Operation And Technical Information Manual On

Transcription

OPERATION
AND
TECHNICAL INFORMATION
MANUAL ON
Home StandBy
Commercial / Light Industrial
Diesel & Gaseous Generator Set
HSG-20
HSD-22
HS-REV02 – 2004/09
1
California
Proposition 65
Warning
Diesel Engine exhaust and
some of its constituents are
known to the State of
California to cause cancer,
birth defects and other
reproductive harm.
HS-REV02 – 2004/09
2
FORWARD
Thank you for purchasing our Genset. This Genset will provide you with excellent performance
and satisfy your professional needs as long as you use it properly and follow the instructions
contained in this manual.
Before using your machine, please read this manual and familiarize yourself with proper
operations and safety precautions.
Always keep this manual for future reference and note the model and serial number of
your machine (below). It will be necessary information when asking for spare parts or
assistance.
Model #
Serial #
NOTE:
Due to constant improvements to the product through a continuous program of
research and development, all procedures, specifications and equipment are subject to change
without notice.
Important Note:
Electrical Equipment must be installed by licensed Electrical personnel and conform to
all applicable codes and regulations. When there is a conflict between any
information contained in this manual and codes and regulations the codes and
regulations take precedence.
HS-REV02 – 2004/09
3
TABLE OF CONTENTS
1.
Safety Labels ................................................................................................ page 5
2.
Safety Precautions ........................................................................................ page 6
3.
How to Move Your Genset............................................................................. page 9
4.
Overall Dimensions ....................................................................................... page 10
5.
Technical Specifications ............................................................................... page 11
6.
Component Identification............................................................................... page 12
7.
Pre-Operation Checks and Installation........................................................... page 25
8.
Gas System Installation................................................................................. page 27
9.
Operation Procedures for Automatic Control Panel ........................................ page 28
10.
Te804 Controller Instruction .......................................................................... page 30
11.
Periodic Maintenance .................................................................................... page 38
12.
Preparation for Storage ............................................................................... page 40
13.
Connection Instruction................................................................................... page 41
14.
Electrical Diagrams ...................................................................................... page 49
15.
Appendix A (KN) .......................................................................................... page 53
16.
Appendix B (Engine Governor) ..................................................................... page 55
HS-REV02 – 2004/09
4
1.
SAFETY LABELS
Carefully follow the warnings indicated on labels and do not remove them from their original position.
ELECTRICAL EQUIPMENT WARNING LABEL
)
CYCLE CRANK LABEL
HOT SURFACE WARNING LABEL
HOT SURFACE WARNING LABEL
EXHAUST GAS IS POISONOUS
DO NOT OPERATE IN AN UNVENTILATED ROOM
SHOCK HAZARD / HIGH VOLTAGE
SHOCK HAZARD / HIGH VOLTAGE
BATTERY HAZARD WARNING
NO FIRE AND OPEN FLAME
GROUND INDICATOR LABEL
DO NOT CONNECT GENERATOR SET TO COMMERCIAL
POWER LINE AND MAKE SURE APPLIANCES
ARE NOT CONNECTED WHEN STARTING
ROTATING EQUIPMENT WARNING
HS-REV02 – 2004/09
STOP ENGINE BEFORE REFUELING
CHECK ENGINE OIL
5
2.
SAFETY PRECAUTIONS
GENMAC is not responsible for personal injury or equipment damage resulting from non-observance of
safety precautions and/or improper use of the Genset.
2.1
GENERAL PRECAUTIONARY RULES
Do not allow your Genset to be operated by unskilled people and/or children.
Keep children and animals away from your Genset while in operation.
Never inspect your Genset while in operation. Be sure to stop the engine before inspection and do not
touch hot parts. Only trained personnel should inspect the Genset while in operation. Operation by
untrained personnel could cause equipment damage or personal injury up to and including death. Read
this manual and familiarize yourself with proper operation and maintenance.
Never connect the Genset to a commercial power line. Connections to commercial power lines may short
circuit or destroy the Genset as well as damage any connected appliances, lead to fire, cause shock
hazard to utility personnel or personal injury up to and including death.
Close attention must be given to the routing of wiring from the Genset to the connected load. If the wire is
pressed under the Genset or in contact with a vibrating part, it may fray – short and possibly cause a fire,
equipment damage, electric shock hazard or personal injury up to and including death.
If excessive noise, odour or strange vibration occurs, stop the engine immediately and contact your local
EPS service centre.
2.2
GENSET SURROUNDINGS
GENMAC recommends that the Genset is installed and securely mounted to a concrete pad. This pad
should extend a minimum of 6 inches past the Genset base on all sides. If the Genset is tilted or moved
during operation, fuel may spill and/or the Genset may tip over, causing a hazardous situation or personal
injury up to and including death.
Proper lubrication cannot be expected if the Genset is operated on a steep incline or slope. In such a
case, engine damage may occur even if the oil level is correct. This could result in loss of warranty
coverage.
Do not locate this Genset around dry bushes, twigs, cloth rags or other materials that may block air vents
and/or exhaust pipe.
Keep Genset at least one meter (3 feet) away from buildings or other structures. All exhaust emissions
must be directed away from building surfaces and air intakes to prevent exposure to poisonous gases.
Keep Genset away from flammables or hazardous materials.
2.3
FIRE PREVENTION
Be sure to stop the engine before refuelling. Do not operate the Genset near diesel fuel, gasoline or
gaseous fuel, because of the potential danger of explosion and fire. Keep spare fuel only in approved
containers and in well-ventilated areas, far from open flames. Do not operate while smoking or near open
flame. Do not operate near inflammables or other such potential fire hazards.
HS-REV02 – 2004/09
6
Only for HSD-22: when refuelling, care must be taken not to overfill fuel tank. Make sure that the tank cap
is tightened before operating generator.
If spillage does occur, wipe away spilt fuel thoroughly and wait until fuel has dried before starting the
engine.
When changing oil make sure the fill cap, oil gauge and oil drain bolt are correctly tightened before
starting engine to prevent spillage.
Do not operate the Genset with the covers open or off. Do not enclose or cover the Genset when it is
operating. The Genset has a built-in forced air-cooling system, and may become overheated if it is
enclosed or the factory designed airflow is not maintained (covers on), with potential danger of explosion,
fire or personal injury up to and including death.
2.4
EXHAUST PRECAUTIONS
Do not operate Genset indoors or in an enclosed area such as a garage, shed, cave, tunnel or other
insufficiently ventilated area.
Always operate Genset in well-ventilated areas or the engine may become overheated. During operation
the Genset exhaust generated contains carbon and carbon monoxide.
¾
¾
¾
¾
¾
2.5
Monoxide gases contained in exhaust gases are poisonous and can cause sickness,
unconsciousness or death.
Carbon monoxide is colourless and odourless and can cause death if inhaled.
If the Genset must be used indoors, the area must be well ventilated and extreme caution must
be taken regarding the discharge of exhaust gases.
Warning! Never inhale exhaust gases!
Keep exhaust pipe free of foreign objects.
EXPLOSION PREVENTION
¾
Gases are explosive and can cause fire.
When the battery is being charged it releases hydrogen and oxygen, an explosive mixture, additionally
battery acid can shoot out of the vent holes and cause serious personal injury and equipment damage.
The battery must always be charged in a well-ventilated area and away from sparks or open flames.
HS-REV02 – 2004/09
7
2.6
SHOCK PREVENTION AND WARNING
¾
¾
¾
2.7
Never touch electric components when the Genset is in operation.
Do not handle Genset and/or electric parts with wet hands. The operator may suffer severe electric shock
and/or personal injury up to and including death.
Make sure the Genset is properly grounded.
HOT SURFACE WARNING
¾
¾
2.8
Do not touch engine or hot parts when the Genset is in operation or just after stopping it. The
components may still be hot.
Do not remove protective covers or devices before the Genset cools.
ROTATING PARTS WARNING
¾
¾
¾
[Warning!] Do not remove safety shields, enclosure panels and/ or guards when the Genset is
in operation.
When engine is running keep at a safe distance.
When you are near mechanical rotating parts protect hands and feet, tie your hair and to not wear
loose clothes.
[Caution!] When you need to remove protective covers or devices, be sure to stop the Genset and to reassemble protections carefully before re-starting the generator.
2.9
ACCIDENTAL START PREVENTION
[Caution!] Before carrying out any maintenance operations on the Genset remove cables from battery
and battery charger to avoid any accidental starts, and to avoid any electrical shock hazard disconnect
from utility service.
HS-REV02 – 2004/09
8
3.
HOW TO MOVE THE GENERATOR
When moving your Genset use the Specific Hooks as shown in figure 1, or place and secure your
Genset on a pallet as shown in figure 2, and move it using a lifter / forklift.
[Caution!] Never move Genset when it is in operation.
Never attempt to lift the Genset by only 2 of the 4 lifting eyes provided.
Figure 1. Lifting Method Drawing
Figure 2. Moving with Pallet
HS-REV02 – 2004/09
9
HS-REV02 – 2004/09
10
MPSG
OVERALL DIMENSIONS
MPSD
4.
5.
TECHNICAL SPECIFICATIONS
MODEL #
MPSD22
DIESEL FUEL
NATURAL
GAS
L.P.G.
27.5kVA – 22kW
22.5kVA –
18kW
25kVA –
20kW
25kVA – 20kW
20kVA – 16kW
22.5kVA –
18kW
FUEL TYPE
ELECTRICAL STANDBY
RATING
OUTPUT
ELECTRICAL CONTINUOS
RATING
OUTPUT
MPSG20
VOLTAGE (V)
120/208/240/416
AMPERAGE
(STANDBY)
(@208V 3~ PF=0.8)
ENGINE MFG.
LOMBARDINI
TOFAS
ENGINE MODEL
LDW 2004/T
TOFAS 1.6L
76.3A
ENGINE HP
120/208/240/416
62.5A
69A
(@208V 3~
PF=0.8)
(@208V 3~
PF=0.8)
36.7 HP
34 HP
38 HP
(@ 1800 RPM)
(@ 2400 RPM)
(@ 2400 RPM)
ENGINE DISPLACEMENT
2068cc (TURBO
CYLINDERS
4
4
COOLING SYSTEM
50 / 50 - Glycol / Water
50 / 50 - Glycol / Water
FUEL CONSUMPTION AT FULL LOAD
2.2 - 8.5
US gal/h - (Litre/h)
8.8 –311
3
m /h – cu.ft/h
14 –3.7
Litre/h – GPH
SOUND LEVEL @ 23 FT, 7 m,
NO LOAD
70 dBA
71 dBA
71 dBA
OPERATING FUEL PRESSURE
N/a
8 to 11 in WC
DRY WEIGHT lbs. (kg.)
1322lbs (600 kg)
1135lbs (516 kg)
71" x 35" x 37½”
1800 x 890 x 950 mm -
DIMENSIONS L x W x H
DIESEL FUEL TANK CAPACITY
23 US gal - 87Litre
PROTECTION
IP 33
HS-REV02 – 2004/09
1600cc
CHARGED)
11
IP 33
6.
COMPONENT IDENTIFICATION
HSD 22 DRAWING A
HS-REV02 – 2004/09
12
HSD 22 DRAWING B
HS-REV02 – 2004/09
13
HSD 22 DRAWING D
HS-REV02 – 2004/09
14
GENMAC Parts List
HSD-22
DRAWING
REF#
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
HS-REV02 – 2004/09
DESCRIPTION
Main Frame - Tank Kit
Fuel Tank
Upper Tank Holder
Extension, Fuel Tank Drain
Lower Tank Holder
Plug, Fuel Tank
Copper Washer
Rubber Plate
Pin
Pin
Union M1/4 gas
Union 1/4 gas
Ø1/4 Copper Washer
Fuel Pipe
Cable Gland Ø18
Low Fuel Switch (approx. <10%)
Fuel Level Sender
Screw 8x70
Alternator Side Housing Complete Kit
Alternator Side Housing
Internal Panel Alternator Side
Battery Tray
Control Panel Holder
Gas – Spring Holder
Engine Side Housing Complete Kit
Engine Side Housing
Internal Panel Engine Side
Side Radiator Shield
Mid Radiator Shield
Central Radiator Shield
Housing Top Cover Complete Kit
Housing Top Cover
Lifting Ring Plate
Lifting Ring
Refuelling Box
Fuel Tank Cap
Rubber Seal, Central Panel
Control Board Door
Locking Device
Hinge, Control Door
Battery Holder
Gas – Spring 45kg
Central Panel
Internal light assembly
Light Bulb, 12V
Radiator Bottom Plate
Rear Panel
Front Panel
Locking Pin - Plate
Hinge, Hood
Latch
Rubber Seal, Hood
Locking Device
Spring, Hood Lock
15
QTY
1
1
4
1
2
1
1
10
2
2
1
1
2
1
4
1
1
2
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
4
4
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
3
2
1
1
1
DRAWING REF#
A
A
A
A
A
A
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
HS-REV02 – 2004/09
56
57
58
59
60
61
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
46
47
48
49
50
DESCRIPTION
Locking Hook, Hood
Hood
Rubber Seal, Control Door
Rubber Seal, Alternator, Top
Inlet Tank Hose
Hose Clamp
Radiator Kit
Radiator
Coolant Level Switch, Low
Ø22 Copper Washer
Rubber Hose 104cm, Overflow
Fan Housing
Rubber Mounts, Radiator
Radiator Holder
Fan Shield Low T.
Fan Shield Low A.
Fan Shield High A.
Fan Shield High T.
Mid Radiator Bracket
Cross Member
Rubber Mounts
Engine Foot
Heater Holder
Coolant Manifold
Union screw
Oil sensors manifold
Water temperature sender
Muffler
Flexible Exhaust Pipe HSD22
Air Cleaner Holder
Rain Shield
Rain Cap Exhaust Pipe
Handle, Hood
Key
Inlet Pipe HSD22
Drain Flange
Seal
Plug, Coolant
Union 18x1.5
Union 14x1.5, Oil Drain
Copper washer
Inlet Rubber Hose 8cm
Lower Radiator Hose
Rubber Hose Ø09-16 25cm, Manifold to Radiator
Rubber Hose Ø15-22 27cm, Heater to Manifold
Rubber Hose Ø11-18 11cm, Manifold to Base
Rubber Hose R6 ½ 21cm, Oil Drain
Rubber Hose ½, Closed crankcase ventilation
Air Cleaner Inlet Hose 50cm
Alternator support
Upper Radiator Hose 12cm
Loose Parts Kit
Coolant Rubber Pipe 70cm, oil cooler
Coolant Manifold Hose 6cm, Top
Upper Heater Hose 46cm
16
QTY
1
1
1
1
1
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
6
2
1
1
1
1
1
1
1
1
8
1
1
2
1
2
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
GENMAC Parts List
MPSD18 - 22
DRAWING REF#
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
51
52
53
54
55
56
57
58
59
60
61
62
63
64
66
67
69
70
71
72
74
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
PART#
DESCRIPTION
Recirculation pipe
Oil pressure sender
Outlet Air Cleaner Elbow
Inlet Fuel Hose 70cm
Outlet Fuel Hose 76cm
Upper Radiator Manifold
Plug Connector
Receptacle Connector
Plug Housing
Receptacle Housing 11,2cm
Hose Clamp 25x45x8
Hose Clamp 14x24x8
Hose Clamp 40x60x8
Hose Clamp 47x67x8
Fuel Hose Clamp
Exhaust Pipe Clamp
Electric Heater
Hose Clamp 18x28x8
Alternator MHSD22
Engine HSD22
Fan
Battery Charger 3A
Insulator M8
Fuse Box 80A (Glow Plugs)
Current transformer 100/5
Magnetothermic Switch HSD22 (3 poles 100A)
Switch Holder
Te804 Generating Set Controller
Panel Fuse Holder (5A Fuse: P/N: 12357)
Warning Red Light
Relay Holder 70A (Glow Plugs)
Relay 70A (Glow Plugs)
Relay Holder 30A (Starting)
Relay 30A (Starting)
EMC Filter
Terminal Board M8
Generator A.V.R.
Fuse 80A (Glow Plugs)
Panel Plate
Ground terminal
2
Terminal (4 mm )
Internal Fuse Holder (5A Fuse: cod.: 12357)
Internal Fuse Holder (25A Fuse: cod.: 15179)
Complete Control Panel HSD22
6.
P
HS-REV02 – 2004/09
17
QTY
1
1
1
1
1
1
1
1
1
1
7
17
4
2
4
1
1
2
1
1
1
1
4
1
3
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
8
10
2
1
HS-REV02 – 2004/09
31
15
35
31
32
28
35
29
20
30
21
24
25
23
24
36
25
35
40
38
44
37
43
22
39
36
16
26
15
18
41
8
31
35
35
31
6
17
27
28
30
7
18
1
30
29
9
19
42
3
10
5
36
34
12
36
11
38
4
33
13
2
45
HSG-20 DRAWING A
14
HS-REV02 – 2004/09
58
59
60
64
97
100
61
116
93
63
117
57
111
98
111 112
110
115
113
97
92
94
76
70
114
95
78
79
62
66
94
77
1
96
99
76
103
75
74
80
68
104
101
20
64
73
87
HSG-20 DRAWING B
106
19
72
102
69
81
17
52
71
67
54
65
90
8
18
14 88
22
105
89
88
13
86
9
55
50
85
89
21
53
49
90
91
5
6
84
19
56
83
51
18
3
15
7
107
23
10
82
35
47
34
4
46
48
24
16
32
45
33
44
42
11
43
2
12
37
26
30
36
40
25
28
109
29
41
31
109
27
108
38
39
24
HS-REV02 – 2004/09
1
16
5
7
TEST
AUT
MAN
RESET
STOP
START
15
?
HELP
MAIN
ENTER
GEN
EXIT
2
8
2
9
2
2
14
12
22
4
9
13
5
8
21
20
6
18
23
19
7
24
HSG-20 DRAWING C
20
11
GENMAC Parts List
HSG 20
DRAWING REF#
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
B
B
B
B
B
B
B
B
B
HS-REV02 – 2004/09
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
1
2
3
4
5
6
7
8
9
DESCRIPTION
Main Frame
Cable Gland ø18
Lower Alternator Panel
Alternator Side Housing Complete Kit
Alternator Side Housing
Internal Panel Alternator Side
Control Panel Holder
Battery Tray
Rubber Seal
Control Board Door
Rubber Seal, Inner Panel Alternator Side
Hinge, Control Door
Battery Holder
Gas – Spring 45Kg
Central Panel
Lighting Device
Lamp
Lighting Device Holder
Engine Side Housing Complete Kit
Engine Side Housing
Internal Panel Engine Side
Central Radiator Shield
Mid Radiator Shield
Side Radiator Shield
Radiator Bottom Plate
Housing Top Cover Complete Kit
Housing Top Cover
Lifting Ring Plate
Lifting Ring
Rear Panel
Front Panel
Locking Pin - Plate
Hinge, Top cover
Latch, Top cover
Hood
Locking Device
Locking Hook, Top Cover
Spring, Top Cover Hook
Rubber seal, Top cover
Cover Plate
Positive battery Cable
Negative battery Cable
Air cleaner Cap (Donaldson 5”)
Engine (Tofas 1.6 Lt.)
HSG-20 Alternator
Bell Housing
Housing window band
Pin (holed)
Pin (threaded)
Centaflex Coupling
Screws and Pins Kit for Centaflex Coupling
Hub for Centaflex Coupling
21
QTY
1
4
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
2
2
1
1
2
2
4
4
1
1
1
3
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DRAWING REF#
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
HS-REV02 – 2004/09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
DESCRIPTION
Multiplier Gear Box
Plug 3/8, Gear Box
Plain rubber washer, Gear Box
Key 8x7x60 UNI6604-69
Coupling Washer
Coupling Flange
Bolt M12x1.25 L.65
Ignition Coil Bracket
Bolt M10x1.25 L.18
Pickup B&C
Temperature Switch M16x1.5 115°C
Union M10x1
Union M22x1.5
Engine Support
Rubber Mounts, Engine and Alternator assembly
Alternator Mount
Front Alternator Grill
Air Cleaner Inlet Hose ø50
Controller GAC ESD2210-12
Donaldson Air Cleaner 5”
Clogging Sensor
Air Cleaner Support
Breather Hose
Air Cleaner Bushing
Engine Breather Pipe
Air Cleaner Inlet Hose ø50
Heater Holder
Engine water Heater
Connector
Plug Connector
Connector Case
Connector plug Case
Natural gas Solenoid/Nipple/Union Kit
Nipple Support
Nipple
Fuel Strainer
Fuel Solenoid valve
Hose Fitting
Nipple
Fuel Regulator
Regulator Mounting Bracket
Support
Fuel Adjustment Valve
Fuel Hose, Regulator to Adjustment Valve
Fuel Hose, Adjustment Valve to Intake
Fuel Hose solenoid to regulator
Spring, Fuel hose Protection
Radiator
Low Coolant Switch
Copper Washer
Draining Hose
Fan Housing
Fan Shield
Belt Shield
Rubber Mounts, Radiator
Radiator Holder
22
QTY
1
1
1
1
1
1
3
1
10
1
1
1
1
1
4
1
1
L.52cm
1
1
1
1
1
0.2
L.44cm
L.49cm
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
L.62cm
L.18cm
L.55cm
1
1
1
1
L.104cm
1
4
1
3
1
GENMAC Parts List
HSG20
DRAWING REF#
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
HS-REV02 – 2004/09
DESCRIPTION
Fan
Pulley
Pulley Spacer
Stud, Fan Assembly
Upper Radiator Holder
Low Hose to Radiator
Mid Hose, Lower
Pipe Radiator to W/Pump
Mid Hose, Upper
Inlet Pipe to W/Pump
Stud, Inlet
Gasket
Upper Hose to Radiator
Upper Pipe Engine to Radiator
Upper Hose Engine to Radiator
Coolant Manifold
Upper heater Hose
Low heater Hose
Draining Pipe
Hose manifold to radiator
Hose (from Manifold to Drain Flange)
Hose (from Manifold to W/pump pipe)
Drain Flange
Seal (for Oil and Coolant Draining Plugs)
Plug (for Oil and Coolant Draining)
Oil draining Hose
Actuator Kit
Inlet Manifold
Gasket, Actuator
Support, Actuator
Carburetor Butterfly
Carburetor Lever
Swivel
Actuator Device
Setting Screw Bracket
Blank Rubber Plug
Flexible Exhaust Pipe
Exhaust Gasket
Exhaust Nut
Muffler
Exhaust pipe Clamp
Alternator Flange
Air Cleaner Holder
Spacer ø24X15
Union Screw M14x1.5
Copper Washer ø14
Oil Sensors Manifold
Low Oil Sensor Pressure
Rain Shield, Visors
Rain cap exhaust Pipe
Handle
Key
23
QTY
1
1
1
4
1
1
1
1
1
1
4
1
1
1
1
1
L.67cm
L.28cm
L.70cm
L.62cm
L.11cm
L.45cm
2
2
2
L.58cm
1
1
2
1
1
2
2
1
1
1
1
1
4
1
1
1
1
2
1
2
1
1
4
1
1
2
GENMAC Parts List
HSG 20
DRAWING REF#
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
HS-REV02 – 2004/09
1
2
4
5
6
7
8
9
11
12
13
14
15
16
18
19
20
21
22
23
24
DESCRIPTION
Battery Charger 3A
Insulator M8
Current transformer 100/5
Magnetothermic Switch HSG20 (3 poles 80A)
Switch Holder
Te804 Generating Set Controller
Panel Fuse Holder (5A Fuse: P/N: 12357)
Warning Red Light (utility presence)
Relay 30A 87/87a (GAC)
Relay Holder 30A
Relay 30A
EMC Filter
Terminal Board M8
Generator A.V.R.
Panel Plate
Ground terminal
2
Terminal (4 mm )
Internal Fuse Holder (5A Fuse: P/N.: 12357)
Complete Control Panel HSG20
24
QTY
1
4
3
1
1
1
1
1
1
3
2
1
2
1
1
1
8
10
2
1
1
7.
PRE-OPERATION CHECKS AND INSTALLATION
When starting Genset perform the following checks to insure safe operation.
7.1
GROUNDING THE GENSET
Before operating your Genset be sure to adequately ground it or severe electrical shock or personal injury up to
and including death may result. To ground the generator, connect the grounding terminal of the Genset to a
grounding rod driven into the ground. (See Figure below)
[Warning!] When grounding the Genset be sure to use a cable and rod that meets local codes.
[Caution!] Always carry out the following checks before operation.
7.2
CHECK ENGINE OIL LEVEL
Before checking or refilling oil, be sure that the Genset is placed on a stable and level surface with engine stopped.
Open the top cover of your generator, remove oil dipstick and check oil level. If engine oil level is below the lower
level line refill with suitable oil.
Use oil according to the table below and for additional information read the engine manual.
USE ENGINE OIL OF CLASS “CD”
(API ranking)
Viscosity of oil
SAE 30 (Diesel only)
SAE 10W-30 (Diesel and Gaseous)
Temperature
+40°C to +10°C
+20°C to -10°C
[Caution!] Low-grade oil or deteriorated oil can cause engine problems and shorten the engine life. Change oil
according to (Section 11) periodic maintenance.
HS-REV02 – 2004/09
25
7.3
CHECK ENGINE COOLANT
Check the engine coolant level. For coolant refilling, remove cap and pour coolant into radiator.
Required coolant: automotive antifreeze coolant mixture according to the ambient temperature.
[Warning!] Do not remove engine coolant cap while engine is running or hot.
7.4
CHECK GEARBOX OIL (GASEOUS ONLY)
Genset is delivered with oil inside gearbox (oil type: SAE 90; quantity: 0.6 liter)
Remove the side cover plug for oil level check.
7.5
CHECK ENGINE FUEL (DIESEL ONLY)
[Warning!] Do not refuel while smoking, near open flame, or other such potential fire hazards. Otherwise
fire accidents may occur.
•
•
•
•
Check fuel level on the controller display.
In case of fuel level <20% you will have A10 alarm (FUEL LEVEL WARNING) on the controller display.
In case of fuel level <10% you will have A11 and A13 alarms (LOW FUEL LEVEL) on the controller display.
If fuel level is low, refill with correct fuel type. Above alarms will automatically disappear.
[Warning!] Do not refill tank while engine is running or hot. Be careful not to let dust, dirt, water or other foreign
objects into fuel. Wipe up spilt fuel thoroughly and allow area to dry before starting the engine. Keep away from
open flames or equipment damage and/or personal injury up to and including death may result.
7.6
CHECK BATTERY
Check the battery electrolyte level. (not applicable if maintenance free battery) If the electrolyte level is below the
lower level mark, add distilled water up to the upper level mark. Check that the battery terminals are corrosion
free and connected properly.
7.7
CHECKING COMPONENTS
Visually inspect the following items before starting the engine:
¾
¾
¾
¾
7.8
Fuel system for leakage
Connections, Bolts and nuts for looseness
Components for damage or breakage
Genset not resting on or against any adjacent wiring.
CHECK GENSET SURROUNDING
[Warning!]
Make sure you review the following items in order to prevent fire hazard:
¾
¾
¾
¾
¾
¾
¾
¾
Keep area clear of flammables or other hazardous materials
Keep Genset at least 1 meter (3 feet) away from buildings or other structures.
Only operate Genset in well ventilated area
Keep exhaust pipe clear of foreign objects
Keep Genset away from open flame. No smoking!
Keep Genset on a stable and level surface.
Do not block the Genset air vents. (Leaves, Snow, etc…)
Do not allow exhaust pipe to be positioned such that exhaust can enter living areas.
HS-REV02 – 2004/09
26
8.
GAS SYSTEM INSTALLATION
FOR THE INSTALLER
The following information is generally addressed to the installer and trained personnel. The technical data is
noted on the identification label placed on the side panel of generator.
8.1
GENERAL INFORMATION
The Genset must be installed in compliance with local codes and by trained personnel only. The
manufacturer declines all responsibility for personal injury or equipment damage resulting from nonobservance of safety precautions, local code regulations in force and/or improper installation.
8.2
VENTILATION
The Genset must only be installed and operated in a well-ventilated area or outdoors, to insure proper ventilation
and Genset performance.
8.3
GAS CONNECTION
The Genset connection to a gas commercial source or to a cylinder must be carried out by authorized personnel
only and in compliance with the applicable regulations.
¾
¾
¾
Pressure fuel line must be minimum: 8 in WC – 4.5 oz – 22mbar; maximum: 11 in WC – 6 oz – 28mbar.
Gas pressure regulators must be in compliance with applicable regulations.
For safety purposes install a manual valve between the supply line and the generator. The manual valve
must be easily accessible after connecting generator.
¾
[Caution!] Connections require the use of a flexible hose in compliance with applicable regulations.
8.4
GARRETSON MODEL KN SYSTEM
Gaseous Gensets come equipped with the Garretson Model KN style fuel system. This system is described in
Appendix A. This system operates automatically on all types of gaseous fuels listed in Appendix A. Review
Appendix A for operation, installation and trouble shooting of this system.
8.5
OTHER IMPORTANT POINTS
[Warning!]
¾
¾
¾
¾
¾
¾
Flexible pipe length must not exceed 1.5m (meters).
Pipes must not be deformed or cross-sectional area reduced.
Keep pipes away from sharp objects, sharp edges or whatever else could damage the pipes.
Keep pipes away from surfaces over 50°C.
Make sure flexible pipes are visible and can be checked along the entire length of the connecting line.
If visual inspections reveal damage replace lines.
HS-REV02 – 2004/09
27
9.
OPERATING PROCEDURES FOR AUTOMATIC CONTROL PANEL
[Warning!] Carefully study the instructions of your automatic control panel before starting your Genset
set, so you will be able to operate your Genset safely.
[Warning!] Before starting your generator, check that there are no obstructions around it.
[Caution!] When starting the Genset the first time or after a long storage, let the engine warm up at least
5 minutes. This prolongs the life of the Genset .
[Warning!] The automatic control panel should only be set up and operated by trained personnel. Local
codes must be followed in order to avoid equipment damage, and /or personal injury up to and including
death.
[Caution!] Always check that the technical data printed on the nameplate corresponds to your specific
requirements.
These products have been manufactured to minimize RFI that could damage or interfere with equipment.
Note: Due to a constant drive to improve the product through research and development, all procedures, specifications and
equipment are subject to change without notice.
9.1
OPERATING PROCEDURES - GENERAL -
•
•
•
•
•
•
•
9.2
Programming of the control panel should be done by trained personnel.
Any programming done to the control panel should be performed with the Engine off and the load
disconnected.
Electrical connections must be carried out in compliance with local codes. AC cables, particularly,
must be sized and placed so that the cable does not attain temperatures over 50°C Ambient
temperature.
It is necessary to check that cables have not loosened at the respective terminals and to remove any
dust or other materials that have fouled the control panel during installation. The cleaning must be
done by means of a vacuum, avoiding blowing dust into the control panel with air.
Connections to the terminal board must be made using a cable of correct cross section, per electric
diagram.
To open the control panel front door use the special key supplied with the control panel. Only
trained personnel should have access to this key.
To protect from electric shocks and any atmospheric discharges, it is necessary to provide adequate
earthen ground.
TECHNICAL TERM DEFINITION
Refer to the following definitions whenever these terms are mentioned in the manual:
Set-up: This is the set up of the controller. This is done before or during the installation of the Genset.
There are three different menus in order to have access to the parameters setting and relative data. All
operating times and calculations that affect the system functioning can be set up and the parameters are
stored in a permanent memory.
Only trained personnel can reach this function and it is password protected.
Starting Cycles: The sequence of diesel Genset (HSD-22) starting is as follows: First glow plugs are
energized (programmable duration), and then the fuel solenoid valve is activated. After these two steps
the control panel enters into a start interval (programmable duration), alternating with intervals of cool
down (programmable duration). Once the engine is on, the starting attempts stop immediately.
The sequence of gaseous Genset (HSG20) starting is as follows: First the gas valve is activated; for the
first starting attempt primer is energized. The Electronic Ignition is energized at the same time as the gas
valve; to avoid over-speed alarm RPM governor (this device is described in Appendix B) is energized after
a time delay (after cranking). After these steps the control panel enters into a start interval (programmable
duration), alternating with intervals of cool down (programmable duration). Once the engine is on, the
starting attempts stop immediately.
HS-REV02 – 2004/09
28
Genset Stopping Procedure: The transfer switch opens and the Genset continues to run for a cool down
period (programmable) at the end of which the fuel solenoid valve(for HSD-22) or the gas valve +
Electronic Ignition + rpm governor (for HSG-20) are switched off and the engine stops. In case of
emergency stop, the above-mentioned procedure takes place without considering the cool down time.
Engine On: The engine is considered on when the “engine ON “ signal, which comes out of the engine
alternator battery charger, exceeds the programmed value. Its led shows the engine-on signal. For safety
reason generator output voltage is also monitored to verify that the engine is running.
Alarms On: Oil pressure and high temperature alarms are enabled after a delay time (programmable)
greater than the engine-on signal time. The “engine ON” led flashing indicates the engine is on but the
alarms are not enabled, and becomes on steady when the engine is running and the alarms are enabled.
During the stopping cycle, the alarms are disabled and the fuel solenoid valve close simultaneously.
Utility-Off: The utility-off signal occurs when the utility voltage / frequency is out of the fixed limits (lower
than the minimum fixed values or higher than the maximum fixed values) and remains in that state longer
than the programmable time. This causes the transfer switch to transfer to the emergency position (after
Generating set has started and met requirements).
Utility-On: In the same way, the utility-on signal occurs when (as a programmable time is exceeded) the
voltage / frequency are inside the fixed limits. The transfer switch function will depend on the selected
operating procedure.
Generator-On: Generator-On signal works as the utility-on signal described above.
Frequencies and delay intervals are independent.
The Voltages /
Utility/Genset and Generator/Utility Switching: The remote control switches between the utility and
Genset. A delay time occurs to avoid simultaneous connections.
9.3
OPERATING MODES
Note: Please refer to Te804 controller instructions (section 10), if you
need more information.
The digital controller has 4 different modes:
Reset
Automatic
Manual
Test
You select the mode you need by pressing the corresponding button
and its LED lights up. It is always possible to skip from one operating
procedure to another.
Warning! For safety reasons, on controller power-up, the
operating Mode will always be RESET.
When one of the four operating Mode LED’s is flashing, it indicates that the unit is being controlled by a
supervision system (remote control).
HS-REV02 – 2004/09
29
10.
Te804 CONTROLLER INSTRUCTIONS
10.1
KEYBOARD
HELP key – The illuminated LED means a help message is available. By pressing the key, a help message
concerning the current operation is displayed.
ENTER and EXIT keys - Press ENTER to confirm operations or to enter the menu. Press EXIT to refuse an
operation or to exit a menu and help message.
“⇓
⇓” and “⇑
⇑” arrow keys – Press these keys to shift to the different pages of data display or to select parameters.
“–“ and “+” keys – Press these keys to display alternative data of the selected data page or to modify the
parameters.
OFF/RESET, MAN, AUT and TEST keys – Press these keys to select the operating mode. The illuminated LED
indicates the selected operating mode; if it is flashing, remote control is active.
START and STOP keys – These keys work in MAN operating mode only, to start and stop the engine. By quickly
pressing the START key, one start attempt takes place; by keeping the START key pressed, the duration of the
start attempts can be extended. The flashing LED of the engine symbol denotes engine started, with alarms
inhibited; and is constantly on at the end of the alarms inhibition time. The engine can be stopped using the
OFF/RESET key.
MAINS and GEN keys – They are enabled only in MAN operating mode only, they are used to control the ATS
and switch the load from utility to generator and vice versa. The illuminated Leds of the utility and generator
symbols indicate the respective voltages are within preset limits. The illuminated Leds of the changeover symbols
indicate the actual closing of switching devices; when flashing, there is a incorrect feed-back signal for the actual
closing or opening of the switching devices.
10.2
LCD SCREEN
⇓” or “⇑
⇑” keys to view the
The LCD shows data and information in graphic and alphanumeric forms. Press the “⇓
data pages. Press the “–“ or “+” keys to see alternative data on the same page. Te804 is set to return to the main
page 60 seconds after the last key was pressed.
10.3
POWER-UP
At power-up, Te804 is automatically set to OFF/RESET mode. The option to return to the mode present prior to
power down can be enabled in the program section.
HS-REV02 – 2004/09
30
10.4
OPERATING MODES: RESET, MAN, AUT and TEST
RESET: In reset mode, the controls are not operational. The engine can not operate. If the utility is present, the
load will default to the utility. When changing modes with the engine running from TEST, AUT or MAN to the
OFF/RESET mode the engine is immediately stopped and the alarms are reset. If the cause of the alarm is still
present, it can not be reset and will continue to be displayed on the LCD display. The LCD display will continue to
show measures as well as any valid alarms.
AUTOMATIC: In the Automatic mode the Genset starts when the utility voltage goes out of limits and its
respective control switch is off. After the (programmed) delay, Utility remote control switch gets switched off and
the Genset start cycle begins.
When the Genset is running and its voltage / frequency are within the (programmed) limits, the Genset remote
control switch closes. The Genset will continue operating until the utility voltage is restored. Once the utilities are
within (programmed) limits for the (programmed) time, the remote control switches exchange position, and the
Genset carries out the stop cycle.
When the Genset is running, however, it can always be stopped by means of the RESET or STOP buttons.
In automatic procedure both the remote start and stop are enabled.
MANUAL: The engine can be manually started or stopped using the START and STOP keys. The ATS can only
be switched by holding down on the Manual key and then pressing the MAINS or the GEN keys. The preset
starting time can be prolonged by keeping the key pressed for an extended time. Keeping the Stop key pressed
for more than 6 seconds will result in the fuel valve being disabled for 4 minutes.
The start button begins the start cycle while the stop button begins the stop cycle.
After pushing the stop button you can stop it from beginning the stop cycle by immediately pushing the start
button.
TEST: In test mode the Genset begins the start cycle (even if the utility is present). If the Utility power drops out
while the Genset is in test mode the controller will over ride this function and switch the Generator to the load.
Once the Utility voltage returns, the load will stay on the generator. If the auto mode is enabled, the controller will
transfer the load to the Utility and will start the stop cycle of the generator.
It is possible to program the controller so that the load will be transferred from utility to Genset even if the utility is
present.
10.5
AUTOMATIC TEST (EXERCISE)
The automatic test (EXERCISE) is a periodic check that is carried out by the control panel at programmed
intervals. If the control panel is in automatic mode and the automatic test has been enabled, the Genset runs for
a fixed period before it stops.
It is possible to program the controller so that the load will be transferred from utility to Genset even if the utility is
present. It is also possible to program the controller in order to carry out the automatic test even if the external
(remote) stop is activated.
10.6
PERIODIC MAINTENANCE INTERVAL
By means of set up, a periodic maintenance interval, expressed in hours, is set. When the working hours reach
the fixed amount, the display shows a message noting maintenance is required. The System will not shut down
and continues to work normally.
It is possible to reset anytime the remaining hours (Command Menu). This means that periodic maintenance can
be carried out before the end of the fixed amount of working hours.
10.7
WORKING HOUR CALCULATION
As the Engine runs the working minutes are counted. The calculation, expressed in hours, can be shown on the
display. The calculation continues even in case of disconnection of the electrical input and cannot be set to zero
by the user.
HS-REV02 – 2004/09
31
10.8
ALARMS
When an alarm arises, the alarm is displayed in the lower section of the display. In case of two alarms or more,
they are individually shown in sequence. A help message is available for every alarm, to assist in locating the
possible alarm source. Alarm conditions can be reset by means of the OFF/RESET key; this is to prevent any
unintentional engine starting during alarm conditions. If the alarm does not reset, this means the cause of the
alarm is still present. During event-log sessions and set-up operations, no alarms are displayed.
10.9
ALARM PROPERTIES
Eight different properties can be assigned to each user alarm, including User Alarms:
Alarm enabled. If not enabled, the alarm will not work.
Retentive alarm. The alarm is latched even if the cause of the alarm is removed.
Global alarm. It activates the output assigned to this function.
Siren. It activates the output assigned to this function.
Immediate Engine shutdown.
Shutdown with Engine cool-down.
Active only with engine running.
Modem auto-call. A modem connection is performed according to the modality scheduled by preset
parameters.
All these properties are preset to a default value for the specific applications (Diesel or Gaseous Generating set).
To change these properties, enter the ADVANCED MENU, find the ALARMS menu, press the “⇓” or “⇑” key to
select the alarm, press the “-“or “+” key to select the property and then press the ENTER key to enable or disable
the property. Press the EXIT key to return to the previous menu.
[Warning!] Changing the Alarm Properties could result in equipment damage or personal injury and loss of
warranty coverage.
10.10
SET-UP VIA KEYBOARD
There are three different menus in order to have access to the parameters setting and related data.
User’s menu: Access the setting of those parameters that final user can modify. To enter the menu,
press the OFF/RESET key for 5 seconds then release it.
Commands menu: Access to data resetting, parameter copy and their restore. It is necessary to access
this menu for maintenance hours reset.
To enter the menu, press the OFF/RESET key, subsequently the ENTER key for 5 seconds and then
release them. Press the EXIT key to exit the menu.
Advanced menu: Access to all parameters setting. This menu is protected by a password.
To enter the menu, keep the OFF/RESET key pressed, then push, in the following sequence,
“-“ key twice, “+” key three times and “⇓” key four times then finally release the OFF/RESET
key.
[Warning!] The parameters set-up should only be done by trained personnel. Changing the Set up Values could
result in equipment damage or personal injury and loss of warranty coverage.
Moving within the menu: After entering the menu, press the “⇓” or “⇑” keys to select a sub-menu (or a command
in the case of “Commands menu”). Press the ENTER key to access parameter setting (or to perform the
command). Press “⇓” or “⇑” keys to select the parameter and press “–“or “+” to modify it. Press the EXIT key to
close the sub-menu and push it again to close the set-up.
Data safety copy: A safety copy of the adjustable keyboard set-up data can only be made in Te804 flash
memory. The same data can be restored, whenever required, to Te804 work memory. The commands and data
restore of the safety copy are available in the Commands menu.
HS-REV02 – 2004/09
32
10.11
SET-UP BY MEANS OF PERSONAL COMPUTER (PC)
The set-up can be more easily done/ modified via PC connected to Te804 RS-232 port. Using the software setup, it is possible to transfer parameters (previously set) from Te804 to the PC and vice versa.
In addition to the parameters set-up, with the PC it is possible to define:
Help text of the alarms, descriptions and help text of the User Alarms.
All the data related to the curve characteristic of the pressure, temperature, fuel level sensors and generator
thermal protection.
Custom logo, that appears on the display at power-up and at set-up exit via keypad.
Information page, where one can write information, data, characteristics, etc., concerning a certain application.
10.12
RECOMMENDATIONS ABOUT SET-UP
Safety copy of set-up data: It is highly recommended to save the set-up data on the PC hard disk and make a
safety copy on floppy disk because of the large amounts of data involved with Te804 set-up. Moreover, it is
advisable to update set-up data files each time data parameters are adjusted via keyboard. Bear in mind that a
safety copy of adjustable keyboard set-up data can only be made in Te804 flash memory. This same data can be
restored, whenever required, to Te804 work memory. The commands of safety copy and data restore are
available in the commands menu.
10.13
DIGITAL PROGRAMMABLE INPUTS AND OUTPUTS
All the outputs and a part of the inputs are assigned (set) to specific functions depending on specific application.
See the table in the following pages. To change the function assignment, enter INPUTS or OUTPUTS menu,
press the “⇓” or “⇑” keys to select the exact input or output and press “–“or “+” keys to select the function.
The following properties can be assigned to each input:
NO (Normally Open), command at the input contact closing or NC (Normally closed), command at the
input contact opening
Delay before the contact closes
Delay before the contact opens
To set these properties, enter the INPUTS menu, press the “⇓” or “⇑” key to select the exact input, press the
ENTER key to access the parameter properties, press the “⇓” or “⇑” key to select the parameter property and then
“–“or “+” key to change it. Press the EXIT key to return to the previous menu.
HS-REV02 – 2004/09
33
10.14 COMMANDS MENU
To enter the menu, press the OFF/RESET key, subsequently the ENTER key for 5 seconds and then
release them. Press the EXIT key to exit the menu.
C01 Energy meter reset
C02 Maintenance reset
C03 Engine hour meter reset
C04 Starting counter reset
C05 Parameters to default
C06 Save parameters to flash
C07 Load parameters from flash
C08 Rent hours reset
10.15
ADVANCED MENU
To enter the menu, keep the OFF/RESET key pressed, then push, in the following sequence, “-“ key twice,
“+” key three times and “⇓” key four times then finally release the OFF/RESET key.
“01” UTILITY (LANGUAGES)
Default D-22
Default G-20
Range
English
English
English/Italian/
French/Deutsch/
Spanish
P0102 Year
-
-
1989-2089
P0103 Month
-
-
1-12
P0104 Day of the month
-
-
1-31
P0105 Day of the week
-
-
1-7
P0106 Hour
-
-
0-23
P0107 Minutes
-
-
0-59
P0101 Languages
P0108 Seconds
-
-
0-59
P0109 Clock setting at power-up
ON
OFF
OFF/ON
P0110 Default page return (s)
60
60
OFF/5-999
P0111 Display contrast (%)
50
50
0-100
Default D-22
Default G20
Range
MONDAY
MONDAY
1-7
12
12
00-23
“09” EXERCISE AND MAINTENANCE
P0901 EXERCISE beginning day
P0902 EXERCISE beginning hour (h)
P0903 EXERCISE beginning Minutes (m)
0
0
00-59
P0904 Interval between EXERCISES (days)
07
07
1-30
P0905 EXERCISE duration (m)
OFF
OFF
OFF/1-60
P0906 EXERCISE with load
OFF
OFF
OFF/ON
P0907 Maintenance interval (h)
50
50
OFF/1-999
OFF
OFF
OFF/ON
Default D-22
Default G-20
Range
P0908 EXERCISE with remote / external stop
“10” COMUNICATION PORT
P1001 Serial port address
01
01
1-99
P1002 RS-232 baud rate
9600
9600
OFF/1200-38400
OFF
OFF
OFF/1200-38400
RS232
RS232
RS232/RS485
P1003 RS-485 baud rate
P1004 Modem channel
HS-REV02 – 2004/09
34
Engine temperature warning (analog sensor)
High engine temperature (analog sensor)
Temperature analog sensor fault
High engine temperature (digital sensor)
Oil pressure warning (analog sensor)
Low oil pressure (analog sensor)
Pressure analog sensor fault
Low oil pressure (digital sensor)
Pressure digital sensor fault
Fuel level warning(analog sensor)
Low fuel level(analog sensor)
Level analog sensor fault
Low fuel level(digital sensor)
High battery voltage
Low battery voltage
Inefficient battery
Charger alternator failure
“W” signal failure
Low engine “W” speed
High engine “W” speed
Starting failure
Emergency stop
Unexpected stop
Engine stop failure
Low generator frequency
High generator frequency
Low generator voltage
High generator voltage
Generator asymmetry
Generator short-circuit
Generator overload
External generator protection tripping
Incorrect generator phase sequence
Incorrect utility phase sequence
Wrong system frequency setting
Generator contactor failure
Utility contactor failure
Maintenance requested
System error
Fuel transfer too empty
Fuel transfer too full
Rent hours exhausted
User’s alarm 1
User’s alarm 2 (Dirty air filter)
User’s alarm 3
User’s alarm 4
HS-REV02 – 2004/09
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
35
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Modem auto call
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Active with engine running
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine cool down
X
Engine shutdown
X
X
Siren
A01
A02
A03
A04
A05
A06
A07
A08
A09
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
A28
A29
A30
A31
A32
A33
A34
A35
A36
A37
A38
A39
A40
A41
A42
UA1
UA2
UA3
UA4
Global alarm
List of the alarms for HSD-22
Latched alarm
Alarm properties ⇒
Alarm enabled
10.16
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine temperature warning (analog sensor)
High engine temperature (analog sensor)
Temperature analog sensor fault
High engine temperature (digital sensor)
Oil pressure warning (analog sensor)
Low oil pressure (analog sensor)
Pressure analog sensor fault
Low oil pressure (digital sensor)
Pressure digital sensor fault
Fuel level warning(analog sensor)
Low fuel level(analog sensor)
Level analog sensor fault
Low fuel level(digital sensor)
High battery voltage
Low battery voltage
Inefficient battery
Charger alternator failure
“W” signal failure
Low engine “W” speed
High engine “W” speed
Starting failure
Emergency stop
Unexpected stop
Engine stop failure
Low generator frequency
High generator frequency
Low generator voltage
High generator voltage
Generator asymmetry
Generator short-circuit
Generator overload
External generator protection tripping
Incorrect generator phase sequence
Incorrect utility phase sequence
Wrong system frequency setting
Generator contactor failure
Utility contactor failure
Maintenance requested
System error
Fuel transfer too empty
Fuel transfer too full
Rent hours exhausted
User’s alarm 1
User’s alarm 2 (Dirty air filter)
User’s alarm 3
User’s alarm 4
HS-REV02 – 2004/09
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
36
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Modem auto call
X
X
X
Active with engine running
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine cool down
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Engine shutdown
Siren
A01
A02
A03
A04
A05
A06
A07
A08
A09
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
A28
A29
A30
A31
A32
A33
A34
A35
A36
A37
A38
A39
A40
A41
A42
UA1
UA2
UA3
UA4
Global alarm
List of the alarms for HS-G20
Latched alarm
Alarm properties ⇒
Alarm enabled
10.17
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
10.18
TECHNICAL CHARACTERISTICS
Power supply
Battery rated voltage
12 VDC
Voltage range
9…15.6 VDC
Minimum voltage at the starting
6.7VDC
Maximum current consumption
320mA at 12VDC
Stand-by current
150mA at 12VDC
Micro interruption immunity
200ms
Digital inputs
Input type
Negative
Current input
≤10mA
Input “low” voltage
≤1.5V (typical 2.9V)
Input “high” voltage
≥5.3V (typical 4.3V)
Input delay
≥50ms
Speed input “W”
Input type
AC coupling
Voltage range
5…50Vpp
Frequency range
40…2000Hz
Engine running input for pre-excited generator (D+)
Voltage range
0…40VDC
Maximum input current
12mA
Maximum voltage at +D terminal
12 VDC (battery voltage)
Pre-excitation current
170mA 12VDC
Relay output 4.1-4.2 / 4.3-4.4 terminals (voltage free)
Contact type
1 NC for utility + 1 NO for generator
Rated voltage
250VAC (440VAC max)
Rated current at 250VAC
8A AC1 (2A AC15)
Relay output 5.3-5.4-5.5 terminals (voltage free)
Contact type
1 changeover
Rated voltage
250VAC max
Rated current at 250VAC
8A AC1 (2A AC15)
Relay output 6.2 / 6.3 / 6.4 / 6.5 terminals (+ battery voltage output)
Contact type
1 NO
Rated voltage
30VDC
Rated current at 30VDC
5A DC1
Analog inputs
Pressure sensor current
20mA max
Temperature sensor current
7mA max
Level sensor current
10mA max
Analog ground voltage
-0.5V…+0.5V
Voltage inputs
Maximum rated voltage
480VAC L-L (277VAC L-N)
Measuring range
50…620V L-L (358VAC L-N)
Frequency range
45…65Hz
Measuring method
True RMS
Measuring input impedance
>1.1MΩ L-L (>570kΩ L-N)
Wiring mode
1, 2 or 3 phases, with or without neutral
Current inputs
Rated current Ie
5A
Measuring range
0.02…6A
Measuring method
True RMS
Overload capacity
+20% Ie
Overload peak
50A for 1 second
Power consumption
<0.3VA
Measuring characteristics (-10…+45°C)
Voltage
±1% ±1digit
Frequency
±0.2% ±1digit
Current
±1% ±1digit
Power
±2% ±1digit
Energy
±2% ±1digit
Ambient operating conditions
Operating temperature
-20…+60°C
Storage temperature
-30…+80°C
Relative humidity
<90%
Maximum pollution degree
3
Reference standards
IEC/EN 60255-6, IEC 60664-1, IEC/EN 61000-4-5, IEC/EN 61000-4-4,
IEC/EN 61000-4-3, IEC/EN 61000-4-6, IEC/EN 60255-22-2, IEC/EN 55011,
IEC/EN 60255-21-2, IEC/EN 60068-2-6 (LROS-Lloyd’s Register Of Shipping), IEC/EN 60068-2-52 (RINA-Italian Naval Register), IEC/EN
60028-2-61 and IEC/EN 61010-1.
HS-REV02 – 2004/09
37
11.
PERIODIC MAINTENANCE
[Warning!] Only trained personnel should carry out the maintenance on this Genset. Make sure the
engine is not in operation and that it has cooled sufficiently. Make sure that all loads are disconnected
[Warning!] If the panels of your Genset are removed be sure they are re-assembled correctly prior to
running to avoid overheating or breakage.
11.1 ENGINE OIL LEVEL CHECK
•
•
•
•
Remove oil dip stick and check the engine oil level;
If the oil level is below the lower level line, refill with suitable oil to upper level line.
If oil is contaminated, change it.
Refer to periodic maintenance table.
11.2 ENGINE OIL & FILTER CHANGE
Use only recommended oils (see section 6.2), the first oil & filter change is recommended after the first 50
hours then every 125 hours (Diesel), every 250 hours (Gaseous).
To change engine oil:
•
Switch off your generator, disconnect AC utility. Remove negative cable from battery.
•
Loosen the drain plug located on the outside panel of your Genset and drain oil into an approved
container.
•
•
•
•
•
•
Inspect drain plug and washer for damage and replace as required
After draining the oil, reinstall and carefully tighten the drain plug.
Remove and replace oil filter.
Refill oil to upper level line.
Wipe any spilled or dripped oil off Genset
Dispose of used oil, oil filter and any contaminated rags or materials in a proper manner in
accordance to local standards and to protect the environment.
Note: For additional information on oil change refer to engine manual.
11.3 GEARBOX OIL CHECK and CHANGE (GASEOUS only)
•
Every 250 hours check around the gearbox for leakages. In case of leakages check oil level and, if
necessary, refill.
•
Replace gearbox oil every 1000 hours.
To refill or change oil:
•
Remove the side cover plug for level check
•
Fill from the top 0.6 liter of SAE 90 oil until oil is coming out from the side plug hole.
•
Plug side and top.
11.4 AIR CLEANER MAINTENANCE
If the air cleaner elements are clogged, a decrease in Genset output and/or excessive fuel consumption
may result. Clean or replace filtering element in case of UA2 alarm (dirty air filter).
We recommend replacing air cleaner after 500 hours. Replace more often when operating in dusty
environments.
11.5 FUEL LEVEL CHECK (DIESEL ONLY)
•
•
•
Switch off Genset and make sure the engine has stopped.
Do not overfill!
The Fuel tank capacity is 23 gal (87 liters).
[Warning!] Do not refuel while smoking or near open flame or other such potential fire hazards.
HS-REV02 – 2004/09
38
11.6
BATTERY
[Warning!] Before carrying out any maintenance operations make sure the Genset is switched off and
engine is not in operation.
The only maintenance operation a battery requires is the distilled water refill when necessary. However, it
is important to remember that a battery contains a very explosive gas. Do not smoke or get close to open
flames when working next to battery. Spark and open flames as well as a bad connection of battery poles
could lead to explosion.
[Warning!] Adequate ventilation is required when servicing the battery. The battery electrolyte fluid
contains acid that can burn eyes and clothing. Be extremely careful to avoid contact. If injured, wash the
affected area immediately with large quantities of water and consult a doctor for treatment.
11.7
CHECKING THE SPARK PLUG (Gaseous Version Genset)
• Turn off Control Panel – switch off circuit AC breakers and disconnect battery cables.
• Remove spark plugs using the proper tool.
• Inspect and replace if necessary with a new spark plugs.
11.8
COOLANT CHECK AND CHANGE
Remove radiator cap and, if necessary, refill. In case of low water level alarm refill coolant to correct level.
Every 1000 hours or 2 years Remove and replace engine coolant.
To change engine coolant:
• Switch off your generator, disconnect AC utility. Remove negative cable from battery.
• Loosen the drain plug located on the outside panel of your Genset and drain coolant.
•
•
•
•
11.9
Inspect drain plug and washer for damage and replace as required
After draining the coolant, reinstall and carefully tighten the drain plug.
Refill coolant until radiator is full.
Run Engine for approximately 5 minutes – allow unit to cool and verify coolant level fill if necessary.
MAINTENANCE SCHEDULE
Proper maintenance of the Genset will allow reliable performances and reasonable maintenance cost.
Follow this schedule and change if local conditions require.
ITEM
Check and add engine fuel
Check engine oil level
Check gearbox oil leakages
Check air filters
Engine oil change
Change oil filter
Fuel filter change
Coolant change
Gearbox oil change
HS-REV02 – 2004/09
INTERVAL
…Refill as required
every 50 hours
every 250 hours
every 500 hours
every 125 hours (Diesel); every 250 hours (Gaseous)
every 250 hours (or yearly whichever comes first)
every 250 hours (or yearly whichever comes first)
every 1000 hours (or 2 years)
every 1000 hours
39
12. PREPARATION FOR STORAGE
The following procedures should be followed prior to storage of your Genset for periods
of 6 months or longer:
• Operate the system with Preservative in the fuel to assure that only fuel with
preservative is in the fuel system.
• Drain fuel tank carefully. Do not perform this service near open flames or hot
surfaces.
• Check for loose bolts and screws, tightening them if necessary.
• Clean your Genset thoroughly using specific cleaning products. Spray with
preservative.
• Disconnect and remove battery.
• Store Genset in a well-ventilated, low humidity area.
• Follow engine mfg recommendations for long term storage
HS-REV02 – 2004/09
40
13. CONNECTIONS INSTRUCTIONS
13.1 LOW WYE (DOUBLE STAR) CONNECTIONS 120/208V 3PH
This is the “on factory set” connection.
In order to verify /remake this connection it is necessary to proceed according to the following points.
Do not run the generating set before all these steps have been checked / done.
[Warning!] Internal connections modification can only be made by trained personnel. Local codes must

be followed in order to avoid equipment damage, and /or personal injury up to and including death.
[Warning!] Always check that the Genset voltage/connection corresponds to your specific requirements.

Electrical connections must be carried out in compliance with local codes. AC cables, particularly, must
be sized and placed so that the cable does not attain temperatures over 50°C Ambient temperature.

It is necessary to check that cables have not loosened at the respective terminals.

To open the control panel front door use the special key supplied with the control panel. Only trained
personnel should have access to this key.
13.1.1 GENERATOR TERMINAL BOARD CONNECTIONS:
Verify / modify internal terminal board connections as per above drawing.
13.1.2 ELECTRICAL PANEL CONNECTIONS (SEE B0172.dwg, B0192.dwg)
To avoid damages to
- utility presence lamp
zero start device (block heater)
battery charger
other devices with maximum voltage = 240V
it is necessary to maintain voltage between terminals 30 and 31 of internal terminal board between 208V and
240V. For this reason, in case of 120/208V connection it is necessary to connect terminal 31 with terminal 11 (L1)
and terminal 30 with terminal 12 (L2) (V30-31 = 208V). All above devices will be supply between phase-phase.
120/208V
As soon as you connect utility
verify input voltage on above
devices: it must not exceed
240V.
HS-REV02 – 2004/09
41
13.1.3 CONTROLLER SETUP
Following parameters have to be adjusted – verified on controller set-up:
Menu
Parameter
Adjust to
M02 - General
P0203 – Wiring configuration
P0204 – Nominal voltage (V)
P0801 – Nom. Gen Current (A)
L1-L2-L3-N
208 (or 220)
See following table (Amax)
M08 – Generator Protection
13.1.4 RATED POWER / CURRENT WITH DIFFERENT VOLTAGE
With low wye connection it is possible to obtain:
Voltage
VLL
208
220
HSD 22
VLN
120
127
Amax
76.3
72.2
HSG 20 (LPG)
KVA max
27.5
27.5
Amax
69.4
65.6
KVA max
25
25
13.1.5 A.T.S. CONNECTIONS
Te804 controller can control an external A.T.S.: two contacts are available and connected as per following
diagram.
Utility
Generator
Controller
[Warning!] Voltage between 42/44 and N is 120V.
Carefully verify compatibility with ATS. If necessary connect a transformer.
In case of use of an Elliott A.T.S. it is necessary to consider:
terminal 42 (UTILITY ON) has to be connected to terminal 30 of ATS
terminal 44 (GENSET ON) has to be connected to terminal 32 of ATS
it is not necessary to use transformers
13.1.6 VOLTAGE ADJUSTMENT
Carefully start the generating set and:
1. Check ph-ph and ph-N voltage: values between phase has not to be different (max difference= 2%)
2. Quickly adjust output voltage on “VOLT” potentiometer on generator A.V.R.
3. If output voltage is not inside preset limits before the preset time expires, you will get an alarm.
HS-REV02 – 2004/09
42
13.2 HIGH WYE (STAR) CONNECTIONS 240/416V÷277/480V 3PH
In order to obtain this connection it is necessary to proceed according to the following points.
Do not run the generating set before all these steps have been done.

Modify internal terminal board connections as per above drawing.
13.2.2
ELECTRICAL PANEL CONNECTIONS (SEE B0172.dwg, B0192.dwg)
In order to do not damage
battery charger
240V. For this reason:
in case of 240/416V it is necessary to connect terminal 30 with terminal 14 (V30-31 = 240V). All above
devices will be supply between phase-neutral.
in case of 254/440V – 266/460V - 277/480V it is necessary to connect a suitable step-down transformer
(transformer rated power minimum 1.2kVA).
/
V
240
416
277
/
480 V
As soon as you connect utility verify input voltage on above devices: it must not exceed 240V
HS-REV02 – 2004/09
43
Menu
Parameter
Adjust to
M02 - General
L1-L2-L3-N
416 (or 440, or 460, or 480)
With high wye connection it is possible to obtain:
Voltage
VLL
416
440
460
480
HSD 22
VLN
240
254
266
277
Amax
38.1
36.1
34.5
33.0
HSG 20 (LPG)
KVA max
27.5
“
“
“
Amax
34.7
32.8
31.4
30.0
KVA max
25
“
“
“
diagram.
Utility
Generator
Controller
[Warning!] Voltage between 42/44 and N is 240V (with 416V PH-PH); is 277V (with 480V Ph-PH).
Carefully verify compatibility with ATS. If necessary connect a step-down transformer.
it is necessary to use step-down transformers to reduce voltage up to 120V
HS-REV02 – 2004/09
44
13.3 DOG LEG (ZIG ZAG) CONNECTIONS 120/240V 1ph

battery charger
240V. For this reason, in case of 120/240V (1ph) connection it is necessary to connect terminal 31 with terminal
11 (L1) and terminal 30 with terminal 12 (L2) (V30-31 = 240V). All above devices will be supply between phasephase.
As soon as you connect utility
verify input voltage on above
devices: it must not exceed
240V
120 / 240 V
HS-REV02 – 2004/09
45
Menu
Parameter
Adjust to
M02 - General
L1-N-L2
240 (or 220)
With dog-leg (zig-zag) connection it is possible to obtain:
Voltage
VL1-L2
240
220
HSD 22
VLN
120
110
Amax
88
88
HSG 20 (LPG)
KW max
21
19.3
Amax
75
75
KW max
18
16.5
diagram.
Utility
Generator
Controller
1. Check ph-ph and ph-N voltage: values between phases-neutral has not to be different (max difference=
2%)
2. Quickly adjust output voltage on “VOLT” potentiometer on generator A.V.R
HS-REV02 – 2004/09
46
13.4
HIGH DELTA CONNECTIONS 240V 3ph - 120/240V 1ph

battery charger
240V.
For this reason, in case of this connection it is necessary to connect terminal 31 with terminal 11 (L1) and
terminal 30 with terminal 12 (L2) (V30-31 = 240V). All above devices will be supply between phase-phase.
240 V – 1ph
HS-REV02 – 2004/09
120 / 240 V-3ph
47
As soon as you connect utility verify input voltage on above devices: it must not exceed 240V
Menu
Parameter
Adjust to
M02 - General
240 3ph: L1-L2-L3
120/240V 1ph: L1-N-L2
240
With high delta connection it is possible to obtain:
Voltage
HSD 22
HSG 20 (LPG)
System
3ph L1-L2-L3
V
240
Amax
66.2
KVA max
27.5
Amax
60.1
KVA max
25
1ph L1-N-L2
VL1-L2=240V
VL1-M=120V
88
44
KW max
21
5.3
75
37
KW max
18
4.5
L1-M
diagram.
Utility
Generator
Controller
HS-REV02 – 2004/09
48
14. ELECTRICAL DIAGRAMS
HSD-22
HS-REV02 – 2004/09
49
HSD -22
HS-REV02 – 2004/09
50
HSG 20
HS-REV02 – 2004/09
51
HSG 20
HS-REV02 – 2004/09
52
APPENDIX A
GARRETSON
MODEL KN
Installation & Operation
A.1
GENERAL
The KN is designed for sensitivity and simple operation. It is used with low pressure vaporized gaseous
fuels, where dependable starting is a requirement. Because of its extreme sensitivity, the KN offers
excellent results in most remote starting applications (standby power generators, etc.). With proper
installation and maintenance, the KN will provide years of trouble free service.
[Warning!!!] The KN should be installed and maintained per Garretson instructions and all applicable
federal, state, local laws and codes, and NFPA Pamphlet 58.
SPECIAL NOTE: For indoor installations by NFPA definition, an atmospheric zero governor is not
considered a positive shut-off valve and an approved automatic shut-off device shall be installed to assure
that the flow of fuel will be stopped should the engine fail while unattended.
For a copy of the Pamphlet 58, write the National Fire Protection Association, 470 Atlantic Ave., Boston,
Mass. 02110.
A.2
OPERATION
The KN is an atmospheric zero governor which acts like the float and needle valve in a gasoline
carburetor. Air flow through a venturi in the carburetor creates a vacuum that acts through the outlet of
the KN on the diaphragm. Atmospheric pressure then forces the diaphragm toward the vacuum,
depressing the lever and pulling the valve seat away from the orifice that allows fuel to flow as long as the
demand persists. When the vacuum ceases, a spring force pushes on the lever and forces the valve seat
against the orifice shutting off the fuel flow. It is important to remember that fuel should not flow through
the KN when the engine is not running.
A properly adjusted KN requires a vacuum of only 0.25” to 0.35” of water column to start the opening
sequence. Due to this sensitivity, most installations do not need priming to start unless low cranking
speeds or restricted and lengthy piping are required. If priming is necessary and a manual primer is
installed, use only 1 or 2 second bursts of fuel and immediately try to start the engine. If there is a choke
on the carburetor, do not use it as this will probably cause flooding and hard starting. As you can see, the
operation of this unit is simple and basic. If you are having trouble operating the engine, in most cases
the fuel controller is NOT malfunctioning. There is generally a problem with the engine or fuel supply so
do not make adjustments or attempt to service the KN until you are sure it is needed.
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A.3
SERVICE
The KN should be periodically checked for leakage past the valve seat and the vents on the cover kept
clean and free of obstructions. If the KN needs service we suggest you take it to a qualified serviceman.
If that help is not available we will furnish you a list of repair shops of the proper service information.
A.4
INSTALLATION
The KN should be mounted as close to the carburetor as possible with the arrow on the cover pointing up
and the diaphragm in a vertical position. This helps to minimize the effects of gravity on diaphragm travel.
The unit should also be placed for easy access to the primer if provided.
There are two sets of mounting holes provided. Either set of mounts will adequately support the KN. The
bottom set of holes has a 1 ¾” bolt spacing for use with all Garretson universal mounting brackets. The
mounting bosses on the cover are spaced (5 ¾”) apart for use with 5/16 bolts.
Before installing the fuel supply line, be sure that the gas pressure is no more than the maximum inlet
pressure shown on the front of the KN. If the pressure if greater, leakage could result in a fire hazard and
or hard starting. The piping to the inlet should be of sufficient size to allow full flow to the KN. This is very
important in natural gas installations as any restrictions can affect engine performance. If a solenoid is
used ahead of the KN in the low pressure line, it should have an orifice at least as big as the orifice in the
KN. Flexible piping to the inlet should be used to prevent cracking from vibration if the KN is mounted on
the engine or other vibrating surface.
NOTE: Thread sealing compound should be used on all pipe thread fittings between the KN and the fuel
supply tank, being careful not to get any inside the inlet or fittings. Excess compound could collect on the
seat and orifice and cause hazardous leakage, resulting in poor performance. After piping is complete,
turn on the gas and use a soap solution to check all fittings for leaks.
If an electric solenoid primer is used, follow the wiring and adjusting instructions furnished separately.
The KN outlet is 3/8 NPT and if an outlet fitting has not been provided, select and insert a suitable vapor
fitting taking care not to allow any chips or dirt to enter the outlet. Use of street ells or conventional pipe
fittings in the fuel line between the KN and the carburetor is not recommended as they may restrict the
flow of fuel.
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APPENDIX B
ESD2200 SERIES
SPEED CONTROL UNIT
B.1
APPLICATION INFORMATION
The ESD2200 Series speed control unit is built ruggedly to withstand the engine environment. The unit has been
engine mounted enclosure.
To avoid that water mist or condensation comes in contact with the controller, it has been mounted vertically. The
unit is hard potted to greatly reduce the effects of moisture and vibration.
An overspeed shutdown device independent of the governor system should be provided to prevent loss of engine
control which may cause personal injury or equipment damage.
B.2
WIRING
The ESD2200 Series control unit is in 12V versions. Electrical connections are illustrated in diagram. Battery and
actuator has to be connected to terminals E, F, G and H. The battery positive (+) input terminal is fused as
illustrated in diagram.
Magnetic speed sensor connections to terminals C and D must be twisted or shielded for their entire length. The
speed sensor cable shield should ideally be connected as shown in diagram. The cable shield should be insulated
to insure no part of the shield comes in contact with engine ground, otherwise stray speed signals may be
introduced into the speed control.
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B.3
ADJUSTMENT
Before Starting Engine
Check to insure the GAIN, and STABILITY controls, and if applied the external SPEED TRIM control, are set to
mid-position.
Engine Start
The controller is factory set at approximately engine idle speed. (approx 2430 rpm)
Crank the engine with D.C. battery power applied to the governor system. The actuator will energize fully to the
maximum fuel position until the engine has started. The governor should be controlling the engine at low idle
speed.
If the engine is unstable after starting, turn the GAIN and STABILITY adjustments counter clockwise until the
engine is stable.
Governor Speed Setting
The governed speed set point is increased by a clockwise rotation of the SPEED adjustment control. Fine, precise
speed adjustments can be obtained with an optional Speed Trim control.
Governor Performance
Once the engine is at the operating speed and at no load, the following governor performance adjustments can be
made:
a.
Rotate the GAIN adjustment clockwise until instability develops. Gradually move the adjustment counter
clockwise to insure stable performance. Then move the adjustment 1/8 turn counter clockwise to insure
stable performance.
b.
Rotate the STABILITY adjustment clockwise until instability develops. Gradually move the adjustment
counter clockwise until stability returns. Then move the adjustment 1/8 turn counter clockwise to insure
stable performance.
c.
Gain and stability adjustments may require minor changes after engine load is applied. Normally,
adjustments at no load achieve satisfactory performance.
d.
The dead time compensation can be changed with posts E1, E2, and E3 to optimise the control system. If
a rapid instability, greater than 2 Hz., is present at the actuator lever, cut the jumper between post E1 and
E2. If the fast instability is still present, remove the jumper between posts E4 and E5. If slow instability,
low gain setting, or poor response exists, add a 22 µF. capacitor between posts E2 (-) and E3 (+). If
the
throttle is erratic, but performance is good, removing the E4 to E5 jumper will tend to steady the throttle.
B.4
SYSTEM TROUBLESHOOTING
B.4.1
SYSTEM INOPERATIVE
If the engine governing system does not function, the fault may be determined by performing the voltage tests
described in steps 1 through 6. Positive (+) and negative (-) refer to meter polarity. Should normal values be
indicated during troubleshooting steps, then the fault may be with the actuator or the wiring to the actuator. Tests
are performed with the battery power on, engine off except where noted.
Step Terminals Normal Reading
Probable Cause of Abnormal Reading
1
E(+) & F(-)
Battery Supply Voltage (12 VDC)
1. DC battery power not connected. Check for blown fuse.
2. Low battery voltage.
3. Wiring error.
2
A(+) & B(-)
0-3.9 with speed trim
7.1-7.9 without speed trim
1. Speed trim shorted or miswired.
2. Defective unit.
3
C(+) & D(-)
1.0 VAC RMS min., while cranking
1. Gap between speed sensor and gear teeth is too large.
Check gap.
2. Improper or defective wiring to the speed sensor.
Resistance between D & C should be 30 to 1200 Ω.
3. Defective speed sensor
4
E(+) & H(-)
0.8-1.5 V while cranking
1. Wiring error to actuator.
2. Defective speed control unit.
3. Defective actuator.
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B.4.2 UNSATISFACTORY PERFORMANCE
If the governing system functions poorly, perform the following tests.
Symptom
Test
Probable Fault
Engine overspeed
1. Do Not Crank, Apply D C power to
the governor system.
1. Actuator goes to full fuel. Then disconnect speed
Sensor Terminals C and D.
If actuator still at full fuel-speed control unit defective.
If actuator at minimum fuel position-erroneous
Speed signal. Check speed sensor cable.
2. Manually hold the engine at the
1. if the voltage reading is 1.0 to 1.5 VDC,
Desired running speed. Measure
a) Speed adjustment set above desired speed, turn
The DC voltage between Terminals
counter clockwise.
E(+) and H(-) on the speed control
b) Defective speed control unit.
Unit.
2. If the voltage reading is above 1.5 VDC, actuator
Or linkage binding. Replace actuator.
3. Set point of over speed shutdown device set too low.
4. If the voltage reading is below 0.8 VDC, defective
speed control unit.
Actuator does not
1. Measure the DC voltage between
Energize fully while
Terminals E(+) and H(-) on the
cranking
speed control unit. Should be 0.8
to 1.5 volts, if not:
2. Momentarily connect the Terminal
E to H. The actuator should move
to the full fuel position.
1. replace the battery if weak or undersized.
2. Actuator wiring incorrect.
3. If voltage is greater than 1.5V, speed set too low.
Engine remains
Below desired
Governed speed
1. If voltage measurement is within 1.5 volts or more
of the battery supply voltage level, then fuel control
Restricted from reaching full fuel position.
Possibly due to mechanical governor, carburetor
Spring, or linkage interference.
2. If not, increase speed setting.
B.4.3
1. Measure the actuator output,
Terminals G & H, while running
under governor control.
1. Actuator or battery wiring in error.
2. Actuator or linkage binding. Replace actuator.
3. Defective actuator.
ELECTROMAGNETIC COMPATIBILITY (EMC)
EMI SUSCEPTIBILITY- The governor system can be adversely affected by large interfering signals that are conducted through the cabling or through direct radiation into the control circuits.
All GAC speed control units contain filters and shielding designed to protect the unit's sensitive circuits from
moderate external interfering sources.
Although it is difficult to predict levels of interference, applications that include magnetos, solid state ignition
systems, radio transmitters, voltage regulators or battery chargers, should be considered suspect as possible
interfering sources.
If it is suspected that external fields, either those that are radiated or conducted, are or will affect the governor
systems operation; it is recommended to use shielded cable for all external connections. Be sure that only one
end of the shields including the speed sensor shield, is connected to a single point on the case of the speed
control unit. Mount the speed control unit to a grounded metal back plate or place it in a sealed metal box.
Radiation is when the interfering signal is radiated directly through space to the governing system. To isolate the
governor system electronics from this type of interference source, a metal shield or a solid metal container is
usually effective.
Conduction is when the interfering signal is conducted through the interconnecting wiring to the governor system
electronics. Shielded cables and installing filters are common remedies.
As an aid to help reduce the levels of EMI of a conductive nature, a battery line filter and shielded cables is
conveniently supplied by GAC in KT310. To reduce the levels of EMI of a radiated nature, a shielded container
P/N CA114 can be sourced from GAC and its distributors.
In severe high energy interference locations such as when the governor system is directly in the field of a powerful
transmit- ting source, the shielding may require to be a special EMI class shielding. For these conditions, contact
GAC application engineering for specific recommendations.
In severe high energy interference locations such as when the governor system is directly in the field of a powerful
transmit- ting source, the shielding may require to be a special EMI class shielding. For these conditions, contact
GAC application engineering for specific recommendations.
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B.4.4
INSUFFICIENT MAGNETIC SPEED SENSOR SIGNAL
A strong magnetic speed sensor signal will eliminate the possibility of missed or extra pulses. The speed control
unit will govern well with 0.5 volts RMS speed sensor signal. A speed sensor signal of 3 volts RMS or greater at
governed speed is recommended. Measurement of the signal is made at Terminals C and D.
The amplitude of the speed sensor signal can be raised by reducing the gap between the speed sensor tip and
the engine ring gear. The gap should not be any smaller than 0.020 in. (0.45 mm). When the engine is stopped,
back the speed sensor out by 3/4 turn after touching the ring gear tooth to achieve a satisfactory air gap.
B.4.5
INSTABILITY
Instability in a closed loop speed control system can be categorized into two general types. PERIODIC appears to
be sinusoidal and at a regular rate. NON-PERIODIC is a random wandering or an occasional deviation from a
steady state band for no apparent reason.
The PERIODIC type can be further classified as a fast or slow instability. Fast instability is a 3 Hz. or faster
irregularity of the speed and is usually a jitter. Slow periodic instability is below 3 Hz., can be very slow, and is
some times violent.
If fast instability occurs, this is typically the governor responding to engine firings. Raising the engine speed
increases the frequency of instability and vice versa. If this is the case, cutting the jumper from E1 to E2 will
reduce this tendency. In extreme cases, the removal of the E1 to E2 jumper may not take all the jitter out of the
system. A second jumper, E4 to E5, may be removed to further stabilize the system. Post locations are illustrated
in diagram. Interference from powerful electrical signals can also be the cause. Turn off the battery chargers or
other electrical equipment to see if the symptom disappears.
Slow instability can have many causes. Adjustment of the GAIN and STABILITY usually cures most situations by
matching the speed control unit dynamics. If this is unsuccessful, the dead time compensation can be modified.
Add a capacitor from posts E2 to E3 (negative on E2). Post locations are illustrated in diagram. Start with 10 µF.
and increase until instability is eliminated. The control system can also be optimised for best performance by
following this procedure.
If slow instability is unaffected by this procedure, evaluate the fuel system and engine performance. Check the
fuel system linkage for binding, high friction, or poor linkage. Be sure to check linkage during engine operation.
Also look at the engine fuel system. Irregularities with carburetion or fuel injection systems can change engine
power even with a constant throttle setting. This can result in speed deviations beyond the control of the governor
system. Adding a small amount of droop can help stabilize the system for troubleshooting.
NON-PERIODIC instability should respond to the GAIN control. If increasing the gain reduces the instability, then
the problem is probably with the engine. Higher gain allows the governor to respond faster and correct for the
disturbance. Look for engine mis-wirings, an erratic fuel system, or load changes on the engine generator set
voltage regulator. If the throttle is slightly erratic, but performance is fast, removing the jumper from E4 to E5 will
tend to steady the system.
If unsuccessful in solving instability, contact your nearest GAC factory authorized service center for assistance.
GENMAC group:
Genmac USA, Inc.
12355 SW 129 COURT # 1
MIAMI, Florida 33186
Ph. (001) 305 254 4545
Fax (001) 305 254 4558
Toll Free # 1-877-254-4541
e-mail :
[email protected]
www.genmac-group.com
Head quarter
42044 GUALTIERI
(Reggio Emilia) Italy
via Don Minzoni, 13
Tel.0039-0522.828179
Fax 0039-0522.829218
E-mail: [email protected]
Web space: www.genmac.it
www.genmac-group.com
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