Onan DYC Series Instruction Manual

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FORM NUMBER
973-0304
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.ISSUEDATE
5-77
(SPEC A-G)

SAFETY PIRECAUTOONS
Thefollowingsymbolsinthismanualsignalpotentially
dangerousconditionstotheoperatororequipment.Read
thismanualcarefully.Knowwhentheseconditionscan
exist.Then,takenecessarystepstoprotectpersonnelas
wellasequipment.
ONANrecommendsthatyoureadyourmanualandbecome
thoroughlyacquaintedwithitandyourequipmentbefore
youstartyourunit.Theserecommendationsandthe
followingsafetyprecautionsareforyourprotection.
Fuels, electricalequipment,batteries,exhaustgasesand
movingpartspresentpotentialhazardsthatcouldresultin
serious,personalinjury.Takecareinfollowingthese
recommendedprocedures.
WARNING
Onan uses thissymbol
throughoutthismanualto
warnof possible serious personalinjury.
[CAUTION
This symbolrefersto possible
equipmentdamage.
General
•Keepyourelectricgeneratingsetandthesurrounding
areacleanandfreefromobstructions.Removeany
debrisfromsetandkeepthefloorcleananddry.
•Provideappropriatefireextinguishersandinstallthem
inconvenientlocations.Consultyourlocalfiredepart-
mentforthecorrecttypeofextinguishertouse.Donot
usefoamonelectricalfires.UseextinguisherratedABC
byNFPA.
•Makesurethatallfastenersonthegeneratingsetare
secure.Tightensupportsandclamps,keepguardsin
positionoverfans,drivingbelts,etc.
•Donotwearlooseclothinginthevicinityofmoving
parts, orjewelrywhileworkingonelectricalequipment.
Looseclothingandjewelrycanbecomecaughtin
movingparts.Jewelrycanshortoutelectricalcontacts;
causeshockorburning.
•Ifadjustmentmusfbemadewhiletheunitisrunning,
useextremecautionaroundhotmanifolds,moving
parts, etc.
•Donotworkonthisequipmentwhenmentallyor
physicallyfatigued.
•Coolantsunderpressurehavea higherboilingpoint
thanwater.DONOTopena radiatororheatexchanger
pressurecapwhiletheengineisrunning.Bleedthe
systempressurefirst.
ProtectAgainst Moving Parts
•Keepyourhandsawayfrommovingparts.
•Beforestartingworkonthegeneratingset,disconnect
batteries.Thiswillpreventstartingthesetaccidentally.
Fuel System
•DONOTfijlfueltankswhileengineisrunning,unless
tanksareoutsideenginecompartment.Fuelcontact
withhotengineorexhaustisa potentialfirehazard.
•DONOTSMOKEORUSEANOPENFLAMEinthe
vicinityofthegeneratorsetorfueltank.Internal
combustionenginefuelsarehighlyflammable.
•Fuellinesmustbeofsteelpiping,adequatelysecured,
andfreefromleaks.Pipingattheengineshouldbe
approvedflexibleline.Donotusecopperpipingon
flexiblelinesascopperwillworkhardenandbecome
brittle.
•Be sure allfuel supplies havea positiveshutoffvalve.
Guard Against Electric Shock
•Removeelectricpowerbeforeremovingprotective
shieldsortouchingelectricalequipment.Userubber
insulativematsplacedondrywoodplatformsover
floorsthataremetalorconcretewhenaroundelectrical
equipment.Donotweardampclothing(particularlywet"
shoes)orallowskinsurfacestobedampwhenhandling
electricalequipment.
•Useextremecautionwhenworkingonelectricalcom-
ponents.Highvoltagescauseinjuryordeath.DONT
tamperwithinterlocks.
•'Followallstateandlocalelectricalcodes.Haveall
electricalinstallationsperformedby a qualifiedlicens-
edelectrician.Tagopenswitches.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesemita highlyexplosivehydrogengasthatcan
beignitedbyelectricalarcingorbysmoking.
Exhaust Gases Are Toxic
•Provideanadequateexhaustsystemtoproperlyexpel
dischargedgases.Checkexhaustsystemregularlyfor
leaks. Ensurethatexhaustmanifoldsaresecureandnot
warped. Dohotuseexhaustgasestoheata compart-
ment.
•Besuretheunitiswellventilated.
Keep theUnitandSurroundingArea Clean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.

TABLE OFCONTENTS
TITLE PAGE
SafetyPrecautionsInsideCover
Introduction 2
Specifications 3
Description 9
Installation12
Operation22
General Maintenance27
Parts Catalog31
WARNING
TO AVOID POSSIBLE PERSONAL INJURY OR
EQUIPMENT DAMAGE, A QUALIFIED ELECTRI-
CIAN OR AN AUTHORIZED SERVICE
REPRESENTATIVE MUST PERFORM IN-
STALLATION AND ALL SERVICE.

INTRODUCTION
FOREWORD
MODEL IDENTIFICATION
This manualisapplicabletotheDYC Series electric Identify yourmodelbyreferringtbtheMODELand
generatingset, consisting ofanONANURgenerator,SPECIFICATIONNO.asshownontheOnan
drivenbyan Allis-Chalmers 3iMHHMPEngine.Seenameplate.Electricalcharacteristicsareshownon
SPECIFICATIONS forgenerator sizes.'V^ f^iXju4JL#thelowerPortionofthenameplate.
The manualisdividedintotwo sections. 90.0DYC15R/ 1
Section T providesinformationoninstallation,opera-
tion ahdtroubleshooting.
Section 2 isa PartsCatalogforONANoptional'and
stahdard equipment.
The manualshouldbeusedinconjunction with the
Allis-Chalmers enginemanual,forspecificengine
information.
12 3 4 5
1.Indicateskilowattrating(90kW).
2. Factorycodefor SERIES identification.
3.15= 60Hz.Reconnectible
515= 50Hz.Reconnectible
R—Indicates remotestartingfeature.
4.Factorycodefordesignatingoptionalequipment.
5.Specification letter. (Advanceswhenfactory
makes productionmodifications.)
Whencontactinga dealerorthefactoryregardingthe
set, alwaysmentionthecompleteModel, Spec No.
andSerialNo.asgivenontheOnannameplate.This
nameplateinformationis necessaryto properlyiden-
tify yourunitamongthemanymanufactured.Referto
theenginenameplatewhenrequestinginformation
from itsmanufacturer.TheOnannameplateis
locatedontherightsideofthegenerator;the Allis-
Chalmers nameplateisonthe left handsideofthe
engineblock.
Leftsideandrightsideareconsideredwhenviewed from the
engineor front endofthegeneratingset.
WARNINGI
ENGINE EXHAUSTGAS(CARBONMONOXIDE)IS DEADLY!
Carbon monoxideIsanodorless,colorlessgasfonnedbyincomplete
combustion ofhydrocerbonfuels.CarbonmonoxideIsa dangerousgas that
can cause unconsciousness snd is potentially lethal. Some ofthe symptoms or
signs ofcarbonmonoxideinhalationare:
•Dizziness
•IntenseHeadache
•Weaknessand Sleepiness
Vomiting
Muscular Twitching
ThrobbingInTemples
Ifyouexperienceanyoftheabovesymptoms,getoutintofreshair
immediately.
The best protection against carbon monoxideInhalation is a regular inspection
ofthscompleteexhaust system. Ifyounoticea changeInthesoundor
appearance ofexhaust system, shuttheunitdownimmediatelyandhaveIt
inspected andrepairedatoncebya competentmechanic.

SPECIFICATIONS
75kW*
\ft
ENGINE DETAILS
EngineManufacturer• I Allis-Chalmers
EngineSeries> 6500MKT!(Turbocharged)
NumberofCylinders6
Displacement426-in3(6.97litre)
BHP@ 1800 r/min 162(121kw)
CompressionRatio15.5:1
Bore4.25-inch(107.95mm)
Stroke5.0-inch(127.0mm)
FuelASTMNo2 Diesel
BatteryVoltage24
RecommendedBatteries(BeginSpecG)*
Two12-Volt,74A.HFitsStandardBatteryRack
Two12-Volt,225A.HRequiredforusewithAutomaticTransferSwitch
StartingMethodSolenoidShift
GovernorRegulation.,5%NoLoad—FullLoad
BatteryChargingCurrent35-Amperes
*75and90kWModelsPriorto Spec G useTwo 6-volt 135A.H.batteries.
GENERATOR DETAILS
Type.. UR1560Hz
'- UR51550Hz
Rating(Watts)
60HertzContinuousStandby75,000.(93.75kVA)
50H6rtzContinuousStandby62,500(78.13kVA)
ACVoltageRegulation±2%
60Hertz r/min 1800
50Hertz r/min 1500
OutputRating0.8PF
ACFrequencyRegulation3 Hz
CAPACITIES AND REQUIREMENTS
CoolingSystem,EngineandRadiator34-quarts(32litres)
EngineOilCapacity(Filter,Lines,Crankcase)31-quarts(29.3litres)
ExhaustConnection(inchespipethread)4 (101.6mm)male
AIR REQUIREMENTS (1800 r/min)
EngineCombustion250-ft3/min(0.11m3/s)
RadiatorCooledEngine7100-ft3/min(3.4m3/s)
TotalforRadiatorCooledModel7350-ft3/min(3.5m3/s)
AlternatorCoolingAir(1800r/min)• 1000-ft3/min(0.5m3/s)
(1500r/min)833-ft3/min(0.4m3/s)
FuelConsumptionatRatedLoadASTMNo.2 Diesel6.7gal/hr.(25.4lit/hr)
GENERAL
Height52.5-inches(1.3m)
Width33.0-inches(0.84m)
Length84.31-inches(2.14m)
ApproximateWeight(Mass)2600-lb.(1180kg)

SPECIFICATIONS
90kW
ENGINE DETAILS
EngineManufacturer:(.Allis-Chalmers
EngineSeriesr./.......:: , ; S86Q9^Kit±5a3cB'oigb-^ed)
NumberofCylinders6
Displacement426-in3(6.97litre)
BHP@ 1800r/min.; 162(121kw)
Compression.Ratio••••15.5:1
Bore4.25-inch(107.95mm)
Stroke5.0-inch(127.0mm)
FuelASTMNo2 Diesel
BatteryVoltage: 24
RecommendedBatteries(BeginSpecG)*
.Two12-Volt,74A.H:.FitsStandardBatteryRack
Two12-Volt,225A.HRequiredforusewithAutomaticTransferSwitch
StartingMethodSolenoidShift
GovernorRegulation.5%NoLoad—FullLoad
BatteryChargingCurrent:.... 35-Amperes
*75and90kWModelsPriorto Spec G useTwo 6-volt 135A.H.batteries.-
GENERATOR DETAILS
Type.. : UR1560Hz
UR51550Hz
Rating(Watts)
60HertzContinuousStandby..:..-...90,000(112.5kVA)
50HertzContinuousStandby.;75,000(93.75kVA)
ACVoltageRegulation..* ......±2%
60Hertz r/min 1800
50Hertzr/min...: 1500
OutputRating; 0.8PF
ACFrequencyRegulationv..3 Hz
CAPACITIES AND REQUIREMENTS
CoolingSystem,EngineandRadiator34-quarts(32litres)
EngineOilCapacity(Filter,Lines,Crankcase)31-quarts(29.3litres)
ExhaustConnection(inchespipethread)..4 (101.6mm)male
AIR REQUIREMENTS (1800 r/min)
EngineCombustion; - 300-ft3/min(0.14m3/s)
RadiatorCooledEngine...7100-ft3/min(3.4 m3/sl
TotalforRadiatorCooledModel; 7400-ft3/min(3.5m3/s)
AlternatorCoolingAir(1800r/min). ...i000-ft3/min(0.5m3/s)
(1500r/min),:833-ft3/min(0.4m3/s)
FuelConsumptionatRatedLoadASTMNo.2 Diesel8-gal/hr:(30.3lit/hr)
GENERAL
Height...,52.5-inches(1.3rri)
Width; 33.0-inches(0.84m)
Length85.44Hnches(2.17m)
ApproximateWeight(Mass)••-2670^lb(1212kg)

SPECIFICATIONS
100kW
ENGINE DETAILS ^O-TY^UC^Cm"S^CcMKn)
EngineManufacturerC Allis-Chalmers
EngineSeries^SOO'-MKII-CT-uiUwtTaffaed)
NumberofCylinders6
Displacement'. 426-in3(6.97litre)
BHP@ 1800 r/min 162(121kW)
CompressionRatio15.5:1
Bore• 4.25-inch(107.95mm)
Stroke5.0-inch(127.0mm)
Fuel, ASTMNo2 Diesel
BatteryVoltage24
RecommendedBatteries(BeginSpecG)*
Two12-Volt,74A.HFitsStandardBatteryRack
Two12-Volt,225A.HRequiredforusewithAutomaticTransferSwitch
BatteryGroupTwo12-Volt225Amp.Hr.
StartingMethodSolenoidShift
GovernorRegulation5%NoLoad—FullLoad
BatteryChargingCurrent35-Amperes
GENERATORDETAILS
TypeUR1560Hz
UR51550Hz
Rating(Watts)
60HertzContinuousStandby100,000(125KVA)
50HertzContinuousStandby80,000(100kVA)
ACVoltageRegulation±2%
60Hertz r/min 1800
50Hertzr/m in 1500
OutputRating: 0.8PF
ACFrequencyRegulation3 Hz
CAPACITIES AND REQUIREMENTS
CoolingSystem,EngineandRadiator36-quarts(34.05litres)
EngineOilCapacity(Filter,Lines,Crankcase)Sl-quarts(29.32litres)
ExhaustConnection(inchespipethread)4 (101.6mm)male
AIRREQUIREMENTS (1800 r/mln)
EngineCombustion'. 315-ft3/min(8.82m3/min)
RadiatorCooledEngine7650-ft3/min(214.20(m3min)
TotalforRadiatorCooledModel7965-ft3 /min(222.60m3/min)
AlternatorCoolingAir(1800r/min)1000-ftVrnin(28.00m3/min)
(1500r/min)833-ft3/min(23.32m3min)
FuelConsumptionatRatedLoadASTMNo.2 Diesel8.4gal/hr(31.83litres/hr)
GENERAL
Height52.5-inches(1.3m)"
Width•.33.0-inches(0.84m)
Length:.: 86.81-inches(2.17m)
ApproximateWeight(Mass)2755-lb(1250kg)

TABLE 1
URGENERATORVOLTAGE/CURRENT OPTIONS
75kW93.75kVA
DOUBLE
SERIES
PARALLEL SERIES
REF VOLTAGE
VOLTS
FREQ
PHASE AMPERES DELTA DELTA WYE WYE
WIRE (W12)TAP
110/220 50 Hz 1
355*
X
H6
115/230 50
Hz 1
340* x H6
120/240 60 Hz 1
391*
X
H5
110/190 50
Hz
3 237 .
X
H3
115/200 50
Hz
3
226
X
H4
120/208 50 Hz
3
217
X
H4
120/208 -60 Hz
3
260
X
H3
110/220 50 Hz
3 205
X
H6
127/220 50 Hz
3 205
X
H5
127/220 60 Hz
3 246
X
H4
115/230 50 Hz
3 196
X
H6
120/240 60
Hz
'3 226
X
H5
139/240 60 Hz
3 226
X
H5
220/380 50 Hz
3 119
X
H3
230/400 50 Hz
3 113 *
X
H4
240/416 50 Hz
3 . 108
X
H4
240/416 60
Hz 3 130
X
H3
254/440 50
Hz
3
103
X
H5
254/440 60
Hz
3 123
X
H4
277/480 60
Hz
3 113
X
H5
9X H5—Not
347/600 60 Hz
3
90 Reconnectible
Thiscurrentvalue is availableonlyfromspeciallongstackunits(optionB125).
Astandard 3-phase generatorconnectedinto a DoubleDeltaconfigurationwilldeliver
2/3 current valueshown(355x .66 = 237amperes).
TABLEIA
URGENERATORVOLTAGE/CURRENT OPTIONS
90 kW
75 kW
112.5 kVA
93.75 kVA
DOUBLE
SERIES
PARALLEL
SERIES
REF VOLTAGE
VOLTS
FREQ
PHASE AMPERES DELTA DELTA WYE WYE
WIRE (W12)TAP
110/220 50 Hz 1
426*
X
H6
115/230 50 Hz 1
408*
X
H6
120/240 60 Hz 1
469*
X
H5
110/190 50
Hz
3
285
X H3
115/200 50 Hz
3 271
X
H4
120/208 50
Hz 3 260
X
H4
120/208 60 Hz
3 312
X
H3
110/220 50
Hz
3
246
X
H6
127/220 50 Hz
3 246
X
H5
127/220 60
Hz
3 295
X
' H4
115/230 50 Hz
3 235
X
H6
120/240 60
Hz 3 271
X
H5
139/240 60
Hz
3 271
X
H5
220/380 50
Hz
3 142
X
H3
230/400 50 Hz 3
135
X
H4
240/416 50 Hz
3
130
X
H4
240/416 60 Hz
3
156 .
X
H3
254/440 50
Hz
3
123
X
H5
254/440 60
Hz
3
148
X
H4
277/480 60 Hz
3
135
X
H5
9X H5—Not
347/600 60
Hz 3
108 Reconnectible
Thiscurrentvalue is availableonlyfromspeciallongstackunits(optionB125). A standard
3-phase generatorconnectedinto a DoubleDeltaconfigurationwilldeliver 2/3 current
valueshown (426x .66= 284amperes).

TABLE 1B
GENERATORVOLTAGE/CURRENT OPTIONS
100kW
80kW 125kVA60Hz 100kVA50Hz
DOUBLE
SERIES PARALLEL SERIES
REF VOLTAGE
VOLTS FREQ PHASE AMPERES DELTA DELTA WYE WYE
WIRE (W12)TAP
110/220 50Hz 1 455
X
-H6
115/230 50Hz 1 435
X
H6
120/240 60Hz 1 521 X
H5
110/190 50Hz 3 304.
X
H3
115/200 50Hz 3
289
X
H4
120/208 50Hz 3
278
X
H4
120/208 60Hz 3
347
X
H3
110/220 50Hz 3
262
X
H6
127/220 50Hz 3
262
X
H5
127/220 60Hz 3
328
X
H4
115/230 50Hz
3
251
X
H6
120/240 60Hz
3
301
X
H5
139/240 60Hz
3
301
X H5
220/380 50Hz 3 152
X H3
230/400 50Hz
3 144
X
H4
240/416 50Hz 3 139
X
H4
240/416 60Hz 3 173
X
H3
254/440 50Hz
3 131
X H5
254/440 60Hz 3
164
X H4
277/480 60Hz
3 150
X
H5
9X H5—Not
347/600 60Hz 3
120 Reconnectible
Singlephasecurrentvalueisavailableonlyfromspeciallong-stackunit
(optionB125).A standard 3-phase generatorconnectedintoa DoubleDelta
singlephaseconfigurationwilldeliver2/3currentvalueshown
(i.e. 455x .667= 303amperes)

INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER—,
RUNNINGTIME
METER
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT-
PHASESELECTOR
SWITCH
FIELDCIRCUITBREAKER
ViTURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
•OILPRESSURE
GAUGE
-WATERTEMPERATURE
GAUGE
DCAMMETER
-RUN-STOP-REMOTESWITCH
(ALSOA RESETSWITCHFOR
ENGINEMONITOR)
FAULTLAMP
FIGURE 1.STANDARD CONTROL PANEL (ONE FAULT LAMP)
DUALRANGEACAMMETER
INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER—%
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT-
FREQUENCY
METER
RUNNINGTIME
METER
FIELDCIRCUITBREAKER
PHASESELECTORSWITCH
—ViTURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
-DCAMMETER
-RUN-STOP-REMOTESWITCH
(ALSOA RESETSWITCHFOR
ENGINEMONITOR)
LAMPTESTBUTTON
FAULTLAMPS
FIGURE 2.OPTIONAL CONTROL PANEL (FIVE FAULT LAMPS)
8

DESCRIPTION
GENERAL
AnOnanDYCserieselectricgeneratingsetisa
completeunitconsistingofanenginedrivenAC
generator,withstandardandoptionalcontrolsand
accessoriesasordered.
ENGINE
yg^ontheDYCisanAllis-Chalmers
Jfrasdescribedintheenginemanual.Basic
measurementsandrequirementswillbefoundunder
SPECIFICATIONS.Foroperation,maintenanceand
serviceinformation,consulttheAllis-Chalmers
manual.
AC GENERATOR
ThegeneratorisanONANTypeUR,12 lead, 4-pole
revolving field, reconnectible,brushlessunit.The
mainrotorisattacheddirectlytotheengineflywheel,
thereforeenginespeeddeterminesgeneratoroutput
frequency.The60Hzsetoperatesat1800r/min,the
50Hzat1500r/min.Excitationisachievedas
follows—
Residualalternatingcurrentfromthestatorwinding
isappliedtothevoltageregulator,whereitis
comparedwitha referencevoltage,rectifiedand
returnedtothefieldwindingoftheexciter.Current
theninducedintheexciterrotorisrectifiedandfed
intothegeneratorrotor.Thisinducesa currentin
generatorstatorwhichisappliedtothe load.
CONTROL PANEL
Thefollowingisa briefdescriptionofeachofthe
standardcontrolsandinstrumentslocatedonthe
faceofthepanel.SeeFigure1.
DC Panel
OilPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitiocatedonthe
engine).
WaterTemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeterIndicatesbattery
chargingcurrent.
Run-Stop/Reset-RemoteSwitch:Startsandstopsthe
unitlocallyorfroma remotelocation.Resetsengine
monitorrelayinStop/Resetposition.
WarningUght:Indicates"Fault"inengineoperation.
AC Panel
ACVoltmeterIndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
VoltageRegulatorRheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreakerProvidesgeneratorexciter
andregulator,protectionfromoverheating,in-the
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeterRegistersthetotalnumberof
hours, to1/1 Oth, thattheunithasrun.Useittokeepa
recordforperiodicservicing.Timeisaccumulative,
'metercannotbereset.
VoltmeterPhaseSelectorSwitch:Selectsphasesof
generatoroutputtobemeasuredbytheACvoltmeter.
OPTIONAL EQUIPMENT
DC Panel
WarningLights:Eliminatestheone"Fault"lightand
substitutesfiveindicator(seeFigure2)lightstogive
warningof—
a.Overcrank
b.Overspeed
c.Lowoilpressure
d. Highenginetemperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.,
ResetSwitch:Manualresetforenginemonitorafter
malfunctionshut-down.
LampTest:Presstotestwarninglampbulbs(when
engineisrunningonly).
AC Panel
ACAmmeterIndicatesACgeneratoroutputcurrent.
Dualrangeinuseshownonindicatorlights.
FrequencyMeterIndicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30r/min.)

CONTROL PANEL INTERIOR
Theonlyequipmentsdiscussedinthissectionwillbe
thosewhichtheoperatormayhavereasontoadjustor
inspectforservice.
TerminalBoard(TB)21:ConnectionofwireW12to
terminalsH3,H4,H5,andH6ismadeatthispoint,to
changereferencevoltagewhenreconnecting
generatorfordifferentvoltages.
VoltageRegulator,BeginSpecE:Solidstateunit,
consistingofprintedcircuitboardVR21;anSCR
bridgeCR21,witha commutatingreactorL21are
locatedinthecontrolpanelaspartofthevoltage
regulatorsystem.ACoutputfromgeneratoris con-
trolledatpredeterminedlevelregardlessof load;
regulationisplusorminus2%fromnoloadtofull
load, at0.8PF.
EngineMonitorPrintedcircuitplug-inmodules
providethefollowingfunctions:
1. A 75secondcrankingperiod.
2. Approximatelya 12.5secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampand
shutdownthesetforalarmconditionssuch.as:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Overspeed(enginespeedreaches2100rpm).
c.Lowoilpressure14psi(96.53kN/m2).
d. Highenginetemperature215°F (102°C).
HighEngineTemperatureCutoffwillshut
downengineInanoverheatconditiononlyIf
coolantlevelissufficientlyhightophysicallycontactshutdown
switch. Lossofcoolantwillallowenginetooverheatwithout
protectionofshutdowndevice,therebycausingseveredamageto
theengine.ItIsthereforeimperativethatadequateenginecoolant
levelsbemaintained,toensureoperational integrityofcooling
systemandenginecoolantovertieatshutdownprotection.
Onstandardcontrolpanels,allfouralarmsarewiredintoone
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperature)lightsa fault
lamponly.RefertoTable2.
StandardCrankingModule:Limitsenginecranking
timeto75seconds.Ifenginefailstostartafter75
secondstheenginemonitorlightsa faultlampand
opensthecrankingcircuit.
OPTIONAL MODULES
CycleCranker:Plug-inmodulereplacesstandard
crankingcircuit.Automaticallyprovidesa 15-second
cranktimeanda 10-secondresttimeforthreeONand
twoOFFcyclesin65seconds.Ifenginefailstostart,
after75-secondstheenginemonitorlightsa fault
lampandopensthecrankingcircuit.
Pre-Alarm: Givesadvancewarningforlowoil
pressureorhighenginetemperature.Requirestwo
sensorseachforenginetemperatureandoilpressure.
10

TABLE 2. FAULT LAMPOPTIONS
FAULT STOP EXTERNAL
PRE-
SYSTEM FAULT
LAMP
ENGINE
ALARM ALARM
PENNSTATE Overcrank
X X X
SINGLELIGHT Overspeed
X X X
LowOilPressure
X X
HighEngineTemperature
X X
STANDARD Overcrank
X X X
'
SINGLELIGHT Overspeed
X X X
LowOilPressure
X X X
HighEngineTemperature X X X
5LIGHT Overcrank X X X
Overspeed
X X X
LowOilPressure
X X X
HighEngineTemperature
X X X
LowEngineTemperature
X
5LIGHT Overcrank X X X
PRE-ALARM Overspeed X X X
LowOilPressure
X *
X X
HighEngineTemperature
X
*
X
X
LowEngineTemperature
X
-Withadditional optionalsensors.
ENGINE SENSORS
Resistanceunitsandswitchesintheengine
temperatureandoilpressuremonitoringandshut-
downsystemsaresealedunitsandarenotrepairable.
Forlocation,refertoFigures4 and5.Whenchanging
asensor,donotsubstitute,userecommended
replacementparts.Resistanceunitsarematchedto
thegaugetheysupply,andcut-offswitchesareclose-
toleranceactuationparts,madeforaspecificapplica-
tion.
COOLANT
TEMPERATURE
SENDER
HIGH
ENGINE
TEMPERATURE
CUTOFFik
LOW
ENGINE
TEMPERATURE
SWITCH
OIL
PRESSURE
SENDE
FIGURE4.ENGINETEMPERATUREMONITORS FIGURE5.OILPRESSUREMONITORS

THLMSLE
(SEEDETAIL)
DUCT
SWEEPINGELBOW
EXHAUSTLINE
TOMUFFLER
AUTOMATIC
LOADTRANSFER
SWITCH
IS
FLEXIBLE CONDUIT;
SECTION
VIBRATIO
ISOLATORS
TFUELLINE CONCRETEBASE
FLOWOFHEATEDAIRAND
COOLING AIRMAYBE
CONTROLLEDBY AUTOMATICALLY
OPERATED SHUTTERS
FIGURE 6. TYPICAL INSTALLATION
12

INSTALLATION
GENERAL
Installationsmustbeconsideredindividually.Use
theseinstructionsasa generalguide.Allinstallations
mustmeetregulationsofstateandlocalbuilding
codes,fireordinances,etc.,whichmayaffectinstalla-
tiondetails.SeeFigure6.RefertoONANTechnical
BulletinT-030forfurtherinstallationinformation.
Requirementstobeconsideredpriortoinstallation:
1. Levelmountingsurface.
2. Adequatecoolingair.
3.Adequatefreshinductionair.
4. Dischargeofcirculatedair.
5.Dischargeofexhaus.tgases.
6.Electricalconnections.
7.Fuelinstallation.
8. Watersupply(citywatercoolintj).
9.Accessibilityforoperationandservicing.
10. Vibrationisolation.
11. Noiselevels.
VENTILATION
Generatorsetscreateconsiderableheatwhichmust
beremovedbyproperventilation.Outdoorin-
stallationsrelyonnaturalaircirculationbutindoor
installationsneedproperlysizedandpositionedvents
fortherequiredairflow.SeeSPECIFICATIONSfor
theairrequiredtooperatewithratedloadunder
normalconditionsat1800r/min.
Radiatorsetcoolingairtravelsfromtherearoftheset
andisremovedbya pusherfanwhichblowsout
throughtheradiator.Locatetheairinlettotherearof
theset.
Locatethecoolingairoutletdirectlyinfrontofthe
radiatorandascloseaspossible.Theopeningfree
areamustbeatleastaslargeastheradiatorarea.
Lengthandshapeoftheairoutletductshouldoffer
minimumrestrictiontoairflow.Usea ductofcanvas
orsheetmetalbetweentheradiatorandtheairoutlet
opening. Theductpreventsrecirculationofheated
air.
LOCATION
Providea locationthatisprotectedfromtheweather
andisdry,clean,dustfreeandwellventilated.If
practical, installinsidea heatedbuildingforprotec-
tionfromextremeweatherconditions.
Foroperationoutsidea building,a shelterhousing
withelectricallyoperatedlouvresisavailableasan
option. Transformersconnectedacrossthegenerator
outputsupplycurrenttothemotors.
MOUNTING
Generator,setsaremountedona rigidskidbase
whichprovidespropersupport.Theengine-
generatorassemblyisisolatedfromtheskidbaseby
rubbermountswhichprovideadequatevibration
isolationfornormalinstallations.Forinstallations
wherevibrationcontroliscritical,installadditional
spring-typeisolatorsbetweenskidbaseandfounda-
tion.
Forconvenienceingeneralservicingandchanging
crankcaseoil,mountsetonraisedpedestalatleasts-
inches(150mm)high.
Whenthegeneratorisoperating,currentinthe
transformersactuatethemotorsandopenthe
louvres.Thelouvresareheldopenforthedurationof
thesetoperation,thenareclosedbyreturnsprings
whenthesetisshutdown.
CityWatercooledsetsdonotusetheconventional
radiator.A constantlychangingwaterflowcoolsthe
engine.Sufficientairmovementandfreshairmustbe
availabletoproperlycoolthegenerator,disperseheat
convectedofftheengineandsupportcombustionin
theengine.
Installationsrequireanauxiliaryfan(connectedto
operateonlywhentheunitisrunning)ofsufficient
sizetoassureproperaircirculationandevacuationof
fumes.
13

COOLING SYSTEM
StandardRadiatorCooling,uses a set mounted
radiator and enginedrivenpushertype fanto cool
enginewaterjacket. Air travelsfrom the generator
end ofthe set,acrosstheengineandoutthrough the
radiator. An integraldischargeductadapterflange
surrounds the radiatorgrille.
HeatExchangerCooling(optional),uses a shell and
tubetypeheatexchangerinstead ofthe standard
radiator andfan. Enginejacketcoolantcirculates
through the shellside ofthe heatexchanger,while
rawcoolingwater is pumpedthrough the tubes.
Enginecoolantandrawwaterdonotmix.Thistypebf
coolingseparation is necessarywhen theraw water
containsscaleforminglimeandotherimpurities.
Thissystemreduces set enclosureairflowandnoise
levels. Properoperationdependsupon a constant
supply ofraw water for heatremoval. The engine
coolantside ofthe system maybe protectedfrom
freezing theraw watersidecannot. See Figure 7 for
typicalinstallation.
c
EXPANSION
TANK
HEATEXCHANGER
- -rn ENGINE
FROM
ENGINE
M
DRAIN
SOLENOID
VALVE
(OPENSWHEN
SET IS RUNNING)
ADJUSTABLE
VALVE
(RATE OF FLOW)
zJ- L WATER
IN
STRAINER
Thissystemreduces set enclosureairflow re-
quirements and noiselevels.Properoperation is
dependentonaconstantsupplyofcoolingwater.The
systemcannotbeprotectedfrom freezing. SeeFigure
8.
ANTI-SIPHON —I
SOLENOIDVALVE
(OPENWHEN
SET IS RUNNING)
N
STAND
PIPE
STRAINER
DRAIN
:FROM
ENGINE
•TOENGINE
ADJUSTABLEVALVE
(RATE OF FLOW)
Rev.
FIGURE 8.STANDPIPE(TYPICAL)
FIGURE 7.HEATEXCHANGER(TYPICAL)
StandpipeCooling(optional)substitutes a mixing
(tempering)tank forthe standardradiator andfan.
Coolingwatercirculatingthroughtheenginejacket is
mixedwith raw water in thetank.Becauserawwater
flbwsthrough the enginejacket, it must not contain
scaleformingimpurities or fouling ofthe engine
waterwilloccur.Foulingresults in engine
overheating and costlyrepairbills.
RemoteRadiatorCooling(optional),substitutes a
remotemountedradiatorand an electricallydriven
fan, for thesetmountedcomponents.Removalofthe
radiator andfan from theset reduces set enclosure
airflowrequirementsandnoiselevelswithoutforcing
dependence ona continuouscoolingwatersupply.
Theremoteradiatorsystem canbe completely
protectedagainstfreezing.
Thissystemmust be designed to meetspecific
requirements ofthe application.
WaterJacketHeater(optional) maybe installed to
keepenginecoolantwarmwhileengineisshutdown.
Itheatsandcirculatesthecoolantwithin the engine,
whichreducesstart-uptimeandenginewearcaused
bycoldstarts. Itis electricallyoperated and ther-
mostaticallycontrolled.
14-

COOLING CONNECTIONS
Theradiatorcooled(standard)setdoesnotrequire
anyexternalconnectionsexceptasdiscussedunder
Ventilation.Allowclearancearoundthesetforaccess
toservicetheradiatorandfanbelts.SeeFigure6.
HeatExchangerandStandpipecooledsetsmustbe
connectedtoa pressurizedsupplyofcoldwater.
Makeconnectionstothesetwithflexiblepipeto
absorbvibration.Onthecoolwaterlineinstalla
solenoidvalvetoshutofftheflowwhenthesetisshut
downanda rateofflowvalvetocontrolengine
temperature.Thisvalvecanbeeithermanualor
automatic.Actualrateofflowwilldependoninlet
watertemperature.
Adjusttheflowtomaintainwatertemperature
between165°Fand195° F (73.9°C and90.6°C)while
viewingthewatertemperaturegauge.
Beforefillingcoolingsystemcheckallhardwareforsecurity.This
includeshoseclamps,capscrews,fittingsandconnections.Use
flexiblecoolantlineswithheatexchanger,standpipeorremote
mountingradiator.
Remoteradiatorplumbingwillvarywithinstallation.
Allsystemsmustcomplywiththefollowing
conditions—
1. Makeallconnectionstothesetandtothe
radiator,withflexiblepipe.
2. Installanauxiliarycirculatingpumpifthe
horizontaldistancebetweentheengineand
pumpexceeds15-feet(4.65m).
3.Installa hot-wellsystemtorelieveexcessengine
waterjacketpressureifthetopoftheradiatoris
morethan15-feet(4.65m)abovethecenter-line
oftheenginecrankshaft.
RAINCAP
EXHAUST
WARNING Inhalationofexhaustgasescanresultin
death.
Engineexhaustgasmustbepipedoutsidebuildingor
enclosure.Donotterminateexhaustpipenearinlet
ventsorcombustiblematerials.Anapprovedthimble
(Figure9)mustbeusedwhereexhaustpipespass
throughwallsorpartitions.Pitchexhaustpipes
downwardorinstalla condensationtrap(Figure10)
atthepointwherea riseintheexhaustsystembegins.
Avoidsharpbends;usesweepinglongradiuselbows.
Provideadequatesupportformufflersandexhaust
pipes. RefertoFigure6 fora typicalexhaustinstalla-
tion. Shieldorinsulateexhaustlinesifthereisdanger
^ofpersonalcontact.Allowatleast9-inches(230mm)
ofclearanceifthepipesrunclosetoa combustible
wallorpartition.Usea pipeatleastaslargeasthe4
inch(101.6mm)pipesizeoutletoftheenginewitha
flexibleportionbetweentheengineandthemuffler.
DRIPCAP
HOLESINENDOF
INNERSLEEVE
ROOF
WALLORPARTITION
HOLESIN
ENDOF
INNERSLEEVE
NOTE: VENTILATEDTHIMBLEDIAMETER6'
miTHANEXHAUSTLINE LARGER
FIGURE9.EXHAUSTTHIMBLE
IFEXHAUSTLINEMUSTBEPITCHEDUPWARD.
.CONSTRUCTA TRAPOFPIPEFITTINGSAT
POINTOFRISE
DRAINCONDENSATIONTRAP
•PERIODICALLY
FIGURE10.EXHAUSTCONDENSATIONTRAP
Minimumdiametersandmaximumlengthsofpipeare
asfollows:
SingleExhaustSystem:
4- inchpipe75-feet(23m)
5-inchpipe250-feet(76.2m)
6-inchpipe500-feet(152.4m)
Maximumpermissibleexhaustrestriction(back
pressure)is13.5-inchesH20(25.4mmHg).
15

FUEL SYSTEM
Allis-ChalmersenginesusedpntheDYCsetsare
designedforusewithASTMNo."2 Diesel fuel. They
willhowever,operateondieselfuelswithinthe
specificationsdelineatedintheAllis-Chalmers
enginemanual.
FUEL CONNECTIONS
Checklocalregulationsgoverningtheinstallationof
afuelsupplytank.-
Inanydieselengineinstallation,fuelsystemcleanlinessIfof
utmostimportance.Makeeveryefforttoprevententranceof
"moistureorcontaminantsOfany kind.' Donotuselinesorfittingsof
galvanizedmaterial.
A'fuelliftinexcessof8-feet(2.44m)isnot
recommendedwithouta daytankinstallation,
becauseoffueldrainage.Horizontalrun,ifthesupply
tankislevelwiththefuelpumpshouldnotexceed25-
feet(7.6m).However,a daytankisagain
recommended.
Thefuelinletistothetransferpumpandisthreaded
for 1/8-inch pipe.Injectorpumpreturnlineiscom-
monwiththeinjectors'returnline,andrequiresa 1/8-
inchlowpressurehoseconnection.
Maximumfuelreturnlinerestrictionis6.1-inches
(155m)Hg.
:FUEL
RETURN
LINE
INJECTORS
FUELPUMP
HAND
PRIMER
PUMP
FUEL
INLET
3400-4CONNECTION
FILTER
FIGURE11.FUELSYSTEM

DAYTANK
Generatorsetinstallationsmaybeequippedwithan
optionalseparatefueldaytank.A floatoperatedvalve
controlsfuelflowintothefueltank.Thecorrectlevel
ismaintainedtoassurea constantsourceof fuel. Itis
necessarytoinstallanoverflowlinebetweentheday
tankandmainfueltank.Refertotheinstallations
includedwiththetank.SeeFigure12foranexample
ofa daytankinstallation.Tankandlinesmustbe
belowlevelofinjectorpumpreturnoutlet.
FUELPUMP
RETURNLINE
FUEL
FILTER
FUEL
PUMP
"DAY*TANK:-
5GAL.(20litre)
MINIMUMCAPACITY
-INJECTOR
FUELRETURN
LINE
Allmodelsrequirefuelreturnlinefrom
injectorstotank.
VENTLINE•
VENTED
.FILLCAPFLOATTYPESWITCH
CONNECTTO
ACOUTPUT
CD
FUELTRANSFER
PUMP- ELECTRIC
MOTORDRIVE
LARGER^--r*n
OVERFLOW1
LINE
SUPPLY
LINE
•- FILL
PIPE
UNDERGROUND
FUELTANK
FIGURE 12.DAYTANK (TYPICAL)
17

BATTERYBEGIN.SPEC.G)
Startingtheunitrequires24-voltbatterycurrent.Use
twol2-volt(seeSPECIFICATIONS)batteriesfora
normalinstallation.Connectthebatteriesinseries
(negativepostoffirstbatterytopositivepostof
second)asinFigure13.Necessarybatterycablesare
onunit.Servicethebatteriesasnecessary.Infrequent
unituse(asinemergencystandbyservice)mayallow
thebatteriestoself-dischargetothepointwherethey
cannotstarttheunit.Ifinstallinganautomatic
transferswitchthathasnobuilt-inchargecircuit,
connecta separatetricklecharger.Onanautomatic
transferswitchesincludesucha batterycharging
circuit.
75kWand90kWmodelspriortoS^ecG use12voltbattery
current.Usetwo6 volt,135AmpHourbatteriesconnectedInseries
fortheseoldermodels.
WARNING Donotsmokewhileservicingbatteries.Lead
acidbatteriesgiveoffexplosivegaseswhile
beingcharged.
STARTINGMOTOR
SOLENOID BATTERVPOSITIVE
CONNECTION
CONNECTNEGATIVECABLETO
CONVENIENTBOLTONENGINE
TMECONNECTIONMUSTBECLEAN
ANDPAINTFREE
B348 2-12VOLT.225AMP/MR
BATTERIES
FIGURE13A.BATTERYCONNECTION
212-VOLT225AMP/HR
BATTERIES
Ifunitisinstalledwitha tranaferswitch,a batteryinstallationas
shownInFigure13A.mustbeused.Thebatteriesaremounted
outsidethe skid.
CIRCUIT
BREAKER
TWO, 12VOLT,74AMP
HOURBATTERIES
FIGURE13.BATTERYCONNECTION
BATTERY, HOTLOCATION
Batterieswillselfdischargeveryquicklywhenin-
stalledwheretheambienttemperatureisconsistently
above90°F (32.2°C)suchasina boilerroom.Tb
lengthenbatterylife,dilutetheelectrolytefromits
normal1.275specificgravityreadingatfullchargeto
a1.225reading.Thecrankingpowerisreduced
slightlywhentheelectrolyteissodiluted,butifthe
temperatureisabove90°F (32.2°C),thisshouldnot
benoticed.Thelengthenedbatterylifewillbeworth
theeffort.
1. Fullychargethebattery.
2. Withthebatterystilloncharge,drawoffthe
electrolyteabovetheplatesineach cell. DONOT
ATTEMPTTOPOUROFF;useanhydrometeror
fillerbulbanddisposeofitinasafemanner.Avoid
skinorclothingcontactwiththeelectrolyte.
3.Refilleachcellwithdistilledwater,tonormal
level.
4. Continuechargingfor1 hourata 4 to6 hour
rate.
5.Testeach cell, Ifthespecificgravityisstillabove
1.255, repeatsteps2,3,iand4untilthereadingis
reducedto 1.225. Usually,repeatingstepstwiceis
sufficient.
18