Onan DYG Series Instruction Manual

RATOR'S MANUAL
A
SERliS
ELECTRIC GENERATING SETS
4
FORMNUMBER
973-0306
ISSUEDATE-
6-77
(Spec A-F)

SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpotentially
dangerousconditionstotheoperatororequipment.Read
thismanualcarefully.Knowwhentheseconditionscan
exist.Then,takeinecessarystepstoprotectpersbnnelas
wellasequipment.
ONANrecommendsthatyoureadyourmanualandbecome
thoroughlyacquaintedwithitandyourequipmentbefore
youstartyourunit.Theserecommendationsandthe
followingsafetyprecautionsareforyour'protection.
Fuels, electricalequipment,batteries,exhaustgasesand
movingpartspresentpotentialhazardsthatcouldresultin
serious,personalinjury.Takecareinfollowingthese
recommendedprocedures.
WARNINGj Onan
K
US
#
eS*hiS Syn?b?1
mm—m—m-mmml throughoutthismanualto
warnof possible serious personalinjury.
CAUTION
This symbolrefersto possible
equipmentdamage.
General
•Keepyourelectricgeneratingsetandthesurrounding
areacleanandfreefromobstructions.Removeany
debrisfromsetandkeepthefloorcleananddry.
•Provideappropriatefireextinguishersandinstallthem
inconvenientlocations.Consultyourlocalfiredepart-
mentforthecorrecttypeofextinguishertbuse.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.
ProtectAgamst Moving Parts
•Keepyourhandsawayfrommovingparts.
•Beforestartingworkonthegeneratingset,disconnect
batteries.Thiswillpreventstartingthesetaccidentally.
Fuel System
•DONOTfillfueltankswhilerengineisrunning,unless
tanksareoutsideenginecompartment.Fuelcontact
withhotengineorexhaustisa potentialfirehazard.
•DdNOTSMOKEORUSEANOPENFLAMEinthe
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.DON'T
tamperwithinterlocks.
•Followallstateandlocalelectricalcodes.Haveall
electricalinstallationsperformedbya qualifiedlicens-
edelectrician.Tagopenswitches.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesemita highlyexplosivehydrogengasthatcan
beignitedbyelectricalarcingorbysmoking.
Exhaust Gases Are Toxic
•Provideanadequateexhaustsystemtoproperlyexpel
discharged.gases.Checkexhaustsystemregularlyfor
leaks. Ensurethatexhaustmanifoldsaresecureandnot
.warped.Donotuseexhaustgasestoheata compart-
ment.
•Besuretheunitiswellventilated.
Keep theUnitandSurroundingArea Clean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.

TABLE OFCONTENTS
UNLESS INDICATED,ALL SECTIONS WILL
^ APPLY TO150,175AND200kW SETS
TITLE PAGE
iSafetyPrecautions.InsideCover
Introduction ••1
Specifications (150,175kW)4
Specifications (200kW)....5
Description 8
installation13
Electrical (150,175kW)18
Electrical (200kW)22
Operation26
General Maintenance32
Parts Catalog34
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
This manualisapplicabletotheDYGSerieselectric
generatingset,drivenbyanAllisChalmers, 17000
MK11engine.The150.0and175.0kWset consists of
a URSeriesGenerator,whilethe 200.0 kWset
consists ofa YBSeriesgenerator.
Information isprovidedoninstallation,operation,
troubleshootingandpartsorderingfortheDYGset.
Themanualshouldbeusedinconjunction with the
Allis-Chalmers enginemanual,asyour.specific
enginemayhavevariationsduetooptionalequip-
mentavailable.
MODEL IDENTIFICATION
Identify yourmodelbyreferringtotheMODELand
SPECIFICATION NO.asshownontheOnan
nameplate.Electricalcharacteristicsareshownon
thelowerportionofthenameplate.
150.0DYG15R/ID
45
1.IndicatesKilowattrating.
2.Factorycodefor SERIES identification.
3.Indicatesvoltagecode.
15indicates60Hzreconnectible.
R indicatesremoteelectricstart.
4.Factorycodefordesignatingoptionalequipment.
5.Specification letter. (Advanceswhenfactory
makes productionmodifications.)
Ifitisnecessarytocontacta dealerorthefactory
regardingtheset,alwaysmentionthecomplete
Model, Spec No.andSerialNo.asgivenontheOnan
nameplate.Thisnameplateinformation is'necessary
toproperly identify yourunitamongthemanytypes
manufactured.Refertotheenginenameplatewhen
requestinginformation from itsmanufacturerThe
Onannameplateislocatedonthe right sideofthe
generator;theAllis-Chalmersnameplateisonthe
right side,ontheengineblock.
ENGINE EXHAUST GAS (CARBON MONOXIDE) IS DEADLYI <
Carbon monoxideI*anodortma,coloiietsgatlormedbyIncomplete
combustionofhydrocaibonfuel*.Carbonmonoildelaa dangerousgaa that
can cause unconsciousness and Is potentiallylethal.Someolthesymptomsor
signs olcarbonmonoxideInhalationare:
Dizziness
IntenseHeadache
Weakness andSleepiness
•Vomiting
•MuscularTwitching
•ThrobbingInTemples
IIyouexperienceanyoltheabovesymptoms,getout Into Ireshair
Immediately.
ThebestprotectionagainstcarbonmonoxideInhalation Is a regularInspection
otthecompleteexhaustsystem.IIyounoticea changeInthesoundor
appearanceolexhaustsystem,shuttheunitdownImmediatelyandhaveIt
Inspected andrepairedatoncebya competentmechanic.

FLAMMABLE LIQUIDS
Carelessnessisa deadlyhabitwhenhandlingelectricgeneratingsets.
Theingredientsofanexplosionaresimple—acombustiblemixtureanda meansofignitingit.Internal
combustionenginesoperateonnaturalgas,manufacturedgas,gasolineanddieseloil fuel. Liquid
fuelsalonewillnotburn.Airhastobemixedwiththefuelsothatitreacheswhatiscalleda "fumic
state." Onlythenwilla liquidfuelignite.Soitisgoodtorememberthat—
IF YOUCAN SMELL FUMES, YOUHAVE HALF THE INGREDIENTS FORAN
EXPLOSION.
Witha combustiblemixture,allthatisneededisa wayofignitingthefumes.Therearemany:faulty
engine-ignitioninsulation,arcingrelaysorbrushes,welding,droppinga steelwrenchona concrete
floor,andofcoursea cigarette.
THIS
DON'TSMOKE
INTHEVICINITY
OFFUEL!
Thefollowingexampleisa vferyrealpossibility:A looseconnectionina fuelline;ordirtina solenoid
valveallowsfuelvaporstoescape.
Anoperatorsmokingacigaretteisinthevicinityoftheescaping fuel. Now,coalatthecigaretteendhas
ate'mperatureof1000oF,andrisesupto11750F(538°Cto635°C)whenairisdrawnthroughit.That
coalishotenoughtoignitea fuelvapormixture.
Couldtheexplosionhavebeenprevented?Theanswerisobviously"yes."Thisaccidenthappened
becausea PlannedMaintenanceProgramwaseithernon-existent,orwasnotbeingfollowed.Most
accidentshappenbecausesomeindividualdoesnotfollowthesimplefundamentalrulesofsafety.
MOST ACCIDENTS CANBE PREVENTED!

SPECIFICATIONS
150.0Kilowatts175.0Kilowatts
ENGINE DETAILS
EngineManufacturerAllis-Chalmers
EngineSeries« 17000MKII(Turbocharged)
Numberof.Cylinders' 6
Displacement844-inch3(13.8lit)
BHP@ 1800RPM276(206kW)
CompressionRatio15.1:1
Bore5.25-inches(133.35mm)
Stroke6.50-inches(165.10mm)
Fuel: ASTMNo2 Diesel
BatteryVoltage24VDC
BatteryGroup(Two12-Volt,225A.H.)8D
StartingMethodSoienoidShift
GovernorRegulation5%Maximum
BatteryChargingCurrent35Amperes.
GENERATOR DETAILS
Type...::.... UR1560Hz
UR51550Hz
UR9X60Hz
Rating(Watts)
60HertzContinuousStandby150,000175,000
50HertzContinuousStandby125,000145,000
ACVoltageRegulation„±2%
60HertzRPM1800
50HertzRPM1500
OutputRating;.' 0.8PF
ACFrequencyRegulation........ -. 3 HzMax.Noload—Fullload
CAPACITIES AND REQUIREMENTS
CoolingSystem(IncludingRadiator). 16.5-Gallons(62.5lit)
EngineOilCapacity.(Filter,Lines,Crankcase).....; - 45-Quarts(42.58lit)
ExhaustConnection(inchespipethread): f 6 (Female)
AIR REQUIREMENTS (1800RPM)
EngineCombustion'640-fty18.13mVmin.)690-ft3(19.54rrvVmin)
RadiatorCooledEngine, . 18,400-ft3(521rrvVmin)
TotalforRadiatorCooledModel- 20,040-ft3 (568mVmin)(20,090ft3(569rrvVmin)
AlternatorCoolingAir(1800RPM)1000-ft3(28.32rrvVmin)
(1500RPM)833-ft3(23.6nvVmin)
FuelConsumptionatRatedLoad
ASTMNo.2 Diesel11.5-GPH(43.5lit/hr)13.5-GPH(51.1lit/hr)
GENERAL
Height66.00-inches(1.68m)
Width44.00-inches(1.11m)
Length120.00-inches(3.04m)
Weight(Approximate)5820-lb(2653.5kg)6000-lb(2721kg)

SPECIFICATIONS
200kW
ENGINE DETAILS
EngineManufacturerAllis-Chalmers
EngineSeries17000MKII(Turbocharged)
NumberofCylinders6
Displacement844-inch3(13.8lit)
BHP@ 1800RPM310(231.2kW)
CompressionRatio15.4:1
Bore5.25-inches(133.35mm)
Stroke6.50-inches(165.10mm)
FuelASTMNo2 Diesel
BatteryVoltage24VDC
BatteryGroup(Two12-Volt,225A.h)T 8D
StartingMethodSolenoidShift
GovernorRegulation5%Maximum
BatteryChargingCurrent35Amperes
GENERATOR DETAILS
TypeYB17/1(60Hz)
YB517/1(50Hz)
Rating(Watts)
60HertzContinuousStandby200,000
50HertzContinuousStandby153,000
ACVoltageRegulation±2%
60HertzRPM* 1800
50HertzRPM1500
OutputRating0.8PF
ACFrequencyRegulation3 HzMax.Noload—Fullload
CAPACITIES AND REQUIREMENTS
CoolingSystem(IncludingRadiator)16.5-Gallons(62.5lit)
EngineOilCapacity(Filter,Lines,Crankcase)15-Gallons(56.8lit)
ExhaustConnection(inchespipethread)6 (Female)
AIR REQUIREMENTS (1800RPM)
EngineCombustion670-ft3/min(18.76rnVmin)
RadiatorCooledEngine18,400-ftVrnin(521m 3/min)
TotalforRadiatorCooledModel20,070-ftVrnin(562mVmin)
AlternatorCoolingAir(1800RPM)1000-ftVrnin(28.32mVmin
(1500RPM)833-ftVrnin(23.6mVmin.)
FuelConsumptionatRatedLoad
ASTMNo.2 Diesel15.7-GPH(59.5lit/hr.)
GENERAL
Height70.00-inches(1778mm)
Width44.00-ihches(44.00mm)
Length109.00-inches(2768mm)
Weight(Approximate)6200-lbs.(2814.8kg)

150& 175kW
RUNNINGTIME
INDICATORLAMPS.METER
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
PHASESELECTOR
SWITCH
%TURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANEL'DOORS
OILPRESSURE
-GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
UN-STOP-REMOTESWITCH
(ALSOA RESETSWITCHFOR
ENGINEMONITOR)
FIELDCIRCUITBREAKER FAULTLAMP
FIGURE 1.STANDARD CONTROL PANEL (ONE FAULT LAMP)
150& 175kW
DUALRANGEACAMMETER
INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER—,
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
FREQUENCY
METE
RUNNINGTIME
METER
VJTURNFASTENERS-TURNBOTH
FIELDCIRCUITBREAKER
PHASESELECTORSWITCH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
RUN-STOP-REMOTESWITCH
(ALSO-ARESETSWITCHFOR
ENGINEMONITOR)
LAMPTESTBUTTON
FAULTLAMPS
FIGURE 2.OPTIONAL CONTROL PANEL (FIVE FAULT LAMPS)
6

200 KW
INDICATORLAMPSINDICATE
UPPER AND LOWERSCALE ON
VOLTMETER AND AMMETER
DUALRANGE
ACAMMETER
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT-
FREQUENCY
METER
EXCITER
CIRCUIT
BREAKER
RUNNING
TIME
METER -
1/4TURNFASTENERS - TURN
BOTHSCREWS TO OPENHINGED
CONTROLPANELDOORS
B184
PHASESELECTORSWITCH KILOWATTMETER
(OPTIONAL)
• OIL
PRESSURE
GAUGE
-WATER
TEMPERATURE
GAUGE
FAULT LAMPS
(I STANDARD -
5 OPTIONAL)
pc
AMMETER
RESETSWITCH
FORENGINE
MONITOR
• RUN-STOP-REMOTE
SWITCH
TESTLAMPBUTTON
FIGURE 3. CONTROL PANEL
AC
VOLTMETER
AC
AMMETER
VOLTAGE
REGULATOR
RHEOSTAT-
VOLTMETER
ANDAMMETER
RANGESELECTOR
SWITCH
KILOWATT
METER
(OPTIONAL)
r-REFERENCE
VOLTAGE
TRANSFORMER
ENGINEMONITOR
PANEL
-CYCLECRANKER
(OPTIONAL)
VOLTAGEREGULATOR
DAMPINGANDVOLTAGE
ADJUSTMENTS—
OILPRESSURE
GAUGE
WATER
'TEMPERATURE
GAUGE
— 5 FAULT
LIGHTS
(OPTIONAL)
STANDARD-
ONELIGHT
FIGURE 4. CONTROL PANEL INTERIOR

DESCRIPTION
GENERAL
AnOnanDYGserieselectricgeneratingsetisa
completeunitconsisting,ofanenginedrivenAC
generator,withcontrolsandaccessoriesasordered.
ENGINE
The"engineontheDYGisanAllis-Chalmers
17000MKI I asdescribedintheenginemanual.Basic
measurementsandrequirementswillbefoundunder
Specifications.However,theengineusedforyour
unitmayhavevariationsduetooptionalequipment
available,thereforetheAllis-Chalmersmanual
shouldbeconsulted.
AC GENERATOR
ThegeneratorisanOnanTypeUR(150& 175kW)or
YB(200kW).Itisa 12 lead, 4 polerevolving field,
reconnectiblebrushlessunit.Alternatingcurrentis
generatedinthestatorwinding.Thealternatorrotor,
attacheddirectlytotheengineflywheelturnsat
enginespeed.Therefore,thespeedatwhichtherotor
turns, determinesgeneratoroutputfrequency.The60
hertzsetoperatesat1800rpmandthe50hertzat1500
rpm. ExcitationisachievedbyfeedingACoutputtoa
voltageregulator,whereitiscomparedwitha
referencevoltage,rectifiedandreturnedtothefieldof
theexciter.Currentinducedintheexciterrotoris
rectifiedandfedtothegeneratorrotor.Thisinducesa
currentinthegeneratorstatorwhichisappliedto
load. Thegeneratorisavailablein3-phaseandsingle
phase.Excitationandregulationarethesamefor
eitherunit.
Run-Stop/Reset-RemoteSwitch:Startsandstopsthe
unitlocallyorfroma remotelocation.Resetsengine
monitorrelayinStop/Resetposition.
WarningLight:Indicates"Fault"inengineoperation.
AC Panel
ACVoltmeterIndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
ACAmmeter:IndicatesACgeneratoroutputcurrent.
Dualrangeinuseshownonindicatorlights.
Voltmeter-AmmeterPhaseSelectorSwitch:Selects
thephasesofthegeneratoroutputtobemeasuredby
theACvoltmeterandACammeter.
VoltageRegulator:Rheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreaker:Providesgeneratorexciter
andregulatorprotectionfromoverheatinginthe
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeter:Registersthetotalnumberof
hours, to 1/10th thattheunithasrun.Useittokeepa
recordforperiodicservicing.Timeisaccumulative,
metercannotbereset.
FrequencyMeter:Indicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30rpm.)
CONTROL PANEL
Thefollowingisa briefdescriptionofeachofthe
standardcontrolsandinstrumentslocatedonthe
faceofthepanel.SeeFigure1 and3.
DC Panel
OilPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitlocatedonthe
engine).
WaterTemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeter:Indicatesbattery
chargingcurrent.
OPTIONAL EQUIPMENT
DC Panel
WarningLights:Eliminatestheone"Fault"lightand
substitutesfiveindicatorlightstogivewarningof—
a.Overcrank
b.Overspeed
c.Lowoilpressure
d. Highenginetemperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.
ResetSwitch:Manualresetforenginemonitorafter
shut-down.
LampTest:Presstotestwarninglampbulbs(when
engineisrunningonly).

CONTROL PANEL INTERIOR
Theonlyequipmentsdiscussedinthissectionwillbe
thosewhichtheoperatormayhavereasontoadjustor
inspectforservice.
TerminalBoard(TB)21
ConnectionofwireW12toterminalsH3,H4,H5,and
H6ismadeatthispoint,tochangereferencevoltage
whenreconnectinggeneratorfordifferentvoltages.
RefertoFigure16.
VoltageRegulator
Solidstateunit,consistingofprintedcircuitboard
VR21; anSCRbridgeCR21,witha commutating
reactorL21arelocatedinthecontrolpanelaspartof
thevoltageregulatorsystem.ACoutputfrom
generatoriscontrolledatpredeterminedlevel
regardlessof load; regulationisplusorminus2
percentfromnoloadtofull load, at0.8PF.
CAUTION HighEngineTemperatureCutoffwillshut
downengineinanoverheatconditiononlyif
coolantlevelissufficientlyhightophysicallycontactshutdown
switch. Lossofcoolantwillallowenginetooverheatwithout
protectionofshutdowndevice,therebycausingseveredamageto
theengine.Itisthereforeimperativethatadequateenginecoolant
levelsbemaintained,toensureoperationalintegrityofcooling
systemandenginecoolantoverheatshutdownprotection.
Onstandardcontrolpanels,allfouralarmsarewiredintoone
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperature)lightsa fault
lamponly.RefertoTable3.
Standard Cranking Module
Limitsenginecrankingtimeto75seconds.Ifengine
failstostartafter75secondstheenginemonitorlights
afaultlampandopensthecrankingcircuit.
Engine Monitor
Printedcircuitplug-inmodulesprovidethefollowing
functions:
1. A 75secondcrankingperiod.
2. Approximatelya 12.5-secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampand
shutdownthesetforalarmconditionssuchas:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Lowoilpressure14psi(96.5kPa).
c.Highenginetemperature215° F (102°C).
OPTIONAL MODULES
Cycle Cranker
Plug-inmodulereplacesstandardcrankingcircuit.
Automaticallyprovidesa 15-secondcranktimeanda
10-secondresttimeforthreeONandtwoOFFcycles
in65seconds.Ifenginefailstostart,after75seconds
theenginemonitorlightsa faultlampandopensthe
crankingcircuit.TheONandOFFcycletimesare
nominalandcanbeadjustedatpotentiometersonthe
crankermoduleboard.
Pre-Alarm
Givesadvancewarningforlowoilpressureorhigh
enginetemperature.Requirestwosensorseachfor
enginetemperatureandoilpressure.

TABLE 1. 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
HighEnginefemperature
X X X
5LIGHT Overcrank
X X X
Overspeed
X X X
• LowOilPressure x
X X
High,EngineTemperature
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
-Withadditionaloptionalsensors.
10

EXHAUST SYSTEM
Exhaustfumesarenoxious.Inhalationcancausedeath.
Carbonmonoxide(CO)isanodorless,colorlessgasformedbyincompletecombustionof
hydrocarbonfuels.Designandinstallationofanexhaustsystemisimportantfortworeasons:oneis
fumeevacuation;theotherreasonisthehightemperaturesthematerialsmustwithstand.Thegaugeor
sizeofmaterialsusedisdeterminedbythemaximumallowablebackpressure,andlengthofthe
exhaustsystem.In caseswhereanengineisexhaustedthrough,theroofofa building,itmaybe'
necessarytouseanexhaustboosterfantoaidfumeevacuation,andkeepbackpressurewithin
specifiedlimits.Thepipeattachedtotheexhaustmanifoldshouldbeflexibleenoughtocompensate
forthermalexpansion,contraction.Itshouldalsobeabletoabsorbvibrations.Thisisextremely
importantonturbo-chargedunitswherea rigidpieceofexhaustpipecouldimpartenoughstressand
weighttoseverelydamagebothturbo-chargerandhousing.
Wherepipeisjoined,makesurethejointweldsareleak-free.Exhaustductingwhichisrunalonga
combustiblewallshouldbefarenoughfromthewalltopreventheatorfiredamage.Wherepipeisrun
througha wall, a thimbleshouldbeinstalledwhichwilladjustforthermalmovementandalsoprevent
exhaustheatfromdamagingthe wall. Sharpbendsshouldbeavoided,butwherethisisnotpossible,a
condensationtrapshouldbeinstalled.Drainthistrapfrequently.Donotterminateanexhaustpipein
thevicinityofventilatingairinletductorventuri,otherwiseexhaustgaseswillbepulledbackintothe
building.
EXHAUST FUMES
ARE OEAPIY!
spv
v

SUPPORT
AIROUTLET
DUCT
CANVAS
SECTION
COOLINGAIRINLETMUSTBE
ATLEASTP/,TIMESLARGER
THANRADIATORDUCTOUTLET
AREAONRADIATORCOOLED
MODELS.
FIGURE 5.A TYPICAL STANDBY INSTALLATION
12

INSTALLATION
GENERAL
Installationsmustbeconsideredindiyidually.Use.
theseinstructionsasa generalguide./Meei
regulationsoflocalbuildingcodes,fireordinances,"
etc.,whichmayaffectinstallationdetails.SeeFigure
5.
Installationpointstoconsiderinclude:
1. Levelmountingsurface.
2. Adequatecoolingair.
3.Adequatefreshinductionair.
4. Dischargeofcirculatedair.
5.Dischargeofexhaustgases.
6.Electricalconnections.
7.Fuelconnections.
8. Waterconnections.
9.Accessibilityforoperationandservicing.
10. Vibrationisolation.
11. Noiselevels.
LOCATION
Providea locationthatisprotectedfromtheweather
andisdry,clean,dustfreeandwellventilated.If
practical, installinsidea heatedbuildingforprotec-
tionfromextremesinweatherconditions.
MOUNTING
Generatingsetsaremountedona rigidskidbase
whichprovidespropersupport.Installvibration
isolatorsbetweenskidbaseandfoundation.For
convenienceindrainingcrankcaseoilandgeneral
servicing, mountsetonraisedpedestals(atleast6-
inches[150mm]high).Ifmountinginatrailer,orfor
othermobileapplications,boltsecurelyinplace.
Extrasupportforthevehicleflooringmaybe
necessary.Boltingdownisrecommendedfor
stationaryinstallations.
VENTILATION
Generatingsetscreateconsiderableheatwhichmust
beremovedbyproperventilation.Outdoorin-
stallationsrelyonnaturalaircirculationbutmobile
andindoorinstallationsneedproperlysizedand
positionedventsfortherequiredairflow.See
Specificationsfortheairrequiredtooperatewith
ratedloadundernormalconditionsat1800rpm.
Radiatorsetcoolingairtravelsfromtherearoftheset
tothefrontend.Locatetheroomorcompartmentair
inletwheremostconvenient,preferablytotherearof
theset.Maketheinletopeningatleastaslargeasthe
radiatorarea(preferably1-1/2timeslarger).
Engineheatisremovedbya pusherfanwhichblows
coolingairoutthroughthefrontoftheradiator.'
Locatethecoolingairoutletdirectlyinfrontofthe
radiatorandascloseaspractical.Theopeningsize
shouldbeatleastaslargeastheradiatorarea.Length
andshapeoftheairoutletductshouldofferminimum
restrictiontoairflow.Usea ductofcanvasorsheet
metalbetweentheradiatorandtheairoutletopening.
Theductpreventsrecirculationofheatedair.
Provide a means of restricting the air flow in cold
weather to keep the room or compartment
temperature at a normal point. *
Ashelterhousingwithelectricallyoperatedlouvresis
availableasanoption.Transformersconnected
acrossthegeneratoroutputsupplycurrenttothe
motors.
Whenthegeneratorisoperating,currentinthe
transformersactuatethemotorsandopenthe
louvres.ThelouvresareheldopenforthedurationOf
thesetoperation,thenareclosedbyreturnsprings
whenthesetisshutdown.
Citywatercooledsetsdonotusetheconventional
radiator.A constantlychangingwaterflowcoolsthe
engine.Ventilationisseldoma problem,butsufficient
airmovementandfreshairmustbeavailableto
properlycoolthegenerator,disperseheatconvected
offtheengineandsupportcombustionintheengine.
Forsmallcompartments,aductofequalorlargerarea
thangeneratoroutletisrecommendedtoremovethe
heatedairfromthegeneratorairoutlettotheoutside
atmosphere.Limitbendsanduseradiustypeelbows
whereneeded.A larger,wellventilatedcompartment
orroomdoesnotrequirea hotairduct.
Installationsmadeina smallroommayrequire
installationofanauxiliaryfan(connectedtooperate
onlywhentheplantisrunning)ofsufficientsizeto
assureproperaircirculation.
'13

CITY WATER COOLING
Anoptionalmethodofenginecooling,inplaceofthe
conventionalradiatorandfan,usesa constant
pressurewatersupply.ThisisreferredtoasCITY
WATERCOOLING.Therearetwovarietiesofcity
watercooling;theHEATEXCHANGERSYSTEMand
STANDPIPESYSTEM.SeeFigures6 and7.
VEXPANSION.
TANK
FROM
-—HEATEXCHANGER
•TOENGINE
ENGINE
J
DRAIN
SOLENOID
VALVE
(OPENSWHEN
,, PLANTISRUNNING)-
J7-
ADJUSTABLE
VALVE
(RATEOFFLOW)838
Z^TtwATER
j^S IN
STRAINER
ANTI-SIPHON—
II
STAND
PIPE
SOLENOIDVALVE
(OPENSWHEN
PLANTISRUNNING)
WATER
IN <3«
DRAIN
— FROM
ENGINE
ADJUSTABLE•
VALVE
(RATEOFFLOW)
iTOENGINE
STRAINER
FIGURE7.TYPICALSTANDPIPESYSTEM
TheSTANDPIPESYSTEMusesa mixingortemper-
ingtank.Coolingwater"thatcirculatesthroughthe
enginemixeswitha sourceofcool"raw"water.The
• "raw"watersupplymustbefreeofscaleforminglime
orotherimpurities.
FIGURE6.TYPICALHEATEXCHANGERSYSTEM
Onbothsystemsuseflexiblepipeforconnecting
watersupplyandoutletflowpipestoengine.Pipethe
outletflowtoa convenientdrain.Installanelectric
solenoidvalveanda rateofflowvalveinthewater
supplyline.Theelectricsolenoidvalveopensand
allowswaterflowthroughthesystemonlywhenthe
plantoperates,therateofflowvalve,either
automaticormanual,providesfortheproperflowrate
totheengine.Adjusttheflowtomaintainwater
temperaturebetween165°F and195°F (73.9°C and
90.6°C)whileviewingthewatertemperaturegauge.
TheHEATEXCHANGERprovidesforaclosedengine
coolingsystem.Enginecoolantflowsthroughatubed
chamber,keepingthecoolantseparatefromthecool
"raw"watersupply.Thecoolantchambermustbe
filledforoperation,asfora radiatorcooledset.
BeforefillingcoolingsystemcheckallhardwareforsecurityThis
includeshoseclamps,capscrews,fittingsandconnections.*Use
flexiblecoolantlineswithheatexchanger,standpipeorremote
mountingradiator.
WATER JACKET HEATER (Optional)
Thisheaterisinstalledtomaintainanelevatedengine
temperatureinlower. ambienttemperature
applications.Itheatsandcirculatesenginecoolant,
and.isthermostaticallycontrolled.
14

EXHAUST
WARNINCjj
Inhalationofexhaustgasescanresultin
death.
Engineexhaustgasmustbepipedoutsidebuilding or
enclosure. Donot terminateexhaustpipenearinlet
vents or combustiblematerials.Anapprovedthimble
(Figure 8) must be usedwhereexhaustpipespass
throughwalls or partitions.Pitchexhaustpipes
downward or installa condensationtrap(Figure9) at
thepointwhere a rise in theexhaustsystembegins.
Avoidsharpbends;usesweepinglongradiuselbows.
Provideadequatesupport for mufflers and exhaust
pipes. Refer to Figure 5for a typicalexhaustinstalla-
tion. Shield or insulateexhaustlines if thereisdanger
ofpersonalcontact.Allow at least9-inches(230mm)
ofclearance ifthe pipes run close toa combustible
wall or partition.Use a pipe at leastaslargeasthe 6-
inch (152mm) pipesizeoutlet ofthe enginewith a
flexibleportionbetween the engineand the muffler.
IFEXHAUSTLINEMUST BE PITCHEDUPWARD,
.CONSTRUCT A TRAP OF PIPEFITTINGS AT
POINT OF RISE
DRAINCONDENSATIONTRAP
PERIODICALLY
FIGURE9.EXHAUSTCONDENSATIONTRAP
RAIN CAP
DRIP CAP
HOLES INENDOF
INNERSLEEVE
ROOF 9MINIMUM
(230mm)
9MINIMUM
(230mm)
WALL OR PARTITION
HOLES IN
END OF
INNERSLEEVE
NOTE: VENTILATEDTHIMBLEDIAMETER 6"
B4i (ISOmm) LARGERTHANEXHAUST'LINE.
Donotconnecta flexiblelinetotheexhaustmanifold.
Minimumdiametersandmaximumlengthsofpipeare
asfollows:
SingleExhaust^system:
5-inch (127mm) pipe '. 50 feet (15rri)
6-inch(152.4mm)pipe150feet (46m)
8-inch.(203.2 mm) pipe 500 feet (152m)
Maximumpermissibleexhaustrestriction(back
pressure) is 2-inchesHg.(6754N/m2).
FIGURE8.EXHAUSTTHIMBLE
15

FUELPUMP
RETURNLINE
FUEL
PUMP
FUEL
.FILTER
INJECTOR
fFUELRETURN
LINE VENTLINE
Allmodelsrequirefuelreturnlinefrom*
injectorstotank.
VENTED
FILLCAP FLOATTYPE
SWITCH
*'DAY'TANK
SGALMIN.
CAPACITY
(20LITRE)
WARNING:Itisnecessarythatanoverflow
pipebeinstalledbetweenthedaytankand
mainfueltank.A hazardousfirecondition
existswithspilled fuel.
ISIZELARGER
OVERFLOW
FUELTRANSFER
PUMP- ELECTRIC
MOTORDRIVEN.
SUPPLYLINE
*NOTE;Whereused.
Float-type"Day"Tank
andLinesmustbebelow
injectorreturnoutlet!
-FILL
PIPE
UNDERGROUND
FUELTANK
u
FIGURE 10.DAYTANKINSTALLATION
16

FUEL SYSTEM
Allis-ChalmersenginesusedontheDYGsetsare
designedforusewithASTMNo.2 Diesel fuel. They
willhowever,operateondieselfuelswithinthe
specificationsdelineatedIntheAllis-Chalmers
enginemanual.
FUEL CONNECTIONS
Checklocalregulationsgoverningtheinstallationof
afuelsupplytank.-
Inanydieselengineinstallation,fuelsystemcleanlinessisof
utmostimportance.Makeeveryefforttoprevententranceof
moistureorcontaminantsofany kind. Donotuselinesorfittingsof
galvanizedmaterial.
Afuelliftinexcessof8 feet(2.44m)isnot
recommendedwithouta daytankinstallation,
becauseoffueldrainage.Horizontalrun,ifthesupply
tankislevelwiththefuelpump,shouldnotexceed25-
feet(7.6m).However,a daytankisagain
recommended.
TARTIN©MOTOR
SOLENOID\ BATTERYPOSITIVE
CONNECTION
CONNECTNEGATIVECABLE
CONVENIENTBOLTONENOINE
TMECONNECTIONMUSTBECLEAN
ANDPAINTFREE
2-12VOLT,225AMP/HR
BATTERIES
Thefuelinletistothetransferpumpandisthreaded
for3/8-inchpipe.Injectors'returnlinerequiresa 1/4-
inchlowpressurehoseconnection.
FIGURE11.BATTERYCONNECTION
DAY TANK
Generatorsetinstallationsmaybeequippedwithan
optionalseparatefueldaytank.A floatoperatedvalve
controlsfuelflowintothefueltank.Thecorrectlevel
ismaintainedtoassurea constantsourceof fuel. Itis
necessarytoinstallanoverflowlinebetweentheday
tankandthemainfueltank.Refertotheinstallations
includedwiththetank.SeeFigure10foranexample
ofa daytankinstallation.
BATTERY
Startingtheunitrequires24-voltbatterycurrent.Use
two12-volt(seeSpecifications)batteriesforanormal
installation.Connectthebatteriesinseries(negative
postoffirstbatterytopositivepostofsecond)asin
Figure11.Necessarybatterycablesareonunit.
Servicethebatteriesasnecessary.Infrequentunit
use(asinemergencystandbyservice)mayallowthe
batteriestoself-dischargetothepointwherethey
cannotstarttheunit.Ifinstallinganautomatic
transferswitchthathasnobuilt-inchargecircuit,
connecta separatetricklecharger.Onanautomatic
transferswitchesincludesucha batterycharging
circuit.
WARNING
beingcharged.
Donotsmokewhileservicingbatteries.Lead
acidbatteriesgiveoffexplosivegaseswhile
BATTERY, HOTLOCATION
Batterieswillselfdischargeveryquicklywhenin-
stalledwheretheambienttemperatureisconsistently
above90°F (32.2°C)suchasina boilerroom.To
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;usea hydrometeror
fillerbulbanddisposeofitinasafemanner.Avoid
skinorclothingcontactwiththeelectrolyte.
3.Refilleachcellwithdistilledwater,tonormal
level.
4. Continuechargingforlhourata4 to6 hourrate.
5.Testeach cell. Ifthespecificgravityisstillabove
1.255, repeatsteps2,3,and4 untilthereadingis
reducedto 1.225. Usually,repeatingstepstwiceis
sufficient.
17

ELECTRICAL
150kWAND175kW
REMOTE CONTROL CONNECTIONS
Provisionismadeforadditionofremotestarting.This
isaccomplishedona-4placeterminal.blocksituated
withinthe.controlbox.Connectoneormoreremote
switchesacrossremoteterminalandB+terminalas
showninFigure12.Ifthedistancebetweentheset
andremotestationislessthan1000-feet(305m),use
No. 18AWGwire;between1000-.and«.2000-feet
(305m and610m),useNo.16AWGwire.
REMOTE
SWITCH
Iftheinstallationisforstandbyservice,a double
throwtransferswitchmustalwaysbeused.Gonnect
thisswitch(eitherautomaticormanual)sothatitis
•f impossible-forcommercialpowerandgenerator
currenttobeconnectedtotheloadatthesametime.
Instructionsforconnectinganautomaticload
transfercontrol:areincludedwithsuchequipment:
FIGURE12.REMOTESTARTING
-LINE LOAD
GEN.
NOTE: SHOWNWITHLINECONNECTEDTOLOAD.
FIGURE13.LOADTRANSFERSWITCH
FIGURE14.CONTROLBOX(SIDEPANELREMOVED)
WIRINGCONNECTIONS
Mostlocalregulationsrequirethatwiringconnec-
tionsbemadebya licensedelectricianandthatthe
installationbeinspectedandapprovedbeforeopera-
tion. Allconnections,wiresizes,etc.mustconformto
requirementsofelectricalcodesineffectatthe
installationsite.
ControlBoxConnections:Thefactoryshipsthese12
leadgeneratorswithloadconnectionwires.NOT
connectedtogetherinthecontrolbox.These12wires
arelabeledTlthroughT12andmustbebrought
togetherbeforemakingloadconnections.Proceedas
follows:
1. Removeeitherright,leftortoppanelfromcontrol
box.SeeFigure14.
2. Connectwirestogetherasshownonpanelandin
Figure15accordingtovoltagedesired.
18