HGI Generators WASC60 Series Manual

Publication No. 498-048
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Operation & Maintenance
Manual
Welf-Air Super Compact
Installation Guide
WASC60 Series

Version Harrington Generators International Ltd
Welf-Air Super Compact Installation 498-048 Issue C
Name Position Date
Originator: M. Crowfoot Technical Department Nov 2012
Approved by: K. Croft Technical Department Nov 2012
Document Authorisation
Document History
Date Version Author Reason for change
10.03.11 A C. Coulton First Release for Cabin Install
26.11.12 B Draft 1 M. Crowfoot Updated for Standard Configuration and review
05.12.12 B Draft 2 M. Crowfoot Incorporated comments from BK and issued for
review
05.12.12 B M. Crowfoot Updated following review and released.

Harrington Generators International Ltd
Welf-Air Super Compact Installation 498-048 Issue C
WASC60 Series
3000 rpm Diesel Generator
for Welf-Air Cabins

Contents Harrington Generators International Ltd
Welf-Air Super Compact Installation 498-048 Issue C
Contents
Section Description Page
1 General 1
2 Introduction and Familiarisation 1
3 Standard Installation 1
4 Alternative Installation 2
6 Cabin Outlet Ventilation 3
7 Cabin Distribution Board 3
8 Access and Clearance 3
9 Contact Details 3
10 General Dimensions 5
11 Installation Diagrams (PD901-320) 7
12 DC Wiring (PD961-172) 9
13 AC Wiring (PD950-818) 11
14 Remote Start Wiring (PD960-270) 13
15 Remote Start Lead Wiring (PD960-278) 15
16 Installation Check List 17
5 Inlet Ventilation 3

Installation Guide Harrington Generators International Ltd
Welf-Air Super Compact Installation 1 498-048 Issue C
1.0 General
The Welf-Air Super Compact range of generators
has been designed by HGI to perform
exceptionally well in the confines of a small cabin.
New type mounts are used in the set, so that
vibration is kept to a minimum, when placed on a
cabin floor.
Sound insulation and careful canopy design keep
noise level to an absolute minimum.
The generator engine has been selected for long
life and reliable operation with all its serviceable
items being accessible from the outward facing
side, thus making servicing easy and economic.
The generator is designed for easy install. Do not
hesitate to contact HGI for further advice and
help.
These instructions apply to all variants of this type
machine. LPG versions are available.
2.0 Introduction and Familiarisation
Read the document completely before installing.
PD901-320 (section 11) drawing shows a typical
installation and where the parts supplied are
assembled together. Please refer to this drawing
for dimensions and familiarisation.
Hot air exits the top quarter of the end panel
opposite the air inlet panel. The set is designed to
be pushed up to the right and against a cabin
wall, which should have a louvre panel cut into it.
Other louvres need to be made in the cabin to
allow cool air to enter the generator compartment.
The generator’s exhaust exits vertically. An
exhaust extension tube, clamps and heat wrap
are optional. It is important that heat wrap is
fitted so that operatives do not burn themselves.
It is down to the individual installation engineer (s)
to ensure that the unit is safely and correctly
installed. If in doubt seek qualified advice from
the manufacturer/supplier.
3.0 Standard Installation
3.1 Preparation
The generator is designed to be installed into a
pre-prepared cabin.
3.1.1 Preparing Hot Air Escape Vent
A hot air escape louvre vent should be cut into
the right hand wall of the cabin.
This vent should be a rectangular aperture with
a minimum dimension of 100 mm high x 500
mm wide. It should be positioned 1010 mm up
from the cabin generator compartment floor. All
measurements are made internally. See
drawing (PD901-320 section 11).
Fit a louvre over the vent on the exterior wall to
prevent ingress of weather and detritus from
outside.
3.1.2 Preparing Exhaust Outlet
A horizontal exhaust outlet pipe with an outer
diameter 33 mm should be pre-fitted to the
cabin. This should be positioned approx
1700mm up from the compartment floor. It is
recommended that this be aligned at 103 mm in
from the right hand edge of the generator (see
drawing PD901-320) to keep the exhaust as
upright as possible.
If the wall is a corrugated type this is usually
done in the well of the wall as shown in Fig.1.
3.2 Install Instructions
Place the 50mm2foam gasket around the 4
edges of the generator air outlet duct. Position
the generator in the cabin as shown in the
drawing PD901-320. Secure the generator to
the floor using bolt down points provided at
each corner of the unit. (Item A, Fig 2). The
floor must be a solid, flat surface. See drawing
(040-766/00 section 11) for dimensions.

Installation Guide Harrington Generators International Ltd
Welf-Air Super Compact Installation 2 498-048 Issue C
Fig. 2
A
A
A
B
Fit the flexible exhaust link pipe (Item B, Fig 2)
into position using the clamps provided
ensuring a gas tight fit. If you are unsure if the
pipe has sealed completely remove the link
pipe and use exhaust sealing compound
around the joints and re assemble.
Care must be taken to make a gas tight seal
when connecting the exhaust and that it is
adequately insulated.
To protect the exhaust and prevent potential
burns to operatives, wrap the exhaust link pipe
with heat wrap and secure with clamps or wire
fastenings. HGI can supply these upon request.
4.0 Alternative Installation
As an alternative, a 500cm2 louvre with
combined horizontal exhaust outlet can be fitted
higher up.
With this configuration the generator air outlet
duct would need to be removed and a larger air
duct would have to be fitted to channel the hot

Installation Guide Harrington Generators International Ltd
Welf-Air Super Compact Installation 3 498-048 Issue C
air out and prevent the exhaust pipe from becoming a
burn hazard. HGI can supply heat wrap and securing
clamps to further mitigate this.
Fit the 50mm2foam to the generator below where the
generator air outlet duct was (Item A, Fig 3), and
position and install as per standard installation section
3.2.
Place another foam gasket (Item B, Fig 3) on the top of
the generator to protect and form a seal with the ducting.
Place the alternative hot air outlet duct (Item C, Fig 3) in
position and secure using self-tapping screws around
the outside of the cover.
5.0 Inlet Ventilation
Adequate sized louvre panels should be built into the
cabin doors or walls for generator ventilation purposes.
It is recommended that the typical free inlet should
provide at least 230cm2
Care must be taken to ensure that the machine does
not re-circulate its own exhaust fumes, the machine
must be able to take in cold air in order to perform
correctly.
Check with HGI Ltd if in doubt.
6.0 Cabin Outlet Ventilation
It is recommended that high level ventilation performed
by a grill or fan be installed to keep the generator
generally cool. Typically this is 50% of the inlet area,
see drawings for dimensions.
The outside finish is the responsibility of the cabin
manufacturer but should take into account:
 Weather ingress
 Animals, pests and vermin
 Health & Safety considerations
 Vandalism
Fig 4 Welf-Air Super Compact Installed with
the alternative ducting arrangement

Harrington Generators International Ltd
Welf-Air Super Compact Installation 498-048 Issue C
7.0 Cabin Distribution Board
The cabin AC distribution system should include all
required protection MCBs and for out going circuits and a
RCD earth leakage unit.
8.0 Access and Clearance
The generator needs to occupy a clear space within the
cabin compartment. Water pipes, pumps, tanks, waste
pipes and other items should be mounted away from the
generator.
The cold air inlet must be kept clear.
Suggested Clearances for access:
Left Hand Side - 200mm
Right Hand Side - 25mm
Behind - 100mm
In Front - 100mm
Above - 500mm
9.0 Contact
To discuss Welf-Air Super Compact Generators, do not
hesitate to contact HGI on 01629 824284

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Welf-Air Super Compact Installation 5 498-048 Issue C
10.0 General Dimensions

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Welf-Air Super Compact Installation 7 498-048 Issue C
11.0 Installation Diagrams

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Welf-Air Super Compact Installation 9 498-048 Issue C
12.0 DC Wiring

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Welf-Air Super Compact Installation 11 498-048 Issue
13.0 AC Wiring