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)

CONTROL PANEL INTERIOR
Theonlyequipmentsdiscussedinthissectionwillbe
thosewhichtheoperatormayhavereasontoadjustor
inspectforservice.
TerminalBoard(TB)21:ConnectionofwireW12to
terminalsH3,H4,H5,andH6ismadeatthispoint,to
changereferencevoltagewhenreconnecting
generatorfordifferentvoltages.RefertoFigure1.
VoltageRegulator,BeginSpecG:Solidstateunit,
consistingofprintedcircuitboardVR21;anSCR
bridgeCR21,witha commutatingreactorL21are
locatedinthecontrolpanelaspartofthevoltage
regulatorsystem.ACoutputfromgeneratoris con-
trolledatpredeterminedlevelregardlessof load;
regulationisplusorminus2%fromnoloadtofull
load, at0.8P.F.
VoltageRegulator,PriortoSpecG:Solidstateunit
consistingofprintedcircuitboardVR21.
Anexciter-regulatorassemblydesignatedVR22containinganSCR
bridgecircuitandcommutatingreactorismountedonthe
generatorendbell(seeFigure4)andworksinconjunctionwith
VR21.
EngineMonitor:Printedcircuitplug-inmodules
providethefollowingfunctions:
1. A 75secondcrankingperiod.
2. Approximatelya 12.5-secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampand
shutdownthesetforalarmconditionssuchas:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Overspeed(enginespeedreaches2100r/min).
c.Lowoilpressure14psi(96.5kPa).
d. Highenginetemperature215°F (102°C).
Onstandardcontrolpanels,allfouralarmsarewiredintoone
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperature)lightsa fault
lamponly.RefertoTable2.
StandardCrankingModule:Limitsenginecranking
timeto75seconds.Ifenginefailstostartafter75
secondstheenginemonitorlightsa faultlampand
opensthecrankingcircuit.
EXCITER-REGULATOR
CHASSISASSEMBLY
(PRIORTO1
SPECQ)
NDBELL
OVERSPEEDSWITCH ROTATINGEXCITER
WITHRECTIFIERS
FIGURE4.GENERATOR(GRILLEREMOVED)
OPTIONAL MODULES
CycleCrankerPlug-inmodulereplacesstandard
crankingcircuit.Automaticallyprovidesa 15-second
cranktimeanda 10-secondresttimeforthreeONand
twoOFFcyclesin65seconds.Ifenginefailstostart,
after75secondstheenginemonitorlightsafaultlamp
andopensthecrankingcircuit.TheONandOFF
cycletimesarenominalandcanbeadjustedat
potentiometersonthecrankermoduleboard.
Pre-Alarm: Givesadvancewarningforlowoil
pressureorhighenginetemperature.Requirestwo
sensorseachforenginetemperatureandoilpressure.

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
1HighEngineTemperature. x
X
STANDARD Overcrank
X X X
SINGLELIGHT Overspeed
X X X
LowOilPressure x
X XA
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
1
PRE-ALARM; 1 Overspeed
X X X
*
•LowOilPressure X . * X X
\HighEngineTemperature
X
*
X X
LowEngineTemperature
X
-Withadditionaloptionalsensors.
10

ENGINE SENSORS
Resistanceunits and switches inthe engine
temperature andoil pressuremonitoring and shut-
downsystemsaresealedunitsandarenotrepairable.
Forlocation,refertoFigures5 and6.Whenreplacing
asensor, do notsubstitute,userecommendeditems.
Resistanceunits are matched tothe gaugethey
supply, and cut-offswitches are close-tolerance
actuationparts,made fora specificapplication.
OILPRESSURE
SENDER ^
FIGURE5.OILPRESSUREMONITORS
TEMPERATURE
SENDER
j(RESISTANCE
UNIT)
WATER
HI-TEMPERATURE
CUT-OFFSWITCH
(HETCO
FIGURE6.ENGINETEMPERATUREMONITORS
s

COOLINGAIRINLETMUSTBE
ATLEASTIVJTIMESLARGER
THANRADIATORDUCTOUTLET
AREAONRADIATORCOOLED
MODELS.
FIGURE 7. TYPICAL MODELDEHINSTALLATION
12

INSTALLATION
GENERAL
Installationsmustbeconsideredindividually.Use
theseinstructionsasa generalguide.Allinstallations
mustmeetregulationsofstateandlocalbuilding
codes,fireordinances,etc.,whichmayaffectinstalla-
tiondetails.SeeFigure7.
Requirementstobeconsideredpriortoinstallation:
1. Levelmountingsurface.
2. Adequatecoolingair.
3.Adequatefreshinductionair.
4. Dischargeofcirculatedair.
5.Dischargeofexhaustgases.
6.Electricalconnections.
7.Fuelinstallation.
8. Watersupply(citywatercooling).
9.Accessibilityforoperationandservicing.
10. Vibrationisolation.
11. Noiselevels.
LOCATION
Providea locationthatisprotectedfromtheweather
andisdry,clean,dustfreeandwellventilated.If
practical, installinsidea heatedbuildingforprotec-
tionfromextremeweatherconditions.
Radiatorsetcoolingairtravelsfromtherearoftheset
andisremovedbya pusherfanwhichblowsout
throughtheradiator.Locatetheairinlettotherearof
theset.MaketheinletopeningatleastIVfe-times
largerthantheradiator.
Locatethecoolingairoutletdirectlyinfrontofthe
radiatorandascloseaspossible.Theopeningsize
shouldbeatleastaslargeastheradiator area. Length
andshapeoftheairoutletductshouldofferminimum
restrictiontoairflow.Usea ductofcanvasorsheet
metalbetweentheradiatorandtheairoutletopening.
Theductpreventsrecirculationofheatedair.
Providea meansofrestrictingtheairflowincold
weathertokeeptheroomorcompartment
temperatureata normalpoint.
Foroperationoutsidea building,a shelterhousing
withelectricallyoperatedlouvresisavailableasan
option. Transformersconnectedacrossthegenerator
outputsupplycurrenttothemotors.
Whenthegeneratorisoperating,currentinthe
transformersactuatethemotorsandopenthe
louvres.Thelouvresareheldopenforthedurationof
thesetoperation,thenareclosedbyreturnsprings
whenthesetisshutdown.
MOUNTING
Generatorsetsaremountedona rigidskidbase
whichprovidespropersupport.Theengine-
generatorassemblyisisolatedfromtheskidbaseby
rubbermountswhichprovideadequatevibration
isolationfornormal.installations.Forinstallations
wherevibrationcontroliscritical,installadditional
spring-typeisolatorsbetweenskidbaseandfounda-
tion.
Forconvenienceingeneralservicingandchanging
crankcaseoil,mountsetonraisedpedestalatleast6-
inches(150mm)high.RefertoONANTechnical
BulletinT-030forfurtherinstallationinformation.
VENTILATION
Generatorsetscreateconsiderableheatwhichmust
beremovedbyproperventilation.Outdoorin-
stallationsrelyonnaturalaircirculationbutindoor
installationsneedproperlysizedandpositionedvents
fortherequiredairflow.SeeSPECIFICATIONSfor
theairrequiredtooperatewithratedloadunder
normalconditionsat1800r/m.
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
onlywhentheunitisrunning)ofsufficientsizeto
assureproperaircirculationandevacuationoffumes.
13

COOUNG SYSTEM
StandardRadiatorCooling,usesa setmounted
radiatorandenginedrivenpushertypefantocool
enginewaterjacket.Airtravelsfromthegenerator
endoftheset,acrosstheengineandbutthroughthe
radiator.Anintegraldischargeductadapterflange
surroundstheradiatorgrille.
HeatExchangerCooling(optional),usesa shelland
tubetypeheatexchangerinsteadofthestandard
radiatorandfan.Enginejacketcoolantcirculates
throughtheshellsideoftheheatexchanger,while
rawcoolingwaterispumpedthroughthetubes.
Enginecoolantandrawwaterdonotmix.Thistypeof
coolingseparationisnecessarywhentherawwater
containsscaleforminglineandotherimpurities.
Thissystemreducessetenclosureairflowahdnoise
levels. Properoperationdependsupona constant
supplyofrawwaterforheatremoval.Theengine
coolantsideofthesystemmaybeprotectedfrom
freezingtherawwatersidecannot.SeeFigure8 for
typicalinstallation.
c
EXPANSION
' TANK
^ HEAT EXCHANGER
•~ -rnENGINE
FROM
ENGINE
J
DRAIN
SOLENOID
VALVE
(OPENSWHEN.
SETISRUNNING)
7"
ADJUSTABLE
VALVE
(RATEOFFLOW)ex
Rev.
JTwATER
IN
STRAINER
FIGURE 8. TYPICAL HEAT EXCHANGER SYSTEM
SiandpipeCooling(optional)substitutesa mixing
(tempering)tankforthestandardradiatorandfan.
Coolingwatercirculatingthroughtheenginejacketis
mixedwithrawwaterinthetank.Becauserawwater
flowsthroughthoenginejacket,itmustnotcontain
scaleforming.impuritiesorfoulingoftheengine,
waterwilloccur.Foulingresultsinengine
overheatingand^ostiyrepairbills.
Thissystemreducessetenclosureairflowre-
quirementsandnoiselevels.Properoperationis
dependentona constantsupplyofcoolingwater.The
systemcannotbeprotectedfromfreezing.SeeFigure
9.
ANTI-SIPHON—I
SOLENOIDVALVE
(OPENWHEN
SETISRUNNING)-
N
STAND
PIPE
WATER
IN
DRAIN
:FROM
ENGINE
TOENGINE
ADJUSTABLEVALVE
(RATEOFFLOW)
STRAINER
FIGURE 9. TYPICAL STANDPIPE SYSTEM
RemoteRadiatorCooling(optional),substitutesa
remotemountedradiatorandanelectricallydriven
fan, forthesetmountedcomponents.Removalofthe
radiatorandfanfromthesetreducessetenclosure
airflowrequirementsandnoiselevelswithoutforcing
dependenceona continuouscoolingwatersupply.
Theremoteradiatorsystemcanbecompletely
protectedagainstfreezing.
Thissystemmustbedesignedtomeetspecific
requirementsoftheapplication.
WaterJacketHeater(optional)maybeinstalledto
keepenginecoolantwarmwhileengineisshutdown.
Itheatsandcirculatesthecoolantwithintheengine,
whichreducesstart-uptimeandenginewearcaused
bycoldstarts.Itiselectricallyoperatedand.ther-
mostaticallycontrolled.

COOLING CONNECTIONS
Theradiatorcooled(standard)setdoesnotrequire
anyexternalconnectionsexceptasdiscussedunder
Ventilation.Allowclearancearoundthesetforaccess
toservicetheradiatorandfanbelts.SeeFigure7.
HeatExchangerandStandpipecooledsetsmustbe
connectedtoa pressurizedsupplyofcoldwater.
Makeconnectionstothesetwithflexiblepipeto
absorbvibration.Onthecoolwaterlineinstalla
solenoidvalvetoshutofftheflowwhenthesetisshut
downanda.rateofflowvalvetocontrolengine
temperature.Thisvalvecanbeeithermanualor
automatic.Actualrateofflowwilldependoninlet
watertemperature.
Adjusttheflowtomaintainwatertemperature
between165° F and195° 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.
GENERAL WATER FILTER
Electricgeneratingsetscanbeequippedwithan
optionalcoolingsystemfilter(corrosionresistor).
Thisfilterisa unitwhichdirectscoolantfromthe
systemthrougha filteringandtreatingdevice.It
softenswater,neutralizesacidityandprotectsagainst
corrosionbytheuseofa replaceablechemically
activatedfilteringelement.Inaddition,theunit con-
tainsa sacrificialmetalplatewhicharrestspittingof
metalsinthesystembyelectro-chemicalaction.
Exactlocationoffilterwillvarybecauseofother
optionalequipmentwhichmayalsobeinstalled.
TwotypesofelementsareavailablefromyourOnan
dealerordistributor.
1. Regularformula(chromate).
2. PAFformula(borate)yearroundtype.
jCAUTION Donotuseanti-freezewithanantMeak
formula.Thestop-leakelementcanprevent
orretardtheflowthroughthefilter,therebyeliminatingthefiltering
processcompletely.
Theregularformulacanbeusedwithplainwaterahd
selectedantifreezes.Thebestprotectionresultswill
begainedbyusingtheborateformulaelementwitha
.permanentantifreeze.
ONANrecommendsthatshutoffvalvesbeinstalledto
theenginesideoftheinletandoutletofthecoolant
filter,foreaseinchangingelements.Anothersugges-
tion, ifsodesired,a thick-walledpyrextubecanbe
insertedandclampedintothelineata convenient
pointtoserveasa flowindicator.Thisflowindicator
willactinthecapacityofa sightgaugetoobserve
generalcondition,possibleairpocketsandpresence
ofcontaminantsinthecoolantflow.SeeFigure10for
installationrecommendations-.
WATEROUTLET
FROMHEATER
WATERHEATER
FLOW
INDICATOR
WATERINLETLINE
FROMBLOCK
SHUT-OF
VALVE
.COOLINGSYSTEM
FILTER
FIGURE10.COOLINGSYSTEM(RADIATOR)
WATER JACKETHEATER (Optional)
Thisheaterisinstalledtomaintainanelevatedengine
temperatureinlowerambienttemperature
applications.Itheatsandcirculatesenginecoolant,
andisthermostaticallycontrolled.
11

EXHAUST
| WARNING
Inhalationofexhaustgasescanresultin
death.
Engineexhaustgasmustbepipedoutsidebuilding or
enclosure. Donot terminateexhaustpipenearinlet
vents or combustiblematerials.Anapprovedthimble
(Figure 11) must be usedwhereexhaustpipespass
throughwalls or partitions.Pitchexhaustpipes
downward or install a condensationtrap{Figure 12)
atthepointwhere a riseintheexhaustsystembegins.
Avoidsharpbends;usesweeping.longradiuselbows.
Provideadequatesupport for mufflers and exhaust
pipes. Refer to Figure 7 fora typicalexhaustinstalla-
tion. Shieldorinsulateexhaustlines if thereisdanger
ofpersonalcontact.Allow at least9-inches(230 mm)
ofclearance ifthe pipes run close toa combustible
wall or partition.Use a pipe at leastaslargeasthe.2-
inch (50mm) pipesizeoutlet ofthe enginewith a
flexibleportionbetweentheengineand the muffler.-
, IF EXHAUSTLINEMUST BE PITCHEDUPWARD,
.CONSTRUCT A TRAP OF PIPEFITTINGS AT
POINT OF RISE
DRAINCONDENSATIONTRAP
PERIODICALLY
FIGURE12.EXHAUSTCONDENSATIONTRAP
RAIN CAP
DRIP CAP
HOLES INENDOF
INNERSLEEVE
ROOF
9"MINIMUM
(230 mm)
9-MINIMUM
(230mm)
m,YHOLES IN
Jf ENDOF
INNERSLEEVE
WALL OR PARTITION-HjyMm11 V
NOTE: VENTILATEDTHIMBLEDIAMETER 6" LARGER
THANEXHAUSTLINE (152mm)
FIGURE11.EXHAUSTTHIMBLE
Donotconnecta flexiblelinetotheexhaustmanifold.
Minimumdiameters and maximumlengths of pipe
(withcriticalmuffler[s]) areas follows:
SingleExhaustsystem:
2.5-inch (67mm) pipe 34 feet(10.5 m)
3.0-inch (76mm) pipe166feet.(50.5 m)
Maximumpermissibleexhaustrestriction- (back
pressure) is 20.4-inchesH2O(5.1 kPa).
16

FUELSYSTEM
Ford-DorsetenginesusedonDEHsetsaredesigned
forusewithASTMNo.2 Dieselfuelwitha minimum
Cetaneratingof43andmaximumSulphurcontentof
0.40.
FUEL CONNECTIONS
Checklocalregulationsgoverningtheinstallationof
afuelsupplytank.
InanydieselengineInstallation,fuelsystemcleanlinessIsof
utmostimportance.Makeeveryefforttoprevententranceof
moistureorcontaminantsofany kind. Donotuselinesorfittingsof
galvanizedmaterial.
Afuelliftinexcessof6feet(1.8m)isnotrecommend-
edwithouta daytankinstallation,becauseoffuel
drainage.Horizontalrun,ifthesupplytankislevel
withthefuelpump,shouldnotexceed12.5-feet
(3.9 m).However,a daytankisagainrecommended.
Afuelsedimenttrapshouldbeinstalledbetweenfuel
transferpumpandsupplytank.
Thefuelinletistothetransferpumpandisthreaded
for3/8-inchpipe.Injectors'returnlinerequiresa 1/8-
inchlowpressurehoseconnection.RefertoFigure
13.
FUEL
LEAK-OFF
(TOTANK)
OILLEVEL
•PLUG
MAINFUEL
SUPPLYLINE
TWO
SECONDARY
FUELFILTERS
FIGURE13.FUELSYSTEM
17

DAY TANK
Generatorsetinstallationsmaybeequipped with an
optionalseparatefueldaytank.A float operatedvalve
controls fuelflowintothefueltank.Thecorrectlevel
is maintainedto assure a constant source offuel!Itis
necessary toinstallanoverflowlinebetweentheday
tankandthemainfueltank.Refertotheinstallations
included with thetank.SeeFigure14foranexample
ofa daytankinstallation.Tankand lines mustbe
belowlevelofinjectorpumpreturnoutlet.
FUELPUMP
RETURNLINE
FUEL
PUMP
'DAY'TANK:
5GAL.(20litre)
MINIMUMCAPACITY
FUELTRANSFER
PUMP- ELECTRIC
MOTORDRIVE
LARGER*n
OVERFLOW"^
LINE i|
ll
11
11
11
M
11
H
11
11
11
11
U
UNDERGROUND
FUELTANK
FIGURE 14.DAYTANK (TYPICAL)
18