Carrier ASPAS1CCA012 manual

GENERA C POWER SYSTEMS, INC. R R Parts, Adjustment and Maintenance Manual Air-cooled, Prepackaged Automatic Standby Generators Models: ASPAS1CCA007 (6 kW NG, 7 kW LP) ASPAS1CCA012 (12 kW NG, 12 kW LP) ASPAS1CCA015 (13 kW NG, 15 kW LP) DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y!! D ANGER Not intended for use as Primary Power in place of uti[...]

Carrier I NTRODUCTION This Carrier model is a compact, high performance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation. This generat[...]

T able of Cont ents Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Carrier 1 Introduction ........................Inside Front Cover Read This Manual Thoroughly ..............................IFC Contents ................................................................IFC Operation and Maintenance ..................................IFC How to[...]

2 Carrier Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Parts, Adjustment and Maintenance Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to fol[...]

ELE CTR ICAL HA Z AR DS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as t[...]

4 Carrier Section 1 — Post Installation Start-up and Adjustments Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1.1 B EFOR E I N ITIAL S T ART -U P Before starting, complete the following: 1. Set the generator’s main circuit breaker to its OFF (or open) position. 2. Set the generator's AUTO/OFF/MANUAL switch to the OFF position. 3.[...]

1.4 GEN ER A T OR TES TS UN DER L O AD To test the generator set with electrical loads applied, proceed as follows: 1. Set generator’s main circuit breaker to its OFF (or OPEN) position. 2. Turn OFF all loads connected to the transfer switch terminals T1 and T2. 3. Set the generator's AUTO/OFF/MANUAL switch to OFF. 4. Turn OFF the utility po[...]

3. Turn on appliances, lights, pumps, etc., that are on the emergency circuits in an attempt to fully load the generator. Be cautious not to overload the generator. Use the following chart as a guide: 4. When full load has been achieved. Connect a frequency meter to the output lugs of the generator’s main line circuit breaker. 5. The fuel regulat[...]

9. Reverse procedure steps 1-5 to reinstall demand regulator. 10. Reverse the procedure to convert back to natural gas. 1.7 .2 1 2KW AN D 1 5KW , V - T WIN ENGI N ES To reconfigure the fuel system from NG to LP, follow these steps: NOTE: The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 11 to 14 inc[...]

6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment. 1.8.2 1 2 KW AN D 1 5 KW UN ITS 1. Loosen governor clamp bolt (See Figure 1.6). 2. Completely remove the idle spring. 3. With governor arm at wide open throttle position (rotated fully clockwise), rotate gove[...]

• Remove the four screws attaching the valve cover with a #2 or #3 phillips screwdriver. • Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rota[...]

Section 2 — T roubleshooting Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 2.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. Fuse blown. 1. Replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary. 3. Defective starte[...]

Carrier 11 Section 3 — Maintenance Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 3.1 SERVICE S CHEDU LE A TTENTION: It is recommended that all service work be performed by the nearest Carrier Dealer . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y =[...]

CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION BLACK BLACK CUSTOMER SUPPLIED CUSTOMER[...]

Carrier 13 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram — Single Cylinder — Drawing No. 0E90 14 CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION BLACK CUSTOMER SUPPLIED BATTERY 12V LOP H[...]

14 Carrier 13 13 77 77 CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL (STATOR) (STATOR) CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB1 - CIRCUIT BREAKER, MAIN OUTPUT HTO - HIGH OIL TEMPERATURE SWITCH HTO - HIGH OIL TEMPERATURE SWITCH SW1 - AUTO / OFF / MANUAL SWITCH SW1 - AUTO / OFF / MANUAL SWITCH CB2 -[...]

Carrier 15 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic — Single Cylinder — Drawing No. 0E90 1 5 13 77 CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL (STATOR) CB1 - CIRCUIT BREAKER, MAIN OUTPUT HTO - HIGH OIL TEMPERATURE SWITCH SW1 - AUTO / OFF / MANUAL SWITCH CB2 - CIRCUIT BREAKER, [...]

16 Carrier GRD CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) CUSTOMER SUPPLIED CUSTOMER SUPPLIED BLACK BLACK BATTERY BATTERY 12V 12V 0 0 HTO HTO SP2 SP2 SP1 SP1 LOP LOP 0 0 8[...]

Carrier 17 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram — V - T win — Drawing No. 0E90 16 GRD GRD CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) CUSTOMER SUPPLIED BLACK BATTERY 12V 0 HTO SP2 SP1 LOP 0 86 85 IM2 85 IM1 D D BA - BR[...]

18 Carrier 77 77 13 13 FIELD FIELD DPE WINDING DPE WINDING (STATOR) (STATOR) CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL CB2 - CIRCUIT BREAKER, ALT. EXCITATION CB2 - CIRCUIT BREAKER, ALT. EXCITATION SW1 - AUTO / OFF / MANUAL SWITCH SW1 - AUTO / OFF / MANUAL SWITCH CB1 - CIRCUIT BREAKER, MAIN O[...]

Carrier 19 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic — V - T win — Drawing No. 0E90 1 7 77 13 FIELD DPE WINDING (STATOR) CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL CB2 - CIRCUIT BREAKER, ALT. EXCITATION SW1 - AUTO / OFF / MANUAL SWITCH CB1 - CIRCUIT BREAKER, MAIN OUTPUT HTO - [...]

20 Carrier Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram — 8 Circuit Load Cent er — Drawing No. 0E7 68 7A[...]

Carrier 21 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram — 8 Circuit Load Cent er — Drawing No. 0E7 68 7A[...]

22 Carrier Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram — 1 0 and 12 Circuit Load Cent er — Drawing No. 0E7 68 7[...]

Carrier 23 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram — 1 0 and 12 Circuit Load Cent er — Drawing No. 0E7 68 7[...]

24 Carrier F1 F1 B B N2A N2A B B N2A N2A A A B B E2 E2 VR1 VR1 C1 C1 E2 E2 C2 C2 VR2 VR2 T1 T1 T2 T2 T2 T2 T1 T1 N2A N2A NO NO XB XB NO NO B B 205 205 B B XA XA COM COM NC NC 126 126 COM COM NC NC 7 7 7 7 N1A N1A E1 E1 126 126 1 1 N1A N1A E1 E1 9 9 9 9 205 205 N1A N1A 4 4 3 3 6 6 23 23 TR TR 194 194 N1A N1A E1 E1 N2A N2A E2 E2 E2 E2 E1 E1 E2 E2 N2A[...]

Carrier 25 Section 4 - Electrical Data Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electical Schematic — 1 0 and 1 2 Circuit Load Cent er — Drawing No. 0E7 8 1 5 NEUTRAL NEUTRAL CONNECTION CONNECTION INSIDE SWITCH INSIDE SWITCH XB XB NO NO C1 C1 COM COM XA XA VR1 VR1 NC NC NC NC COM COM C2 C2 VR2 VR2 NO NO TR TR 194 194 23 23 1 1 7 7[...]

26 Carrier 68 51 35 PRE PACKAGED UNITS ONLY 52 49 48 51 18 47 20 2 49 43 46 51 49 4 43 37 A 25 33 36 24 32 35 34 23 26 44 79 77 74 35 49 82 80 8 51 46 80 85 81 84 78 72 87 86 5 76 82 48 39 70 92 50 94 91 63 21 15 7 51 71 58 69 42 10 35 11 49 51 31 9 90 49 50 72 73 52 41 58 57 27 91 56 1 44 62 60 19 A 47 40 12 71 67 93 64 51 48 61 50 38 89 22 49 49 [...]

Carrier 27 ITEM PART NO. QTY. DESCRIPTION 1 0C6140 1 ASS E M B LY, E N CLO S U R E B AS E 0D1901 1 ASS E M B LY, E N CLO S U R E B AS E (7K W ) 2 0C6735 2 S UPPO R T, R OOF FOLDI N G 3 0F0063 1 E N CLO S U R E, F R O N T 4 0C7062 1 E N CLO S U R E, EXH A U S T S IDE 0C7062 A 1E N CLO S U R E, EXH A U S T S IDE (7K W ) 5 0E8811 1 E N CLO S U R E, S [...]

28 Carrier 21 46 2 2 37 38 8,32 8,9 27 44 47 10 13 19 23 15 17 49 15 5 34 23 36 39 38 45 48 2 29 21 17 4 6 7 49 23 27 42 12 45 44 20 40 11 1 43 15 35 30 29 3 29 41 24 45 47 31 47 45 31 33 50 13 52 51 53 53 54 55 56 57 59 58 49 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Control Panel — Drawing No. [...]

Carrier 29 ITEM PART NO. QTY. DESCRIPTION 1 0E7886 A 1C I R CUIT B R E A KE R 30 A X 2P 240V (7K W ) 0E7886E 1 CI R CUIT B R E A KE R 50 A X 2P 240V (12K W ) 0E7886F 1 CI R CUIT B R E A KE R 60 A X 2P 240V (13K W ) 0E7886G 1 CI R CUIT B R E A KE R 70 A X 2P 240V (15K W LP) 20 A 1801 1 ASS E M BL Y , B A TTE R Y CH AR GE R E N GI N E 3 083049 1 ASS [...]

30 Carrier 30 1 29 23 16 27 9 22 22 21 16 23 24 10 31 7 9 4 6 11 5 3 2 33 20 4 36 19 25 15 4 32 34 34 35 12 26 14 8 13 3B 3A 17 37 18 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7kW , 8 Circuit Load Center Assembly — Drawing No. 0E7 97 5-B[...]

Carrier 31 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7kW , 8 Circuit Load Center Assembly — Drawing No. 0E7 97 5-B ITEM PART NO. QTY. DESCRIPTION 1 0D4801 1 BO X GT S LO A D CE N TE R 2 0D4800 1 CO VE R , 8 PO S ITIO N GT S LO A D CE N TE R 3 0C2237 1 T RANS FE R SW ITCH HO M E S T AN DBY 100 A 2[...]

32 Carrier 30 1 29 23 16 27 9 22 22 21 16 23 24 10 31 7 9 4 6 11 5 3 2 39 26 4 36 19 25 15 38 33 32 34 34 35 20 37 12 14 8 13 3B 3A 38 18 17 40 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW (1 0 Circuit) and 1 5 kW (1 2 Circuit) Load Center Assembly — Drawing No. 0E7 9 7 3-E[...]

Carrier 33 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW (1 0 Circuit) and 1 5 kW (1 2 Circuit) Load Center Assembly — Drawing No. 0E7 9 7 3-E ITEM PART NO. QTY. DESCRIPTION 1 0D3086 1 BO X GT S LO A D CE N TE R 2 0D3092 1 CO VE R , 12 PO S ITIO N GT S LO A D CE N TE R 0F5211 1 CO VE R , 10 PO[...]

34 Carrier 11 47 33 34 36 35 37 27 45 43 39 18 19 20 23 32 44 48 24 46 11 22 29 28 31 30 17 52 1 14 13 26 38 25 25 40 41 12 21 15 16 6 1 2 4 42 10 5 7 3 8 9 49 51 50 54 53 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine — Drawing No. 0F4 7 1 6 Page 1[...]

Carrier 35 ITEM PART NO. QTY. DESCRIPTION 1 0E3221 1 ASS E M BL Y , CO NN ECTI N G R OD 2 0E1466 1 PI N , PI S TO N D20 3 021533 1 S ET , PI S TO N R I N G 90 MM 4 0E2985 1 PI S TO N , HC 5 071983 2 R ET A I N E R , PI S TO N PI N 20 6 0E8440 1 ASS E M BL Y , C RAN K S H A FT GH410 SMA LL T A PE R 70 A 7628 1 ARM , GO VE RN O R R C45 8 078658 1 PI [...]

36 Carrier 19 20 41 43 21 23 22 40 3 6 28 24 44 39 38 12 6 7 5 6 6 45 8 16 18 17 15 14 13 29 31 30 6 27 49 46 47 50 51 9 10 11 42 10 48 37 1 26 2 33 35 18 25 32 18 34 34 36 4 6 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine — Drawing No. 0F4 7 1 6 Page 2[...]

Carrier 37 ITEM PART NO. QTY. DESCRIPTION 1 0C1069 5 S C R E W , T A PTITE M 6-1.0X8 YELLO W CH R O M E 2 0D2922 1 HOU S I N G, BLO W E R 3 0C8435 1 TUBE, DIP S TICK 4 0C9997 1 GU AR D, F AN 5 088434 1 WRA PPE R , BO TT O M 6 045756 11 S C R E W , T A PTITE M 6-1X10 YELLO W CH R O M E 7 0C4176 A 1 WRA PPE R , T OP 8 0D9004 A 1 ASS Y, S T AR TE R 9 [...]

38 Carrier 143 47, 48, 49, 50, 51, 52, 53, 54, 56, 57, 58, 59, 60, 62, 63, 64 7, 47, 48, 49, 50, 51, 52, 53, 54, 56, 57, 58, 59, 60, 63, 64 144 53 46 48 47 49 50 51 52 40 38 41 42 28 45 44 43 29 143 39 37 26 27 3 31 24 140 32 3 35 55 33 36 20 57 19 58 59 61 60 64 62 63 65 1 2 6 3, 32, 33, 34, 35, 36, 40, 72 27, 28, 29 16A, 16B, 17, 18 4, 5, 6 8, 11[...]

Carrier 39 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GT -990 Eng ine - Drawing No. F4 7 1 5 P age 1 ITEM PART NO. QTY. DESCRIPTION 1 0C5729 1 ASS E M BL Y , C RAN KC AS E HOU S I N G W ITH S LEEVE 2 0E9843 1 S E A L, 38 I.D . C RAN K S H A FT 3 090388 3 S C R E W , T A PTITE M 6-1.0 X 12 YC 4 0C537[...]

40 Carrier 112 112 128 110 133 94 91 84 88 86 89 85 90 89 93 74 80 82 83 81 79 117 102 99 92 97 98 101 113 112 105 107 108 104 103 106 111 109 143 125 87, 123 96 95 143 130 114 75 78 77 76 99 100 118 98 97 121 124 124 119 122 125 137 120 127 126 115 116 131 136 138 132 142 129 134 139 135 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 k[...]

Carrier 41 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GT -990/760 Engine - Drawing No. F4 7 1 5 P age 2 ITEM PART NO. QTY. DESCRIPTION 74 0C5136 A 2K N OB, A I R CLE AN E R 75 0C3024 1 CO VE R , A I R BO X N G/LP 76 0C3040 1 P R E-CLE AN E R , 77 0C8127 1 ELE M E N T, A I R CLE AN E R 78 0D8564 A 1 [...]

42 Carrier Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator - Drawing No. 0D35 04-D 37 6 51 7 8 21 53 9 3 2 1 4 5 23 11 31 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 28 13 39 18 10 40 29 34 35 34 41 42 43 44 48 49 30 45 46 34 36 47 31 50 52[...]

Carrier 43 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator - Drawing No. 0D35 04-D ITEM PART NO. QTY. DESCRIPTION 1 0C6934 1 A D A PTE R , E N GI N E 2 0C9935H 1 S T A TO R 3 0C9934H 1 R OTO R 4 0C6043 A 1C ARR IE R , R E AR BE AR I N G 5 0C8096 1 F AN , 8" CU R VED BL A DE 6 0C9593 1[...]

44 Carrier Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator - Drawing No. 0D3 4 1 7-J 36 35 36 37 6 34 7 8 21 43 9 3 2 1 4 5 23 11 24 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 29 28 13 28 39 18 10 40 29 41 42 36 36 35 41[...]

Carrier 45 Section 5 - Exploded Views and P arts Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator - Drawing No. 0D3 4 1 7-J ITEM PART NO. QTY. DESCRIPTION 1 0C6934 1 A D A PTE R , E N GI N E 2 0C7930 1 S T A TO R 12K W 0 D2359 S T A TO R 13K W / 15K W 3 0C7944 1 R OTO R 12K W 0D2356 R OTO R 13K W / 15K W 4 0C6043 1[...]

46 Carrier ITEM PART NO. QTY. DESCRIPTION 1 0D5694 1 C AS TI N G, T W I N R EGUL A TO R HOU S I N G 2 0F3154 1 S OLE N OID COIL, 12VDC 3 0C4647 1 G AS KET , S OLE N OID 4 0D4166 1 PLU N GE R , LP R EGUL A TO R ASS E M BL Y 5 0C6070 1 S P R I N G- S OLE N OID , PLU N GE R 8 0F4795 4 S C R E W PPH M S E MS M 4-0.7 X 10 9 0C5760E 1 JET , G N 410 E N G[...]

Carrier 47 TYPE HOM 120/240v CBHOM-F TYPE HOM CBHOM-F 120/240v TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM CBHOM-F 120/240v TYPE HOM CBHOM-F 120/240v TYPE HOM CBHOM-F 120/240v TYPE HOM CBHOM-F 120/240v TYPE HOM CBHOM-F 120/240v TYPE HOM CBHOM-F 120/240v TYPE HOM CBHOM-F 120/240v M6PEM-T M6PEM-T M6PEM-T M6P[...]

48 Carrier Section 7 - Notes Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators[...]

Carrier 49 Section 7 - Notes Carrier Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators[...]

PART NO. 0F4709 REV.A (01/12/05) CATALOG NO. 02AS-PA0 FORM ASPAS07-1 PD PRINTED IN U.S.A.[...]