOT SHOWN 12 0E9681 1 GASKET 2 5L FORD INTAKE MAN 13 039253 4 SCREW HHC M8 1 25 X 20 G8 8 14 097962 4 SCREW SHC M6 1 0 X 25 G12 9 ZP 15 022145 8 WASHER FLAT 5 16 M8 ZINC 16 022097 11 WASHER LOCK M6 1 4 17 022129 16 WASHER LOCK M8 5 16 18 043107 11 SCREW HHC M8 1 25 X 25 G8 8 19 022131 19 WASHER FLAT 3 8 M10 ZINC 20 046526 22 WASHER LOCK M10 21 052625 2 SCREW SHC M10 1 5 X 35 G12 9 22 0E9708 2 ENGINE FOOT 2 5L FORD 23 0E9738 1 DIPSTICK 2 5L FORD 24 0E9929 1 BRACKET DIPSTICK TUBE 25 0F0230 1 FAN 16 COOLING 26 0E9834 1 HARNESS 2 5L FORD ENGINE NOT SHOWN 0E9834A 1 HARNESS 2 5L FORD BOSCH GOV NOT SHOWN 27 0D5417 6 SCREW HHC M10 1 0 X 25 G10 9 28 0E5048B 1 FLEXPLATE 2 5L FORD 29 0E9655 1 ADAPT CASTING MACH 2 5L FORD 30 057192 4 SCREW SHC M1
46. damental rules or precautions Bryant cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclu sive If using a procedure work method or operating technique that Bryant does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe Despite the safe design of this generator operating this equipment imprudently neglecting its mainte nance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or maintain this equipment 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 gen erators GENERAL HAZARDS For safety reasons Bryant recommends that this equip ment be installed serviced and repaired by a Bryant Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with applicable
47. dentify any poten tial problem areas Performed monthly this requires approximately 5 man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the 5 amp and 15 amp control panel fuses Turn off the battery charger turn OFF utility supply to ATS Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be perfo
48. deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac Warranty service can be arranged by contacting Generac Power Systems Inc IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Bryant Two Year Limited Warranty for Prepackaged Emergency Automatic Standby Generators which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Bryant 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 Bryant Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty serv ice evidence must be presented showing the date of the sale to the original purchaser owner To arrange for emissions equipment warranty or if you have any questions regarding your warranty rights and
49. e With OFF selected operation will not be possible Figure 3 1 Home Standby Generator Panel With switch set to AUTO engine can crank and start suddenly without warning Such automat ic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on con trol console 3 1 2 FAULT INDICATOR LEDS SEE CHART ON PAGE 13 These LEDs turn ON when one or more of the follow ing engine faults occurs and the engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed Engine Speed Signal Fault High Coolant Temperature Low Coolant Level See Section 1 7 for further explanation of engine pro tection functions DANGER FOR STAND BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATED TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE PART I ATTENTION POUR L ALIMENTATION DE RESERVE CONNECTER LA SORTIE DE LA ICE A UN COMMUTATEUR DE CALIBRE APPROPRIE CONFO CANADIEN DE L ECTRICITE PREMIERE PARTIE RISK OF ELECTRICAL SHOCK DO NOT REMOVE COVER NO USER SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR OUTDOOR INSTALLATION ONLY N AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE T INJURY REMOVE NEGATIVE
50. e gains In Test Mode the gain trimpots are active and can be adjusted See Section 3 4 FOR ST TRANS ATTEN RISK O P LOW COOLANT LEVEL HI COOLANT TEMPERATURE FLASHING GREEN LED NO UTILITY SENSE 5 FLASHING RED LED S EXERCISER NOT SET IN AUTO MODE ONLY SOLID GREEN LED SYSTEM READY UTILITY POWER ON SEE OWNER S MANUAL FOR COMPLETE DETAILS LED INDICATORS RED LED S INDIVIDUAL FAULT OVER CRANK SYSTEM READY LOW BATTERY LOW OIL PRESSURE OVER SPEED OFF MANUAL AUTO START RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN TIME SET EXERCISE TO AUTO POSITION SWITCH IN ON POSITION FOR 1 PLACE AUTO OFF MANUAL SWITCH 2 HOLD SET EXERCISE TIME TO SET EXERCISER TIME 10 SECONDS THEN THE UNIT WILL THE EXERCISER IS NOW SET ALL FIVE RED LED S WILL FLASH FOR THREE SECONDS AND RELEASE ON 0F0653 OFF 16 Bryant Section 4 Maintenance Bryant Liquid cooled 25 kW Generator 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A EVERY THREE MONTHS 1 Check battery condition 2 Inspect and test fuel system 3 Check transfer switch 4 Inspect exhaust system 5 Check engine ignition system 6 Check fan belts B ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature C ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator
51. e has been restored the switch re transfers back to the utility source voltage and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase 3 wire generator AC connection system Figure 1 1 The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can supply 120 VAC 60 Hertz When the two windings are connected in series a 240 VAC 60 Hertz AC output results Typically the two hot leads in the circuit are Wires No 11 and 44 The Neutral leads are the junction of Wires 22 and 33 Figure 1 1 Generator AC Connection System 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for each unit is described in Figure 1 2 0 NEUTRAL Section 1 General Information Bryant Liquid cooled 25 kW Generator Model Rating Phase Actual Current C B Rating over rating Circuit Breaker ASPAS1BBL025 25 000 W 1 104 2 A 125 A 120 125A BQ2 Amp Rating of C B structured under model Figure 1 2 Main Circuit Breaker Bryant 5 1 6 GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is pre fer
52. ed 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 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 Ser
53. eler gauge Adjust the gap to 1 07 1 17 mm 0 042 0 046 inch by carefully bending the ground elec trode Figure 4 2 Figure 4 4 Setting the Spark Plug Gap DANGER Section 4 Maintenance Bryant Liquid cooled 25 kW Generator SET PLUG GAP AT 1 07 1 17 mm 0 042 0 046 inch Bryant 19 4 8 13 COOLANT CHANGE Every year have a Bryant dealer drain flush and refill the cooling system See Specifications for cool ing system recommendations 4 9 MISCELLANEOUS MAINTENANCE 4 9 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by a dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 9 2 BATTERY All lead acid storage b
54. enerator Alternator Drawing No 0F5092 Bryant 47 ITEM PART NO QTY DESCRIPTION 1 0F1659A 1 ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD 0F1657A 1 ROTOR 390 20KW 1P DIRECT HSB 2 5L FORD 0F1655A 1 ROTOR 390 25KW 1P DIRECT HSB 2 5L FORD 0F5073A 1 ROTOR 390__30AD1 HSB TECUM 2 0F1660A 1 STR 390 15AD HSB 382MM LONG 2 5L FORD 0F1658A 1 STR 390 20AD HSB 382MM LONG 2 5L FORD 0F1656A 1 STR 390 25AD HSB 382MM LONG 2 5L FORD 0F5074A 1 STR 390__30AD1 HSB TECUM 3 0E5706 1 REAR BEARING CARRIER 390 DRCT 4 0E5048 REF FLEXPLATE 3 0L FORD 0E5048B REF FLEXPLATE 2 5L FORD 5 0E6668 1 FLYWHEEL ASSY 3 0L HSB LG GEAR 6 0E6076 1 REVCOR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 1 WASHER SHAKEPROOF INT 8 14 0C3993 4 SCREW HHTT M4 0 7 X 25 BP 15 057192 4 SCREW SHC M10 1 5 X 30 G12 9 16 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 19 022264 4 WASHER LOCK 8 M4 20 038150 4 WASHER FLAT 8 ZINC 21 077043F 1 CONDUIT FLEX 1 1 4 30 LG 3 0L FORD amp 3 9L CHRYSLER 077043F 1 CONDUIT FLEX 1 1 4 18 LG 2 5L FORD ROTOR REPLACEMENT PARTS 30 047248 1 BALL BEARING 45
55. erator set or replacement of any parts is necessary dur ing the warranty period you must contact a dealer Failure to have the repair or replacement performed by a Bryant dealer will result in non coverage of warranty repair cost Bryant 25 Section 6 Notes Bryant Liquid cooled 25 kW Generator 26 Bryant Section 6 Notes Bryant Liquid cooled 25 kW Generator Bryant 27 Section 6 Notes Bryant Liquid cooled 25 kW Generator 28 Bryant Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine Drawing No 0F1411 A Bryant 29 Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine Drawing No 0F1411 A 30 Bryant Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Electrical Schematic 2 5L Engine Drawing No 0F1413 A Bryant 31 Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Electrical Schematic 2 5L Engine Drawing No 0F1413 A 32 Bryant Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine 25kW unit Drawing No 0E9982 C Bryant 33 Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine 25kW unit Drawing No 0E9982 C 34 Bryant Section 7 Electrical Data Bryant Liquid cooled 25 kW Generator Electrical Schematic 2 5L 25kW unit Drawing No 0E99
56. generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance Section 2 Installation Bryant Liquid cooled 25 kW Generator 12 Bryant Section 3 Operation Bryant Liquid cooled 25 kW Generator 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems for additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and volume and b is properly purged and leak tested according to code No fuel leakage is permitted 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations
57. ies and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off or sparking
58. igned built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may
59. ill flash for approxi mately 10 seconds then the engine will start and run for it s 12 minute exercise period then shut down The generator will now start and run each week at the same time Figure 3 3 Set Exercise Time Switch If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In this state the generator will still start and run in manual mode or automatically start and run if utility is lost while in Auto mode but it will not perform a weekly exercise cycle If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switch to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set 3 7 CONTROL BOARD DIP SWITCH SETTINGS Located on the control board is an eight position DIP switch see Figure 3 2 The eight different switches are used to configure the control board for the spe cific engine and governor being used and are pre set at the factory If the DIP switch settings are not set correctly the generator may not start or operate correct ly 240 VAC can be present within the control panel If it is necessary to select an alternate switch position move the AUTO OFF MANUAL switch to the OFF position Remove the 5 am
60. ith could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment Bryant strongly recommends that the operator reads this Owner s Manual and thor oughly understands all instructions before using this equipment Bryant also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a dealer Normal maintenance service adjustments and replacement of
61. late an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system is intended to be used with a matched automatic transfer switch It is supplied with a NEMA 3R enclosure The NEMA 3R enclosure is weather proof and can be used indoors or out doors Follow these rules Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors If a transfer switch is not included one may be pur chased separately from a dealer 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors utility power source voltage Should that voltage drop below a pre set value and remain at such a low state for a preset amount of time the generator cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can power them When utility source voltag
62. ment 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 Bryant 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 expenses 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 BRYANT MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states d
63. nitors the battery voltage and turns on the low battery LED if the battery voltage falls below 12 VDC for one minute Low battery voltage is a non latching alarm which will automatically clear if the battery voltage rises above 12 VDC 1 7 7 15A DC FUSE This fuse is located inside the control panel It pro tects the panel wiring and components from damag ing overload The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating 1 8 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 9 LIFTING THE GENERATOR When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 ENGINE Make Ford Displacement 153 inches3 2 5 liters Cylinder Arrangement 4 in line Valve Arrangement Overhead Cam Firing Order
64. o not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you BRYANT S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL BRYANT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF BRYANT S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state Revision 10 01 04 Part No 0F4248 Rev 0 01 19 05 Printed in U S A Catalog No 13AS PA6 Form No OM18 3
65. o operation Ensure that the 5A and 15A fuses in the control panel are removed when connecting or disconnecting battery cables DANGER DANGER Section 2 Installation Bryant Liquid cooled 25 kW Generator MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE 460 feet 140m No 18 AWG 461 to 730 feet 223m No 16 AWG 731 to 1 160 feet 354m No 14 AWG 1 161 to 1 185 feet 565m No 12 AWG Bryant 11 Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not dispose of the battery in a fire The bat tery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes The battery represents a risk of high short
66. p and 15 amp fuses in the generator control panel Move the DIP switch position that needs to be changed to its new position Wait five seconds then re install the 5 and 15 amp fuses The ON position is marked on the switch and the fac tory settings are also shown in Figure 3 3 Switch Position 1 Selects the generator alternator output frequency and is factory pre set for 60 Hz Switch Position 2 Selects the type of transfer switch and is factory pre set for the prepackaged transfer switch Switch Position 3 Selects the type of governor control used and is factory pre set for stepper motor control Switch Position 4 Selects the type of fuel being used and is factory pre set for natural gas NG Switch Position 5 Selects the engine displacement and is factory pre set for a 2 5 liter 2 5L engine Switch Position 6 Selects the number of engine cylinders and is factory pre set for four cylinders Switch Position 7 Selects the direction of rotation of the governor stepper motor and is factory pre set for CCW rotation rotation is observed looking at the stepper shaft as it move from closed throttle to open throttle Switch Position 8 Selects whether the control is in the Normal Mode of operation or Test Mode In the Normal Mode of operation pre determined governor gains are used and the gain trimpots on the control board Gain Stability and Differential are not active and have no effect on th
67. 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 dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by a dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact a dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a Bryant Dealer about parts and service always supply the complete model number and serial number of the unit as given on the front cover of this manual and on the DATA LABEL affixed to the unit DANGER YOUR BRYANT DEALER IS ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ Model No __________ Serial No ___________ Dealer Name Address City State Zip Code Phone Number Table of Contents Bryant Liquid cooled 25 kW Generator Bryant 1
68. rect as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system 19 Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary 20 Perform a 5 minute no load operational run of the unit looking for any post service problems 21 Return the unit to standby setup for operation when required 24 Bryant Section 5 Troubleshooting Bryant Liquid cooled 25 kW Generator TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won t crank 1 15 amp fuse blown 1 Replace fuse 2 Loose or corroded or defective 2 Tighten clean or replace battery cables battery cables as necessary 3 Defective starter contactor 3 Replace contactor 4 Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery 6 5 amp fuse blown 6 Replace fuse Engine cranks but won t start 1 Out of fuel 1 Replenish fuel 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Open Wire 14A from Engine Control 3 Reconnect wire circuit board
69. red refer to Section 1 12 Reconfiguring the Fuel System for LP Vapor Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A separate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability Gaseous fuels such as natural and LP propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Figure 1 3 Engine Protective Devices 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 7 2 HI
70. respon sibilities you should contact Generac at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 www generac com Part 1 Bryant 53 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warrant
71. retaining clip 4 Turn OIL FILTER Figure 4 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 4 8 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 1 See the Service Schedule for air cleaner mainte nance Section 4 10 4 8 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary Figure 4 4 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule Section 6 for recommended inspection 3 Check the spark plug gap using a wire fe
72. rmed only by a dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually this requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually this requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by a dealer 22 Bryant Section 4 Maintenance Bryant Liquid cooled 25 kW Generator Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp to be done Comp to be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Date monthly Initials Break in Initials annually Initials Annually Initials 1 Disable the unit from operating per the first page warning 2 Check the engine oil level Adjust as necessary 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal p
73. rotection level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary Bryant 23 Section 4 Maintenance Bryant Liquid cooled 25 kW Generator Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp to be done Comp to be done Comp Required Comp to be done Date 3 months Date Semi Date to be done Date monthly Initials Break in Initials annually Initials Annually Initials 13 Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Cor
74. s tem normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distri bution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy If an open bottom is used the engine genera tor must be installed over non combustible materials and should be located such that com bustible materials are not capable of accumu lating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standards and regula tions pertaining to the installation After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regula tions NOTE For more information about the installation of a standby system contact a dealer 2 1 1 NFPA STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 NOTE It is essential to use the latest version of any stan dard to ensure correct and current inform
75. s given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot or LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors 1 12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 3 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator 4 Remove pipe plug from Port 2 5 Install brass hose fitting into Port 2 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure and type for configuration 10 Move dip switch position 4 on the control board to the off position LP vapor see Figure 3 2 and Section 3 8 11 Reverse the procedure to convert back to natural gas Figure 1 8 Reconfigure the Fuel System NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made Serious injury or damage may occur if not con figured properly Please consult a dealer with any questions 1 13 ENGINE OI
76. t mixture When adding coolant always add the recommended 50 50 mixture Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethyl ene glycol base anti freeze Using any high sili cate anti freeze boosters or additives will also cause overheating DO NOT use any soluble oil inhibitor for this equipment 1 15 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in Sections 2 5 and 2 6 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power It may be necessary to group the critical essential loads together and wire them into a separate emergency distribution panel This generator can be installed in conjunction with an engineered transfer switch if necessary The standard prepackaged transfer switch does not have sensing or controlling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION Connecting this generator to an electrical sy
77. tion devices will open if the circuit is overloaded If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 7 CHECKING FLUID LEVELS 4 7 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 3 at least every 20 hours of operation or prior to use Figure 4 3 Oil Dipstick and Oil Fill Cap Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils 4 7 2 BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule Fluid should cover separa tors in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 4 7 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Repl
78. urity damage 4 8 8 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required 4 8 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the gover nor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or volt age Only qualified service technicians should adjust the governed speed 4 8 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its
79. use will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset 3 1 5 SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically See Weekly Exercise Cycle 3 1 6 SYSTEM READY LED The System Ready LED green has two main pro poses First the LED will be ON when the AUTO OFF MANUAL switch is in the AUTO position utility is present and there are no system alarms This ON state indicates the system is fully ready for automatic operation The system ready LED will be OFF when the switch is in the manual or OFF positions The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes The LED will flash at the rate of 1 2 second on 1 2 second off if the utility sensing level is below the transfer back threshold This secondary function is only available with dip switch two in the OFF position ATS automatic transfer switch application Section 3 Operation Bryant Liquid cooled 25 kW Generator Condition System Low Low High Over Over Switch Position Ready Green Bat Red Oil Red Temp Red Speed Red Crank Red Manual Auto Off Generator Switch is OFF X OFF OFF OFF OFF O in the OFF Mode System Ready for ON X OFF OFF OFF OFF O Automatic Start Generator Switch is OFF X OFF OFF
80. vice Dealer 5 When the engine is inspected by a Generac Authorized Warranty Service Dealer the owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 St
81. ween the building s main distribution panel and the emergency distribution panel Section 2 Installation Bryant Liquid cooled 25 kW Generator 10 Bryant 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed the Total Circuit Isolation Method may be used The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution panel 2 7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices
82. y from batteries The recommended battery is Group 26 525 CCA 75 AH minimum at 0 F 17 8 C All batteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in Section 4 Maintenance A negative ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed serv iced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equip ment 2 11 1 PRIOR TO INITIAL START UP Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the
83. ypes are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air Install leak detectors accordingly STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be used as installation guide for this equipment NOTE It is essential to use the latest version of any stan dard to ensure correct and current information 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 2 NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES available same as Item 1 3 NFPA No 54 NATIONAL FUEL GAS CODE avail able same as Item 1 4 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 5 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 6 Article X NATION

Download Pdf Manuals

Related Search

Related Contents

Samsung ES9 Εγχειρίδιο χρήσης  USB-Grabber  PDF形式（6685KB）  Dell STUDIO XPS D03M001 Specifications  

Copyright © All rights reserved. Failed to retrieve file