Onan 25.0 DEH-53R Series Instruction Manual

OPERATORS MANUAL
AND
PARTS CATALOO
FOR
ELECTRIC GENERATING SETS
SERIES
FORMNUMBER
976-0306
Pr.otedin U.S.A.
ISSUEDATE
5-77
(SPECH)

TABLE OF CONTENTS
TITLE PAGE
Introduction 1
SafetyPrecautions2
Specifications 4
Description 7
Installation13
Operation22
General Maintenance28
Parts Catalog33
Theneedforaninternationalstandardofmeasurementhasbeenincreasedby
today'simprovedcommunicationandtransportationbetweencountries.
ThishaspromptedformationofmodernizedmetricsknownastheInternational
SystemofUnits,officiallyabbreviatedSI.
ONANproductsappearontheworldmarket,thereforebothmetricandthepresent
Americansystemofunits(CU)willbefoundinthismanual.
Toassistinfamiliarization,refertothefollowingterms.
TERM
Length
Pressure
Mass(Weight)
Volume(Liquid)
Power
Frequency
Energy
BatteryCapacity
RevolutionsperMinute
Temperature
METRIC
millimetre(mm)
kilopascals
.'(kPa)
kilogram(kg)
litre^
kilowatt
hertz(Hz)
Joules(J)
Coulomb(C)
r/min
Celsius(0C)
ENGLISH
Inch(in)
poundspersquare
inch(PSI)
pound(Ib)
gallon(gal)
horsepower(HP)
cyclespersecond
(CPS)
BTU
AmpereHour(AH)
rpm
Fahrenheit(0F)
ThecustomaryunitofBrakeHorsepower(BHP)becomeskilowatts(kW)when
convertedtoS I metricunits.ThiskWratingshouldnotbeconfusedwiththekW
ratingofthegeneratorwhichwillalwaysbelowerduetolossesinherentwithany
electricalinductiondevice.
WARNING
TO AVOID POSSIBLE PERSONAL INJURY OR
EQUIPMENT DAMAGE,A QUALIFIED ELECTRO
CIANORANAUTHORIZED SERVICE
REPRESENTATIVE MUST PERfORM IN-
STALLATION ANDALL SERVICE.' \ "

INTRODUCTION
FOREWORD
ThismanualisapplicabletotheDEHSerieselectric
generatingset,consistingofanONAN30.0kW,UR
generator,drivenbya Ford-Dorset,DieselEngine.
Themanualisdividedintotwosections.
Section 1 providesinformationoninstallation,opera-
tionandtroubleshooting.
Sections isa PartsCatalogforONANoptionaland.
standardequipment.
The. manualshouldbeusedjnconjunctionwiththe
Fordenginemanual,forspecificengineinformation.
MODEL IDENTIFICATION
IdentifyyourmodelbyreferringtotheMODELand
SPECIFICATIONNO.asshownontheOnan
nameplate."Electricalcharacteristicsareshownon
thelowerportionofthenameplate.
30.0DEH15R/ 1 G
T
12 3 4 5
1. IndicatesKilowattrating.
2. FactorycodeforSERIESidentification.
3.15= 60HzReconnectible
515= 50HzReconnectible
R—indicatesremotestartingfeature.
4. Factorycodefordesignatingoptionalequipment.
5.Specificationletter.(Advanceswhenfactory
makesproductionmodifications.)
WARNING| Onan uses thissymbol
•throughoutthismanualto
warnof possible personalinjury.
This symbolrefersto possible
equipmentdamage.
Whencontactinga deialerorthefactoryregardingthe
set,alwaysmentionthecompleteModel,SpecNo.
andSerialNo.asgivenontheOnannameplate.This
nameplateinformationisnecessarytoproperlyiden-
tifyyourunitamongthemanymanufactured.Referto
theenginenameplatewhenrequestinginformation
fromitsmanufacturer.The^nannameplateis
locatedontherightsideofthegenerator;theFord
nameplateisontheupperleftside,onflywheel
housing.
Leftsideand.rightsideareconsideredwhenviewedfromthe
engineorfrontendofthegeneratingset.
_* :•.-1

SAFETY PRECAUTIONS
Throughoutthismanualyouwillfindeye-catching
flagscontainingWarningsandCautions.Thesewill
alertyoutoconditionsthatcouldresultindangerto
youortheequipment,ifthenoticeisignored.
ONANrecommendsthatyoureadyourmanualand
becomethoroughlyacquaintedwithitandyour
equipmentbeforeyoustartyourunit.Theac-
cumulatedexperienceofONANengineersis
availableto-you,enablingyoutooperateyoursetin
themostefficientandsafestmannerpossible.These
recommendationsandthefollowingsafety
precautionsareforyourprotection.Studyandknow
them!
REMEMBER.Mostaccidentsarecausedbyfailureto
followsimpleandfundamentalsafetyrulesor
precautions.
Most accidents can be prevented!
KNOW YOUR MANUAL—KNOW YOUR EQUIP-
MENT
Donotstandona wetfloorwhileworkingon
electricalequipment.Userubberinsulativemats
placedondrywoodplatforms.
WARNING Setforthbelowarea numberofpotential
hazardswhichcouldresultinsomedegreeof
personalinjury.Thesuggestedproceduresshouldbeadheredto.
General
»Keepyourelectricgeneratingsetandthesur-
roundingareacleanandfreefromobstructions.
Removealloildeposits;keepthefloorcleanand
dry.
•Provideappropriatefireextinguishersandinstall
theminconvenientlocations.Consultyourlocal
firedepartmentforthecorrecttypeofex-
tinguishertouse.Donotusefoamonelectrical
fires. UseextinguisherratedABCbyNFPA.
•Makesurethatallfastenersonthegeneratingset
aresecure.Tightensupportsandclamps,keep
guardsinpositionoverfans,drivingbelts,etc.
•Donotwearlooseclothinginthevicinityof
movingparts,orjewelrywhileworkingonelec-
tricalequipment.Looseclothingandjewelrycan
becomecaughtinmovingparts.Jewelrycan
shortoutelectricalcontacts;causeshockor
burning.
»Ifnecessarytomakeadjustmentswhiletheunitis.
running, useextremecautionwhenclosetohot
exhausts,movingparts,etc.
Fuel System
•.DONOTfillfueltankswhileengineisrunning,
.unlesstanksareoutsideenginecompartment.
Fuelcontactwithhotengineorexhaustisa
potentialfire.hazard.
•DONOTSMOKEORUSEANOPENFLAMEin
thevicinityofthegeneratorsetorfueltank.
Internalcombustionenginefuelsarehighlyflam-
mable.
REMEMBER—IFYOUCANSMELLFUMES—A
POSSIBLEEXPLOSIONANDFIRECONDITION
EXISTS!
•Makesurethatoilyragsarenotleftonornearthe
engine.Oilsoakedragsarecombustibleand
presenthazardouswalkingconditions.•
•Fuellinesmustbeofsteelpiping,adequately
secured, andfreefromleaks.Pipingattheengine
should, beapprovedflexibleline.Donotuse
copperpipingonflexiblelinesascopperwillwork
hardenandbecomebrittle.
•Yourengineinstallationshouldbeequippedwith
ameansofpositivefuelshutoffinapplications
whenfuelisconductedfroma remotesource.'
Fuelsunderpressure(e.g.naturalgasorliquefied
petroleumgas)shouldbecontrolledbya positive
shutoffvalve,preferablyautomatic,inadditionto
.anyvalveintegralwiththecarburetororgas
regulatorequipment.
Exhaust System
•Exhaustproductsdfanyinternalcombustion
enginearetoxicandcancauseseriouspersonal
injury,ifinhaled.Allengineinstallations,es-
peciallythosewithina confine,shouldbe
equippedwithanexhaustsystemtodischarge
gasestotheatmosphere.Donotuseexhaust
gasestoheata compartment.
•Inspectexhaustsystemregularlytoassurethat
systemisfreeofleaks.

Coolant System
•Coolantsunderpressurehavea higherboiling
pointthanthatofwater.DONOTopena radiator
orheatexchangerpressurecaporbreaka system
whiletheengineisrunning,andinriocaseuntil
thesystempressurehasbeenbledoff.
•Radiatorfanbeltsareguardedforyourprotec-
tion. DONOTremovecoversorguards.
• Keep your hands away from movingparts.
Ventilation System
•Checkremoteradiatorsfrequently.Removeany
dirt,debris,birdnests,etc.
•Checkventilationlouvresfrequently.Makesure
thatfree-falllouvresandmotoroperatedlouvres
openandcloseproperlyandthatthere,isno
restrictioninthefree-airflow.
Electrical System
•Theelectricalinstallationexteriortoyour
generatorshouldhavebeenperformedby
qualifiedlicensedelectricians.Alllocalandstate
codesshouldhavebeenconsultedandcomplied
with. Itisessentialthatallloadcircuitbreakers
adequatelyprotectelectricalfunctions,a|lcir-
cuitsareproperlygroundedandwiringiscorrect
capacity.
•Tagopenswitches.
•DON'Ttamperwithinterlocks.
•Beforestartingworkonthegeneratingset,
disconnectbatteries.Thiswillpreventinadver-
tentstartingoftheset.
•Useextremecautionwhenmakingadjustments
ontheelectricalcomponentsinthecontrol
cabinetwhiletheengineisrunning.Highvoltages
arepresentandcouldcauseseriouspersonal
injury.
•DONOTSMOKEwhileservicingbatteries.Verify
correctpolarityofbatterycablesbeforeconnec-
ting. Leadacidbatteriesgiveoffa highlyex-
plosivehydrogengaswhichcanbeignitedby
electricalarcingorbysmoking.Whenconnecting
batteries,connectthegroundleadlast.

SPECIFICATIONS
r
ENGINE DETAILS
EngineManufacturerFORD
EngineSeries2711E
NumberofCylinders4
Displacement.254-cubicinches(4.16litres)
BHP@ 1800 r/min ; 63(47kW)
CompressionRatio16.0:1
Bore.-4.22-inches(107.19mm)
Stroke, > 4.52-inches(114.81mm)
FuelASTMNo.2 Diesel
BatteryVoltage12VoltNegativeGround
BatteryGroup(Two6-Volt,135A.H.[486kC])2H
StartingMethod: SolenoidShift
GovernorRegulation..5%Maximum
BatteryChargingCurrent. ...35-Ampere
GENERATORDETAILS
TypeUR1560Hz
UR51550Hz
Rating(Watts)
60HertzContinuousStandby30000(37.5kVA)
50HertzContinuousStandby25000(31.25kVA)
ACVoltageRegulation±2%
60Hertz r/min ; 1800
50Hertzr/min.........1500
OutputRating0.8PF
ACFrequencyRegulation3 HzMax.NoLoadtoFullLoad
CAPACITIES AND REQUIREMENTS
CoolingSystem(IncludingRadiator)1...16Quarts(15-litres)
EngineOilCapacity(Filter,Lines,Crankcase)/' 9.5Quarts(9.0-litres)
ExhaustConnection(inchespipethread)2 (Female)
AIRREQUIREMENTS(1800r/min)
EngineCombustion, 104-cfm(0.05m3/s)
RadiatorCooledEngine6000-cfm(2.83m3/s)
TotalforRadiatorCooledModel6104-cfm(2.88m3/s)
AlternatorCoolingAir(1800r/min), 1000-cfm(0.5rnVsj
(1500r/min)833-cfm(0.4m3/s)
FuelConsumptionatRatedLoadASTMNo.2 Diesel2.6-gph(2.73cm3/s)
GENERAL
Height45.6-inches(1.16m)
Width33.0-inches(0.84m)
Length; 66.0-inches(1.68m)
ApproximateWeight(Mass)1-Phase..1700-lbs(771.1kg).
3-Phase1575-lbs(714.4kg)

TABLE I. URGENERATORVOLTAGE/CURRENTOPTIONS
VOLTS
FREQ PHASE
AMPERES
DOUBLE
SERIES PARALLEL
SERIES
REF VOLTAGE
DELTA DELTA WYE WYE
WIRE (W12)TAP
110/220 50 Hz 1
142* X H6
115/230 50 Hz 1 136*
x H6
120/240 60 Hz 1 156*
x H5
110/190 50 Hz
3
95
X H3
115/200 50
Hz 3 90
X
H4 .
120/208 50 Hz 3
87 X
H4
120/208 60
Hz 3 104
X H3
110/220 50 Hz 3
82 x H6
'
127/220 50 Hz
3 82
X
H5
127/220 60
Hz
3
98
X
H4
115/230 50 Hz
3
78 x H6
120/240 60 Hz 3 90
X H5
139/240 60
Hz 3 90
X-
H5
220/380 50
Hz 3 47 x' H3
230/400 50 Hz 3 45 x H4
240/416 50 Hz 3 43 x H4
240/416 60
Hz
3 52 x H3
•254/440 50
Hz.
3
41 x H5
254/440 60 Hz 3 49 x H4
.
277/480 60 Hz
3 45
X
H5
9X H5—Not
347/600 60 Hz
3
36 Reconnectible
3 .
H5—Not
120/240 60 Hz 1'
L
156
Reconnectible
30 kW37.5kVA60Hz
25 kW31.25kVA50Hz
* - Thesecurrentvaluesareavailableonlyfromspeciallongstackunits(Bl25option).Whenstandard3phaseunitisconnected
intoDoubleDeltaconfiguration,maximumcurrent is2/3 that of valuegiven.

120/240 VOLT, 1 PHASE, 60 HERTZ
347/600 VOLT, 3 PHASE, 60 HERTZ
NAMEPLATEVOLTAGECODE 3
Tl
• TO
T2
CONNECTLEAD FROM
TERMINAL 63TOHS
NAMEPLATEVOLTAGECODE 9X-
Tl
" 1
TO
-CONNECTLEAD
FROM
raf
TERMINAL 63TOH5
THIS DIAGRAM APPLIES TO12 LEADGENERATORSONLY
GENERATOR
CONNECTION
SCHEMATIC
DIAGRAM
GENERATOR CONNECTIONWIRINGDIAGRAM
(WITH CURRENTTRANSFORMERS WHEN USED)
15
515
120/240
115/230
110/220
.60
HS
H6
H6
Tl T2T6T11T8T12T4T9.f5T7TJT10
15
120/240 60 HS
515
11'5/230
110/220
H6
H6
1011
CT21
Tl T10T6T7T2TllT4T8T3T12T5T9.
15
120/208
12^220
13^240
H3
H4
H5
515
110/190
115/200
12(^208
127/220
H3.
H4
H4
HS
LO 11
L2
CT22
L3
CT23^L|ir:>
TT
T3 T9
T4 T6Tll
TS TIOT12
Tl T7, T2 T8
IS
240/»16
254/140
277/480
H3
H4
HS
515
220/380
230/400
240/416
254/440
H3
H4
H4
H5
10Ll
L2
L3
CT21
TT
CT22_a_.
CT24 _f"
CT23
T10 TllT12TlT7T4
T2 T8TST3T9T6
98C2193
FIGURE 1. GENERATORRECONNECTIONS
6

DESCRIPTION
GENERAL
AnOnanDEHserieselectricgeneratingsetisa
completeunitconsistingofanenginedrivenAC
generator,withstandardandoptionalcontrolsand
accessoriesasordered.
ENGINE
TheengineontheDEHisa Ford-Dorset 271 IEas
describedintheenginemanual.Basicmeasurements
andrequirementswillbefoundunder
SPECIFICATIONS.Foroperation,maintenanceand
serviceinformation,consulttheFord-Dorsetmanual.
AC GENERATOR
ThegeneratorisanONANTypeUR,12 lead, 4-pole
revolving field, reconnectible,brushlessunit.The
mainrotorisattacheddirectlytotheengineflywheel,
thereforeenginespeeddeterminesgeneratoroutput
frequency.The60Hzsetoperatesat1800r/min,the
50Hzat1500r/min.Excitationisachievedas
foi lows-
Residualalternatingdurrentfromthestatorwinding
isappliedtothevoltageregulator,whereitis
comparedwitha referencevoltage,rectified-and
returnedtothefieldwindingoftheexciter.Current
theninducedintheexciterrotorisrectifiedandfed
intothegeneratorrotor.Thisinducesa currentin
generatorstatorwhichisappliedtothe load.
CONTROL PANEL
Thefollowingisa briefdescriptionofeachofthe
standardcontrolsandinstrumentslocatedonthe
faceofthepanel.SeeFigure2.
DC Panel
PanelLightandSwitch:Illuminatescontrolpanel.
OilPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitlocatedonthe
engine).
WatertemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeter:Indicatesbattery
chargingcurrent.
Run-Stop/Reset-RemoteSwitch:Startsandstopsthe
unitlocallyorfroma remotelocation.Resetsengine
monitorrelayinStop/Resetposition.
WarningLight:Indicates"Fault"inengineoperation.
AC Panel
ACVoltmeterIndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
VoltageRegulatorRheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreakerProvidesgenerator"exciter
andregulatorprotectionfromoverheating,inthe
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeter:Registersthetotalnumberof
hours, to 1/1 Oth, thattheunithasrun.Useittokeepa
recordforperiodicservicing.Timeisaccumulative,
metercannotbereset.
VoltmeterPhaseSelectorSwitch:Selectsphasesof
generatoroutputtobemeasuredbytheACvoltmeter.
OPTIONAL EQUIPMENT
DC Panel
WarningLights:Eliminatestheone"Fault"lightand-
substitutesfiveindicator(seeFigure3)lightstogive
warningof—
a.Overcrank
b.Overspeed
c.Lowoilpressure
d. High.enginetemperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.
ResetSwitch:Manualresetforenginemonitorafter
shut-down.
LampTest:Presstotestwarninglampbulbs(when
engineisrunningonly).
AC Panel
ACAmmeterIndicatesACgeneratoroutputcurrent.
Dualrangeinuseshownonindicatorlights.
FrequencyMeterIndicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30r/min.)

RUNNINGTIME
METER
INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
PHASESELECTORSWITCH-
%TURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
PANELLIGHTANDSWITCH
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
«UN-STOP-REMOTESWITCH
(ALSOA RESETSWITCHFOR
ENGINEMONITOR)
FIELDCIRCUITBREAKER FAULTLAMP
FIGURE 2. TYPICAL CONTROL PANEL (ONE FAULT LAMP)
DUALRANGEACAMMETER
INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
O.NVOLTMETERANDAMMETER—.
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
FREQUENCY
METER
RUNNINGTIME
METER
%TURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
PANELLIGHTANDSWITCH
FIELDCIRCUITBREAKER
PHASESELECTORSWITCH
OILPRESSURE
GAUGE
ATERTEMPERATURE
GAUGE
DCAMMETER
UN-STOP-REMOTE SWITCH
(ALSO A RESET SWITCHFOR
ENGINE MONITOR)
FAULTLAMPS
TESTLAMPBUTTON
ENGINEMONITORRESETSWITCH
USEDONLYONCONTROLPANELS
WITHFIVEFAULTLAMPS
FIGURE 3.OPTIONAL CONTROL PANEL (FIVE FAULT LAMPS)