AIE SQ Series User manual

SQ10000 INSTALL &
MAINTENANCE MANUAL

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TABLE OF CONTENTS
MODEL IDENTIFICATION 6
SPECIFICATIONS 8
PACKAGE CONTENTS 9
LOCATION OF IMPORTANT COMPONENTS AND CONNECTIONS 10
FUEL RECOMMENDATIONS 12
ENGINE OIL RECOMMENDATIONS 12
STARTING BATTERIES 13
OPERATOR INTERFACE 13
MOUNTING THE GENSET 15
FUEL TANK INSTALLATION 16
HIGH VOLTAGE ELECTRICAL CONNECTIONS 17
AC WIRING TERMINATION 17
AUXILIARY WARNING, SHUTDOWN, AND EMERGENCY STOP WIRING 18
AUTO MODE REMOTE START SETUP 19
CONNECTING THE BATTERY 19
PRE-START CHECKS 20
PRIMING THE FUEL SYSTEM 20
STARTING THE GENSET 20
STOPPING THE GENSET 23
OPERATING AT HIGH ALTITUDES 23
OPERATING IN HOT AMBIENT TEMPERATURES 23
INSTALLATION 14
OPERATION 19
SAFETY
INTRODUCTION
3
6

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OPERATING IN COLD AMBIENT TEMPERATURES 24
OPERATING IN DIRTY ENVIRONMENTS 24
BREAKING IN A NEW ENGINE 24
STORAGE AND RETURNING TO SERVICE
MAINTENANCE
TROUBLESHOOTING/ FAULT ICONS
APPENDIX A: DC WIRING SCHEMATIC
APPENDIX B: AC WIRING SCHEMATIC
25
26
27
31
32
SAFETY
Thoroughly read this manual before operating the genset. The following symbols are used throughout this manual and on the
genset to warn of the potential hazards to the operator, service personnel, or equipment.
When using the AUTO starting feature, electric shock and moving parts hazards are possible due to unexpected starting. Make sure
that the genset is not in AUTO mode whenever performing maintenance or service or when the genset is stored.
***All operators, no matter how knowledgeable, should read this and related manuals before operating the engine or any
attached equipment. It is the owner’s responsibility to instruct all operators in safe operation. Be sure to observe the following
warnings for safe operation.***
Alerts you to an immediate hazard that will result in severe personal injury or death.
Alerts you to a hazard or unsafe practice that can result in severe personal injury or death.
Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage.

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SAFETY
• Diesel fuel is combustible. Do not smoke or make/break electrical connections when diesel fumes are present.
• Keep ames, sparks, pilot lights, and arc-producing equipment and all other sources of ignition well away from
engine fuel.
• Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
• Disable any automatic starting systems before performing inspections or service on the genset to avoid electric shock
from unexpected start.
• Generator electrical output connections must be made by a trained and experienced electrician in accordance with
applicable codes.
• The genset must not be connected to the public power utility or any other source of electrical power. Back-feed could
lead to electrocution of utility personnel and/or damage equipment. An approved switching device must be used to
prevent interconnections.
• Use caution when working with live electrical equipment. Remove jewelry, wear tight tting clothing, and only use
insulated tools.
• Electric shock can be deadly. Always insulate yourself from ground and never operate the genset when wet.
EXHAUST GAS IS DEADLY
GENERATOR VOLTAGE IS DEADLY
• Engine exhaust fumes can be very harmful if allowed to accumulate. Only operate the engine in a well-ventilated
area.
• Inspect for exhaust leaks at every startup and aer every eight hours of operation.
• Exposure to exhaust gases can cause carbon monoxide poisoning.
• Engine cooling air must not be used for heating working or living spaces or compartments.
• Disable any automatic starting systems before storing the genset in a conned area.
EXHAUST GAS IS DEADLY

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• Wear safety glasses.
• Do not smoke near battery.
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the negative (-) battery cable
rst and reconnect it last.
• Flammable vapor can cause an engine to over speed and become diicult to stop, resulting in possible re,
explosion, severe personal injury and death.
• Do not operate gensets where a ammable vapor environment can be created by fuel spill or leak.
BATTERY GAS IS EXPLOSIVE
FLAMMABLE VAPOR CAN CAUSE AN ENGINE TO OVERSPEED
• Exhaust gas can be extremely hot. Do not point toward people. Keep machine more than 1 meter (3 feet) from
ammable materials.
• Check for fuel leaks before each operation.
• Stop the engine before adding fuel to tank (where applicable)
• Anti-freeze coolant contains ethylene glycol, which is toxic to humans and animals. Clean up spills and dispose of
used engine coolant in accordance with local regulations.
• Disable any automatic starting systems before performing inspections or service on the genset to avoid unexpected
start.
• Do not wear loose clothing or jewelry near moving parts such as fans, belts and pulleys.
• Keep hands away from moving parts.
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
GENERAL CAUTIONS
SAFETY

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INTRODUCTION
This manual covers the installation, rst run operation, and maintenance of the SQ Genset. Be sure to read the entire manual
thoroughly before rst use and obey all safety warning information contained within. Proper installation and use as described
in this manual will ensure your genset operates at peak performance. The owner is responsible for proper installation
observing all local electrical and building codes. The owner is also responsible for performing regular maintenance as
described in the supplied engine Operator’s Manual.
MODEL IDENTIFICATION
The genset model and serial number can be found on the primary nameplate located on the door side of the enclosure.
Figure 1: Genset Model and Serial Number
GENSET MODEL & SERIAL NUMBER LOCATION

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INTRODUCTION
MODEL # SERIAL #
GENSET:
ENGINE:
GENERATOR:
The engine model and serial number can be found either on genset baseframe just inside the genset door, to the right.
OR on top of the control panel box.
NOTE: You should record the model and serial numbers below for quick reference in the future.
Engine Model and Serial Number Locations

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MODEL UNIT SQ9000 SQ10000
GENERATOR
Manufacturer - Linz
Model - CPT18MF
Type - 4-pole, rotating eld
Exciter Type - Brushless, self-exciting
Frequency Hz 60
No. Leads - 12, Recongurable
Rated Voltage V 120/240 120/208 120/208/240 277/480 120/240 120/208 120/208/240 277/480
Phase ø Single Three Three Delta Three Single Three Three Delta Three
Number of Poles - 4
Insulation Class H
Temp. Rise ºC 125
Voltage Regulation (AVR) % 1
Peak Motor Starting kVA @
20% Transient Voltage Dip kVA 40 36 40 36
ENGINE
Manufacturer - Kubota
Model - D1005-E4BG D1105-E4BG
EPA Certicate - Tier 4 NRTC
Type - Vertical, water-cooled, 4 cycle diesel engine
Number of cylinders - 3
Fuel - Ultra Low Sulfur Diesel (15 ppm Sulfur) (ASTM D975)
Bore x Stroke in 2.99 x 2.90 3.07 x 3.09
Displacement L 1.001 1.123
Engine Speed rpm 1800
Oil Capacity gal 1.03
Coolant Capacity gal 0.82
SPECIFICATIONS
INTRODUCTION

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MODEL UNIT SQ9000 SQ10000
GENERATOR SET
Standby Power kW (kVA) 8.6 (8.6) 8.6 (10.7) 10.0 (10.0) 10.0 (12.5)
Prime Power kW (kVA) 7.7 (7.7) 7.7 (9.5) 8.9 (8.9) 8.9 (11.0)
Governor Type - Mechanical
Fuel Consumption (100%
Load)
gal/hr
0.77 0.89
Fuel Consumption (75%
Load) 0.58 0.67
Fuel Consumption (50%
Load) 0.38 0.45
Fuel Consumption (25%
Load) 0.19 0.22
Main Breaker Amps 42 35 15 42 35 15
Voltage Sense Fuses - 2 Amp 3AB Fuse
Battery CCA 500
Starting System - 12V DC Electric
L x W x H in 53.8 x 27.3 x 33.5
Approx Net Wt. lbs 925
Output - Distribution Block in Generator Box
Stop System - High Coolant Temperature, Low Oil Pressure, Over Voltage, Under Voltage, Over Frequency
INTRODUCTION
PACKAGE CONTENTS
Each generator set is shipped with a set of parts and manuals in a ship loose package. This package includes the following:
• Installation Manual
• Kubota Engine Operator’s Manual
• Generator Manual
• Genset Door Keys
• Engine Keys
• Neutral-Ground Bonding Cable

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INTRODUCTION
LOCATION OF IMPORTANT COMPONENTS AND CONNECTIONS
The location of components needed for operation and maintenance are shown below. For more details see the
MAINTENANCE section on page 26.
NUMBER ITEM / FUNCTION
1 Air Inlet
2 Radiator Air Outlet
3Generator Wiring Access
Cover
4 Radiator Cap Access Cover
5 Main Access Door
6 Coolant Drain Plug
7 Oil Drain Plug
8 Air Cleaner
9Coolant Overow Bottle
10 Oil Fill
11 Oil Filter
12 Dipstick
13 Battery
3 4
7 6 5
21
9
111213 10
8
Figure 3: Important Components

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INTRODUCTION
NUMBER ITEM / FUNCTION
14 Exhaust Outlet
15 Fuel Supply Port
16 Fuel Return Port
17 Breaker/Generator Box
18 Fuel Filter
19 Drive Belt
18
17
15
19
1614
Figure 3: Important Components (cont.)

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FUEL RECOMMENDATIONS
***Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke near diesel fuel tanks or
equipment. Keep all ames, sparks, or all other sources of ignition well away.***
INTRODUCTION
The use of ultra-low sulfur fuel (15ppm or 0.0015 wt.%) is mandatory when operated in US EPA regulated areas. The use
of Kerosene, whether blended with diesel or otherwise is prohibited within US EPA regulated areas. Please use No. 2-D
S15 diesel fuel as an alternative to No. 2-D and use No. 1-D S15 for ambient temperatures below -10°C (14°F).
The minimum recommended Cetane rating is 45. A Cetane rating of greater than 50 is preferred, especially for ambient
temperatures below -20°C (-4°F) for elevations above 1500m (5000 .). Kerosene, which is very low in Cetane rating,
adversely aects the engine and is prohibited within US EPA regulated areas and should be avoided in areas outside of US
EPA regulated areas.
Biodiesel blends of up to 5% (B5) may be used in the genset. Blends of biodiesel above 5% may void the engine warranty.
Biodiesel fuels must be blended according to EN 590 or ASTM D975. Raw processed vegetable oils are not acceptable for
use in any concentration.
Reference Engine Operator Manual when using anything other than ultra-low sulfur diesel as the oil change interval will
change.
ENGINE OIL RECOMMENDATIONS
Use engine oil that is CF or better API classication with a high Total Base Number (a minimum TBN of 10 is
recommended). Change the viscosity of engine oil according to the ambient temperature (Figure 4). Synthetic oil may be
used aer the initial break-in period. Maintain proper engine oil change intervals when using full synthetic engine oil, do
not extend the oil change interval.
Figure 4: Oil Viscosity vs. Ambient Temperature

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OPERATOR INTERFACE
INTRODUCTION
STARTING BATTERIES
The genset uses a 12V direct current starting, charging and control system. The battery is a 500 CCA, sealed type. Regular
maintenance of the battery may be required in order to ensure proper starting performance. The genset is shipped with
the battery disconnected and will need to be connected before rst running the genset.
The main operator interface is installed inside the genset, behind the genset’s door, see Figure 5. The Deep Sea 3110
panel is responsible for all genset starting, stopping, and safety monitoring. For more information on using the Deep Sea
panel, see OPERATION on page 19.
On/O Switch - This switch is responsible for supplying main power to the control panel.
Module Display - This screen will display genset status, engine hours, engine rpm, generator voltage, generator
frequency, warning icons and fault icons.
Fault LED - This light will glow when any alarm or shutdown condition is present.
Menu Navigation Button - This button allows the user to cycle through values displayed on the main status display.
Stop/Reset Button - This button will immediately stop the engine when pressed. It will also clear any fault icons when the
engine is in stop mode if the fault condition is no longer present.
Figure 5: Operator Interface Panel
Menu Navigation
Module Display
Manual / Start Mode
On / O Switch
Fault LED. Flashes upon
electrical trip and
Shutdown Fault
Manual / Start Mode LED.
Flashes upon Waiting in
Manual Mode
Stop / Reset Mode
Auto Mode

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Auto Mode Button - This button will toggle the control panel in and out of Auto mode. This is only applicable if a remote start
signal has been connected to the control panel. See STARTING THE GENSET on page 20 for operating instructions.
Manual/Start Mode Button - This button will initiate the pre-heat and start sequence when the engine is in stop mode.
INSTALLATION
This section will guide you through proper installation of the SQ Genset. Proper installation is key to correct genset operation and
ensuring the long life of the unit. Read this entire section thoroughly BEFORE installing the genset.
The SQ Genset requires an external fuel source. It is up to the installer to provide an acceptable fuel tank, run fuel lines, install
the supplied pre-lter, and relocating the installed fuel pump as needed. Only a technician experienced with diesel engines and
generators should install this genset. High voltage electrical connections must be made before operating the genset. All high
voltage electrical connections should be made by an electrician in accordance with all local codes.
Exhaust gas is deadly. Never operate the genset without proper ventilation.
Check for leaks in the exhaust system regularly. Exposure to exhaust
gases can cause carbon monoxide poisoning. Symptoms of carbon monoxide poisoning include dizziness, throbbing in
temples, nausea, muscular twitching, headache, vomiting, weakness and sleepiness, and inability to think clearly. If you
or anyone experiences these symptoms, get to fresh air immediately. If symptoms persist, seek medical attention.
Battery gas is explosive. Do not smoke or introduce any sparks, ames
or arcs near the battery at any time. Do not make direct contact between
battery terminals to prevent sparks.
Electric shock can be deadly. Failure to install a generator set with an electrical system
consistent with governing regulations is UNLAWFUL and may cause ELECTROCUTION
to installer or operator. Never connect this generator to utility power or back feed existing electrical systems without proper
transfer switch gear in place.
Diesel fuel is combustible and can cause severe personal injury or death. Do not
smoke near diesel fuel tanks or equipment. Keep all ames, sparks, or all other
sources of ignition well away.

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INSTALLATION
Many engine components and uids can be hot and cause severe burning
on contact. Exhaust piping, engine oil, engine coolant, exhaust insulation,
radiator core, and other parts can become extremely hot aer extended operation. Do not work on a genset until it has
suiciently cooled.
Moving parts can cause personal injury. Keep hands, feet and clothing away
from belts, pulleys, fans and rotors while engine is operating. Always replace
safety guards, screens and covers before operating the genset.
MOUNTING THE GENSET
The SQ Genset is designed to be mounted with the supplied mounting legs to allow at least two inches of space below
the genset for the unit to properly draw in fresh air. When mounting unit to mounting pad or trailer atness should be
checked before tightening down the genset as shims may be needed to provide a level installation.
Figure 6: Mounting Against a Solid Surface

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INSTALLATION
FUEL TANK INSTALLATION
The SQ Genset is intended to draw from a nearby tank or a sub-base fuel tank below the unit. The genset is shipped with
labeled fuel supply (5/16”) and return (3/16”) barb connections. Fuel lines should be routed so that the fuel lines are not
kinked, pinched, or unprotected around sharp edges as they are routed to the fuel tank, secured as needed.
An electric fuel pump is installed within the genset. When installing the fuel tank, observe the following:
• Mount the fuel tank nearby or underneath the genset.
• The fuel tank bottom should not be more than 10 inches below the genset’s mounting feet.
If the fuel tank bottom is more than 10 inches below the genset’s mounting feet a high li fuel pump will be needed, kit
SQ10000-FUL.P. Observe the following when installing the fuel tank while using the SQ10000-FUL.P kit in its standard fuel
pump location in the genset:
• Mount the fuel tank nearby or underneath the genset.
• The fuel tank bottom should not be more than 54 inches below the genset’s mounting feet.
If the fuel tank bottom is more than 54 inches below the genset’s mounting feet or the distance away from the tank is
excessive the SQ10000-FUL.P kit will need to be mounted remotely and push the fuel to the engine instead of pulling.
Observe the following when installing the fuel tank while using the SQ10000-FUL.P kit remotely:
• Mount the pump as close to the tank as possible. The pump is much better at pushing fuel than it is at pulling.
• It is recommended to mount the pump within 60” vertically of the bottom of the fuel tank.
• Install the supplied fuel pre-lter between the fuel tank and the electric pump.
• Install the fuel pump so that the “Flow” arrow noted on the fuel pump points toward the engine along the fuel line
path.
• Add additional 16 gauge wires to the Deutsch 8 pin plug and route to new fuel pump location, pin 1 is ground, pin 3 is
fuel pump positive.
• Route these two wires inside split-loom or similar protective jacket to the fuel pump, avoiding sharp edges or moving
objects, securing as needed.

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INSTALLATION
Termination of the high voltage wiring is the responsibility of the installer. All high voltage connections must be made to
appropriately sized cord caps or components. A Neutral-Ground bonding strap is provided with the unit to be connected
from Neutral to the labeled ground of the generator box.
AC WIRING TERMINATION
Figure 7: AC Wiring Markings
L1
N
L2
SINGLE PHASE
L1
L3
N
L2
3 PHASE
HIGH VOLTAGE ELECTRICAL CONNECTIONS
All wiring must comply with local electrical codes. A qualied electrician must perform all electrical wiring connections.
All SQ Genset generators are supplied with a main circuit breaker, control panel voltage sense lead fuses, and a
distribution block inside the generator box, see Figure 3 on page 10 and 11 to locate the breaker. The circuit protected
leads and generator Neutral are wired to the distribution block for user connections. Generator ground is located inside
the generator box as well via noted grounding bolt into generator case. A Neutral-Ground bonding wire is provided,
shipped loose. Install as needed per local electrical code or needs.
A schematic of the high voltage wiring system can be found in APPENDIX B: AC WIRING SCHEMATIC on page 32. Please
note Figure 7 for the distribution block AC wiring and cable arrangements.
All high voltage cable should be routed through appropriate cord grips (if using SO cable) or conduit and safely routed
outside of the genset while complying with local electrical codes. Under no circumstances should the customer make
connections directly to the generator.

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INSTALLATION
AUXILIARY WARNING, SHUTDOWN, AND
EMERGENCY STOP WIRING
By default, the SQ90000/SQ10000 uses a red mushroom-style emergency stop to activate the Emergency Stop shutdown
for the engine. When the emergency stop input is active (grounded), the engine will not be allowed to crank or run under
any circumstances. When the emergency stop input is active, the control panel will display the emergency stop icon, see
Figure 8, and will prevent the generator from starting.
An additional input for the emergency stop input is available in pin #5 of the Deutsch 8 pin plug. Supplying a ground (pin
#1 of the Deutsch 8 pin plug) to pin #5 of the Deutsch 8 pin plug will cause the Emergency Stop shutdown to become
active and will immediately stop the generator and prevent the unit from running regardless what the standard generator
emergency stop status is. See Figure TBD on page XX for wiring schematic.
The SQ Genset is also programmed by default for one auxiliary shutdown input, pin #7 of the Deutsch 8 pin plug (Digital
Input C) for user connections. When the ground (pin #1 of the Deutsch 8 pin plug) is connected to pin #7 of the Deutsch 8
pin plug and the 10 second safety timer has expired the Digital Input C shutdown will become active. The control panel
will shut down the engine and display the icon for the auxiliary C shutdown. Active auxiliary shutdown inputs will not
prevent the generator from starting.
A low fuel level warning is also enabled on the control panel for optional use. Supplying a ground (pin #1 of the Deutsch 8
pin plug) to pin #8 of the Deutsch 8 pin plug will cause the Low Fuel Level Warning to become active and display the noted
Low Fuel Level Warning. This will not shutdown the generator or prevent it from starting, although generator performance
and startabilty could be aected as fuel is depleted.
Figure 8: Auxiliary Shutdown and E-Stop Icons
Emergency Stop Icon
Auxiliary Shutdown C Icon
(pin #7 of 8 pin Deutsch Plug)
Low Fuel Level Warning
(pin #8 of 8 pin Deutsch Plug)
(ADD WIRING DIAGRAMS)

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AUTO MODE REMOTE START SETUP
CONNECTING THE BATTERY
The standard 3110 DSE Control Panel comes preset to accept a remote start input. To do this Pin #1 and #6 of the 8 pin
Deutsch plug need to be connected together while the control panel is turned on and in Auto Mode. When the wires are
connected together the unit will begin its start sequence, start, and run automatically. Disconnecting these two wires will
then turn the unit o.
Wires should be routed appropriately, staying away from sharp edges or moving parts and safely routed outside of the
genset. These connections are part of the 12VDC ground so no voltage will be passed through whatever switching device
is used to make this connection remotely. 18 gauge, 2 conductor cable is suicient for most installations.
The DSE 3110 will be powered on while in Auto Mode and waiting for a Run command. Aer being put into Auto Mode the
control panel will go into a Standby Mode, only drawing up to 51mA from the 12VDC battery. Aer 60 minutes the unit will
go into a Deep Sleep Mode, drawing less the 10 µA from the battery, while waiting for the Run Command.
The genset is shipped with the battery disconnected and will need to be connected before rst running the genset. To do
so, attach the positive (red) battery cable to the larger positive post of the battery, this post and clamp is tapered so if the
clamp does not t over the entire post ip the clamp over. Tighten the nut on the clamp until the clamp cannot rotate on
the post. Repeat for the negative (black) cable on the smaller negative post.
OPERATION
Diesel fuel is combustible and can cause severe personal injury or death. Do not
smoke near diesel fuel tanks or equipment. Keep all ames, sparks, or all other
sources of ignition well away.
Exhaust gas is deadly. Never operate the genset without proper ventilation. Check
for leaks in the exhaust system regularly. Exposure to exhaust gases can cause
carbon monoxide poising. Symptoms of carbon monoxide poisoning include: dizziness, throbbing in temples, nausea, muscular
twitching, headache, vomiting, weakness and sleepiness and inability to think clearly. If you or anyone experiences these
symptoms, get to fresh air immediately. If symptoms persist, seek medical attention.
(ADD WIRING DIAGRAMS)

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STARTING THE GENSET
OPERATION
PRE-START CHECKS
PRIMING THE FUEL SYSTEM
In order to prevent problems and identify maintenance situations early, it is important to perform a pre-start check
before each use of the genset. Before each start:
1. Check for oil and coolant leakage
2. Check all air inlets and outlet for obstructions or clogging
3. Check radiator ns for clogging
4. Check for signs of fuel leaks, exhaust leaks or damage to either system
5. Check belt tension
6. Check engine oil level
7. Check engine coolant level
8. Turn o any large loads
The fuel system should be primed before rst being run, aer the replacement of a fuel lter, if the fuel system has been
drained or the unit has run out of fuel. Prime the fuel system by pressing the START button and allowing it to run the fuel
pump for about 8-9 seconds then press the STOP button. Do this procedure several times, waiting 10 seconds between
START button presses. This process is running both the glow plugs and the fuel pump preparing the engine to start. By
pressing the STOP button before 10 seconds the engine will not attempt to start. At least 10 seconds of cool down is
needed between glow plug operations, which is the reason for waiting between START button presses. Without waiting
the 10 seconds, the glow plugs could fail or shorten their life.
Once fuel is to the engine bleed air from the lines by cracking open the air vent cock on the top of the on engine injection
pump. You should never prime the fuel system by cranking the engine. Excessive cranking while the fuel system is dry can
lead to damage of the injection pump or starter motor and void warranty.
The genset can be started from the on board control panel (manual). The control panel has several dierent modes of
operation, for a complete list, see Figure 9 on the following page.