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Generac Power Systems ASPAS1CCL015 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y! This manual should remain with the unit. Not intended f or use in critical life support applications. ! ! Liquid-cooled, Prepac kaged Standb y Generators Model Number: ASP AS1CCL015[...]

  • Page 2

    Carrier I NTRODUCTION Thank you for purchasing a Carrier home standby generator system. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten. However , the manufacturer reserves the right to change, alter or otherwise improve this product(s) at[...]

  • Page 3

    T able of Contents Carrier Liquid-cooled 1 5 kW Generators Carrier 1 INTRODUCTION .................................. IFC SAFETY RULES ...................................... 2 Section 1 — GENERAL INFORMA TION ..................4 1.1 Generator ......................................................4 1.2 Transfer Switch ..............................[...]

  • Page 4

    2 Carrier 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 fu[...]

  • Page 5

    Carrier 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 MA Y RESUL T . • If people must stand on met[...]

  • Page 6

    4 Carrier 1.1 GEN ER A T OR 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 [...]

  • Page 7

    Carrier 5 1.6 GEN ER A T OR F U EL SY S TEM The generator has been factory tested and adjusted using a natural gas fuel system. If propane (LP requirements) gas is preferred, refer to Section 1.12. Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas and at least 2,520 Btus per cubic foot for LP gas. Ask[...]

  • Page 8

    6 Carrier Figure 1.6 - Low Coolant Level Sensor 1.7 .4 OVERSPEED SH UTDO WN The Pre-pack circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator AC power windings, via sensing leads S15 and S16. Should AC frequency exceed about 72 Hz, cir- cuit board action will automatically shutdown the engine (Figure 1.7[...]

  • Page 9

    1.1 0.2 ENGI NE SP ECIF ICA TIONS Make ..............................................................................Mitsubishi Displacement .............................................. 9 2 inches 3 (1.5 liters) Cylinder Arrangement ......................................................4, in-line V alve Arr angement ..............................[...]

  • Page 10

    8 Carrier 1.1 4 ENGI N E OI L R E COMM EN D A TIONS The unit has been filled with 15W -40 engine oil at the factory . Use a high- quality detergent oil classified “F or 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 tempe[...]

  • Page 11

    Carrier 9 NOTE: It is essential to use the latest version of any stan- dard to ensure correct and current information. • NFP A No. 37, ST A TIONARY COMBUSTION ENGINES AND GAS TURBINES. • NFP A No. 76A, ESSENTIAL ELECTRICAL SYS- TEMS FOR HEAL TH CARE F ACILITIES. • NFP A No. 220, ST ANDARD TYPES OF BUILDING CONSTRUCTION • NFP A No. 68, GUIDE[...]

  • Page 12

    10 Carrier 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD 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 isolati[...]

  • Page 13

    Carrier 11 2.1 0 B A T TER Y I NST ALL A TION 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 pr eset level. T o prevent such automatic start-up and possible injury to personnel, do not connect battery cables until the NORMAL[...]

  • Page 14

    12 Carrier Before starting the generator for the first time, the installer must complete the following procedures. F or follow-up maintenance information and/or service intervals, please refer to Section 4, “Maintenance.” 2.1 1.2 TR ANSFER SWIT CH If this generator is used to supply power to any elec- trical system normally powered by an electr[...]

  • Page 15

    Carrier 13 3.1.2 F AU L T IN DICA T OR L AM P The lamp goes ON when one or more of the following engine faults occurs and when engine shuts down. • Low oil pressure • Overcrank • High coolant temperature • Overspeed • Low coolant level 3.1.3 1 5 AMP F USE The fuse protects the control console’s DC control circuit against electrical over[...]

  • Page 16

    14 Carrier 4.1 MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE F ACILITI ES A. EVER Y THR EE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. B. ONCE EVER Y SIX MONTHS 1. T est Engine Safety Devices (lo[...]

  • Page 17

    Carrier 15 4.4.2 BA TTER Y F L U I D Check battery electrolyte fluid at least once a month. Fluid should cover separators in all battery cells. If fluid level is low , add distilled water to cover tops of separators. DO NOT USE T AP W A TER IN BA TTERY . 4.4.3 ENGI NE COOLANT Check coolant level in coolant recovery bottle. See Specifications, Secti[...]

  • Page 18

    16 Carrier Figure 4.2 - Oil Filter After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERA TE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK. 7. Start engine and check for oil leaks. 4.5.1 1 CHANGI NG THE ENGI N E AI R CLEAN ER T o replace the engine air cleaner , (part number 059402), simply remove the air cleane[...]

  • Page 19

    Carrier 17 Once each year , have the generator cleaned and inspected by a dealer . That dealer will use dry , low pressure air to clean internal windings. P arts 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 ar[...]

  • Page 20

    18 Carrier Section 4 — Maintenance Carrier Liquid-cooled 1 5 kW Generators 4.7 S CH EDU LED MAI NTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need[...]

  • Page 21

    Carrier 19 Section 4 — Maintenance Carrier Liquid-cooled 1 5 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask 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) ann[...]

  • Page 22

    20 Carrier Section 4 — Maintenance Carrier Liquid-cooled 1 5 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask 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) ann[...]

  • Page 23

    Carrier 21 Section 5 — T roubleshooting Carrier Liquid-cooled 1 5 kW Generators 5.1 TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. 7.5 amp fuse blown. 2. Replace fuse. 3. Loose or corroded or defectiv e 3. Tighten, clean or replace batter y cables . batter y cables as neces[...]

  • Page 24

    Section 6 - Notes Carrier Liquid-cooled 1 5 kW Generators 22 Carrier[...]

  • Page 25

    Carrier 23 Section 7 - Installation Diagram Carrier Liquid-cooled 1 5 kW Generators Drawing No. 0E1 53 3-B[...]

  • Page 26

    2 6 4 1 1 4 4 RED 1 1 X X 33 33 22 22 11 2 6 44 11 33 2 22 5 5 7 6 TRAN S FER S WIT C H CO NNE C TI ON 5 4 6 4 2 3 6 7 13 11 12 14 15 16 18 17 6 3 5 2 F O R PRE-PA C K TRAN S FE R 194 S WIT C H CO NNE C TI O N S (BLA C K ) (BLA C K ) N 1 A 162 ALTERNATE TR1 1 7 8 ( BLUE ) ( RED ) 224 B 0 4 56 14 T2 1 94 23 T1 1 7 8 14 0 0 0 13 RED 4 5 6 0 1 7 8 183[...]

  • Page 27

    Carrier 25 Section 8 - Electrical Data Carrier Liquid-cooled 1 5 kW Generators Electrical Schematic — Control Panel — Drawing No. 0F5 244 FL 15 GCU 5 6 1 1 7 A B 14 16 4 3 E 12 4 2 3 5 13 1 2 7 D 11 9 10 ( BLACK ) ( RED ) N1A 224 ALTERNATE TR1 B ( BLACK ) N2 ( BLUE ) 2 2 5 S W2 14 S A VR PC B S WIT C H CO NNE C TI O N G ENERA C TRAN S FER FO R [...]

  • Page 28

    26 Carrier Section 8 - Electrical Data Carrier Liquid-cooled 1 5 kW Generators Wiring Diagram — 1.5L Engine — Drawing No. 0E0343-B 0 ELE C TR O NI C CO NTR O LLE R GO VERN OR CO NNE C TI ON LE G EN D CO NTR OL PANEL T O 12-V. 1 12 BATTERY 1 3 9 11 12 1 0 14 14 14 RE D + 5 8 6 4 3 85 0 56 85 85 5 14 D C -VR 4 8 1 0 2 4 1 3 R 1 3 1 3 0 0 4 9 A C [...]

  • Page 29

    Carrier 27 Section 8 - Electrical Data Carrier Liquid-cooled 1 5 kW Generators Electrical Schematic — 1.5L Engine — Drawing No. 0A71 82-C B WT S - WATER TEMPERAT U RE S WIT CH F S - F U EL SO LEN O I D S M - S TARTER M O T OR L OS - L O W O IL S WIT CH G RD - G R OU N D D C A - D C ALTERNAT OR I SC - I G NITI O N S Y S TEM CO NTA CT WL S - WATE[...]

  • Page 30

    ITEM P ART NO . QTY . DESCRIPTION 10 9 82 9 0 1 ASM MO T OR STEPPER 20 9 8 9 41A 1 HOUSING GOVERNOR CONNECT OR 30 9 8 9 58A REF CONNECT OR INTERF ACE ASSEMBL Y 40 9 8 9 42A 1 COVER CONNECT OR HOUSING 50 9 8225 2 SCREW FHM #2 X 5/8 SELF T AP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 0220 9 7 5 W ASHER LOCK M6-1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM 9 [...]

  • Page 31

    ITEM P ART NO . QTY . DESCRIPTION 1 0D8656 1 BASE MOUNTING 1.5L STNRD & A CSTC 2 027482 2 W ASHER SHAKEPROOF EXT 5/16 STL 3 070 9 36 2 D AMPENER VIBRA TION 4 070 9 36C 2 VIB. ISO . 70-75 DURO 50 3 9 253 8 SCREW HHC M8-1.25 X 20 G8.8 6 022145 12 W ASHER FLA T 5/16 ZINC 7 02212 9 16 W ASHER LOCK M8-5/16 8 045771 4 NUT HEX M8-1.25 G8 YEL CHR 9 071[...]

  • Page 32

    30 Carrier N U T S ITEM #2 6. US E L OC TITE ON PANEL F O R A CC E SS E R C ABL E WELD S T U D U NDER R OOF 17 G R OU ND WIRE . FA S TENER T O S E CU R E US E D OO R LAT CH N O TE : 11 24 7 10 4 9 24 26 2 5 1 9 8 5 1 2 1 0 N O TE : 11 2 6 6 4 2 6 18 1 0 1 5 " Y" 2 6 1 3 17 2 6 11 1 7 1 5 1 21 24 3 2 0 2 3 22 11 8 2 11 2 9 Section 9 - Expl[...]

  • Page 33

    ITEM P ART NO . QTY . DESCRIPTION 1 0D8666 1 ROOF A CSTC&STND CMPR TMNT 1.5L 2 0D8664C 1 DUCT CENTER 1.5L 3 0D8657 1 SUPPOR T RADIA TOR 1.5L MITSU 4 0D8660 2 BRA CE SIDE 1.5L MITSU 5 0A7568 2 DOORWELDMENT 1.5EPS 6 0D865 9 1 CORNER POST REAR RH SIDE 1.5L 7 0D8662 1 DOOR REAR COMP ARTMENT 1.5L 8 0D8661 1 BRA CE REAR 1.5L MITSU 9 0D8658 1 CORNER P[...]

  • Page 34

    32 Carrier Section 9 - Exploded Views and P arts Carrier Liquid-cooled 1 5 kW Generators Control Panel — Drawing No. 0F5 240 22 29 26 5 1 28 26 25 10 27 33 9 5 8 6 7 3 1 50 3 4 49 12 28 42 3 40 39 38 41 11 2 30 5 7 1 7 16 28 18 28 29 56 38 13 40 23 24 39 41 1 40 28 35 46 44 45 47 39 36 3 2 3 2 3 7 48 41 4 43 TO 'A' 3 1 53 5 2 55 5 4 &ap[...]

  • Page 35

    Carrier 33 ITEM P ART NO . QTY . DESCRIPTION 10 D 9 322 1 P ANEL BACK & BO TT OM 20 D 9 332 1 P ANEL LH SIDE 3 0F5246A 1 P ANEL FRONT W/SILKSCREEN 40 D 9 330 1 P ANEL RH SIDE C-P ANEL SML BRK 5 0E3783 1 DECAL W ARNING REMO VE FUSE 6 06400 9 1 LIGHT 12VDC .02A LED RED PILO T 7 032300 1 HOLDER FUSE 8 022676 1 FUSE 15A X AGC15 9 0E44 9 4 1 SWITCH [...]

  • Page 36

    6 1 WATERPUMP HARDWARE 13 9 10 11 2 8 7 12 24 10 14 15 16 6 32 5 4 1 24 39 41 30 42 4 2 4 17 11 10 14 1 1 19 17 18 20 26 21 20 25 22 24 57 33 1 1 1 4 9 24 72 10 11 10 14 1 24 35 3 4 36 44 45 14 71 12 46 11 10 49 4 7 70 11 10 6 69 29 56 6 7 59 5 2 5 4 58 6 4 63 65 6 2 60 7 Section 9 - Exploded Views and P arts Carrier Liquid-cooled 1 5 kW Generators[...]

  • Page 37

    ITEM P ART NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 022473 2 W ASHER FLA T 1/4 ZINC 3 057822 1 CLAMP HOSE #8 .53-1.00 4 0A45310258 1 GASKET -EXHAUST MANIFOLD 5 0A4355 1 MANIFOLD-EXHA UST 6 0E2632 1 HEA T SHIELD EXH 1.5L 7 0220 9 7 8 W ASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5 9 052212 2 SCREW HHC M10-1.25 X 25 G8.8 10 046526 4 W[...]

  • Page 38

    17 21 28 ( BOTTOM ONLY ) 28 "A " 22 15 11 16 2 "A " 10 1 9 11 5 1 2 14 3 18 7 6 4 17 14 TUBE (ON BLOCK) 27 13 10 23 26 19 WATER INLET 8 8 8 20 8 ADAPTER 12 2 4 TO THERM OS TAT 6 7 Section 9 - Exploded Views and P arts Carrier Liquid-cooled 1 5 kW Generators Radiator — Drawing No. 0F52 74 36 Carrier[...]

  • Page 39

    ITEM P ART NO . QTY . DESCRIPTION 1 0D8657 1 SUPPOR T RADIA TOR 1.5L MITSU 2 0A5734 1 RADIA TOR 1.5L 3 0A6237 1 VENTURI 1.5L MODINE 4 * 0A6238 1 GU ARD F AN 1.5L MODINE 5 0472 9 0A 1 ASSY . RAD . DRAIN HOSE 6 065852 2 SPRING CLIP HOLDER .37-.62 7 0A2111 2 SCREW SW A GE 10-32 X 5/16 Z/YC 80 99 502 4 CLAMP HOSE #24 B1.06 - 2.00 9 08370 9 1 CLAMP WIRE[...]

  • Page 40

    38 Carrier 4 3 L.P. VAP OR P O R T " OU T 2 " 9 1 3 4 0 41 11 10 " D" 1 5 4 5 21 24 2 5 30 28 33 2 0 1 9 14 " C" 12 17 1 6 31 32 6 6 39 2 6 38 1 41 4 0 37 34 36 35 22 " C" 1 3 8 1 8 27 2 42 6 7 23 ( NATURAL GAS ) " OU T 1 " 11 P O R T 2 9 " D" Section 9 - Exploded Views and P arts Carrier [...]

  • Page 41

    Carrier 39 ITEM P ART NO . QTY . DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E1006 1 ASSY REGULA T OR 1.5L N.G.OR LPV 40 3 9 253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 02212 9 6 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 0A7040 1 BRACKET -RAD HOSE 9 032552 1 BARBED[...]

  • Page 42

    40 Carrier 8 36 13 3 12 5 9 15 14 17 T o Blow e r H ousin g 3 2 2 3 24 35 1 21 28 7 22 33 10 29 16 30 18 2 6 19 20 3 1 2 1 4 T o En g ine C rankshaf t 26 Section 9 - Exploded Views and P arts Carrier Liquid-cooled 1 5 kW Generators Alternator — Drawing No. 0A93 48-F[...]

  • Page 43

    Carrier 41 ITEM P ART NO . QTY . DESCRIPTION 10 9 8671 1 ASSY RO T OR 10KW 0 9 8681 1 ASSY RO T OR 15KW 0 9 8675 1 ASSY RO T OR 20KW 0 9 8 9 36 1 ASSY RO T OR 25KW 2 0A5336A 1 HOUSING BLO WER 3 0A165 9 1 SCREEN AIR OUTLET 4 071 9 12 4 SCREW PPHM M5-0.8 X 8 SS 50 4 9 226 4 W ASHER LOCK M5 6 051713 4 W ASHER FLA T M5 7 02212 9 4 W ASHER LOCK M8-5/16 [...]

  • Page 44

    ITEM P ART NO . QTY . DESCRIPTION 1 077483 REF BA TT 12VDC 75-AH 26 (NO T INCLUDED) 2 038804D 1 CABLE BA TT RED #4 X 20.00 3 038805B 1 CABLE BA TT BLK #4 X 23.00 4 0742600131 1 ASSY ,WIRE#16 RED 1.6 5 022131 1 W ASHER FLA T 3/8 ZINC 6 046526 1 W ASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 075763 3 BOO T , BA TTER Y CABLE 9 0D8668 1 BRA[...]

  • Page 45

    Carrier 43 ITEM P ART NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHA UST 1.5L 2 0E2844 1 NIPPLE T OE 1.5NPTX5.5 BLK IRON 3 036434 3 BOL T U 5/16-18 X 2.0 9 03644 9 3 SADDLE 2 INCH 4 0E010 9 1 PIPE,EXHA UST 1.5L STNDRD&A CSTC 5 0C1318 1 FLEX PIPE EXHA UST 6 0D8657 1 SUPPOR T , RADIA TOR 1.5L MITSU 7 0E0170 1 BLANKET , EXHA UST 1.5L MITSU 80 D 9[...]

  • Page 46

    44 Carrier Section 1 0 – W arranty Carrier Liquid-cooled 1 5 kW Generators CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OU R W ARR ANT Y RIGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * I[...]

  • Page 47

    Carrier 45 EM IS SION CONTROL S Y STEM W AR R ANTY Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-us[...]

  • Page 48

    Part No. 0F4163 Rev . 0 (01/20/05) Printed in U.S.A. Section 1 0 – W arranty Carrier Liquid-cooled 1 5 kW Generators CARR I ER "T WO YEAR" LIMITED WARRANT Y FOR "PR EP ACK A GED EM ERGENCY AUT OMA TIC ST ANDBY GENER A T ORS" F or a period of two years from the date of original sale, Carrier warrants that its generator will be [...]