Onan DYH Series Instruction Manual

DOCS DQ
OPERATO
R'S MANU
AND
FOR
DYH
SERIES
ELECTRIC GENERATING SETS
M
FORMNUMBER
973-0309
ISSUEDATE
6-77
(SpecC-D)

SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpotentially
dangerousconditionstotheoperatororequipment.Read
thismanualcarefully.Knowwhentheseconditionscan
exist.Then,takenecessarystepstoprotectpersonnelas
wellasequipment.
ONANrecommendsthatyoureadyourmanualandbecome
thoroughlyacquaintedwithitandyourequipmentbefore
youstartyourunit.Theserecommendationsandthe
followingsafetyprecautionsareforyourprotection.
Fuels, electricalequipment,batteries,exhaustgasesand
movingpartspresentpotentialhazardsthatcouldresultin
serious,personalinjury.Takecareinfollowingthese
recommendedprocedures.
WARNING\ Snan "s.es*his
syn?b?,
Ithroughoutthismanualto
warnof possible serious personalinjury.
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
•DONOTfillfueltankswhileengineisrunning,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.DON'T
tamperwithinterlocks.
•Followallstateandlocalelectricalcodes.Haveall
electricalinstallationsperformedby a qualifiedlicens-
edelectrician.Tagopenswitches.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesemita highlyexplosivehydrogengasthatcan
beignitedbyelectricalarcingorbysmoking.
Exhaust Gases Are Toxic
•Provideanadequateexhaustsystemtoproperlyexpel
dischargedgases.Checkexhaustsystemregularlyfor
leaks. Ensurethatexhaustmanifoldsaresecureandnot
warped. Donotuseexhaustgasestoheata compart-
ment.
•Besuretheunitiswellventilated.
Keep theUnitandSurroundingArea Clean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.
M
•4

.« > '.V
TABLE OF CONTENTS
TITLEPAGE
SafetyPrecautionsINSIDE COVER
Introduction 2
Specifications 3
Description 7
Installation11
Operation19
General Maintenance25
Parts Catalog27
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
ThismanualisapplicabletotheDYH200kWand
250kWSerieselectricgeneratingset,consistingof
anOnanYB17SeriesACgenerator,drivenbyan
Allis-Chalmers21000MKIIengine.Informationis
providedoninstallation,operation,troubleshooting
andpartsorderingfortheDYHset.Themanual
shouldbeusedinconjunctionwiththeAllis-
Chalmersenginemanual,asyourspecificengine
mayhavevariationsduetooptionalequipment
available.
MODEL IDENTIFICATION
IdentifyyourmodelbyreferringtotheMODELand
SPECIFICATIONNO.asshownontheOnan
nameplate.Electricalcharacteristicsareshownon
thelower,portionofthenameplate.
200.0DYH17R/1 C
45
1. IndicatesKilowattrating.
2. FactorycodeforSERIESidentification.
3.Indicatesvoltagecode.
15indicates60Hzreconnectible.
Rindicatesremoteelectricstart.
4. Factorycodefordesignatingoptionalequipment.
5.Specificationletter.(Advanceswhenfactory
makesprpductionmodifications.)
Ifitisnecessarytocontacta dealerorthefactory
regardingtheset,alwaysmentionthecomplete
Model, SpecNo.andSerialNo.asgivenontheOnan
nameplate.Thisnameplateinformationisnecessary
toproperlyidentifyyourunitamongthemanytypes
manufactured.Refertotheenginenameplatewhen
requestinginformationfromitsmanufacturer.The
Onannameplateislocatedontherightsideofthe
generator;theAllis-Chalmersnameplateisonthe
rightside,ontheengineblock.
IWARNINGI
ENGINEEXHAUSTGAS(CARBONMONOXIDE)ISDEADLY!
CartoonmonoxideItanodorint,colorlettga*formedbyIncomplete
combustionolhydrocaibonluels.CarbonmonoxideIsa dangerousgasthat
cancauseunconsciousnessand Is potentiallylethal.Someofthesymptomsor
signsolcarbonmonoxideInhalationare:
Dizziness
IntenseHeadache
WeaknessandSleepiness
•Vomiting
•MuscularTwitching
•ThrobbingInTemple
Ifyouexperienceanyoltheabovesymptoms,getoutIntofreshair
Immediately.
ThebestprotectionagainstcarbonmonoxideInhalationIsaregularInspection
ofthecompleteexhaustsystem. .11 younoticea changeInthesoundor
appearanceofexhaustsystem,shuttheunitdownImmediatelyandhaveIt
Inspectedandrepairedatoncebya competentmechanic.

SPECIFICATIONS
200kW250kW
ENGINE DETAILS A .. ^ .
EngineManufacturerA"?;S?!SfI
rS
EngineSeries21000MKII
NumberofCylindersx
Displacement • • • 844-cii.mch(13.8litres)
BHP@ 1800RPM325* 390
Compression Ratio • 15-1:1
nn\5A/l
Bbre5.25-inches(133.3mm)
Stroke.. Y.. .. ... 6.5-inches(165.1mm)
Fuel • •• • • ASTMNo.2 Diesel
BatteryVoltage24_
BatteryGroup(Two12-Volt,225A.h)8D- over25°F (-4.C)OperatingTemp.
StartingMethodSoienoidShift
GovernorRegulation5%Maximum
GENERATOR DETAILS
XvDeYB17/1,Brushless(60Hz)
y• YB517/1(50Hz)
Rating(Watts)
60HertzContinuousStandby200,000250,000
50HertzContinuousStandbys 165,000^ 208,000
ACVoltageRegulation*2%
60HertzRPM1800
50HertzRPM1500
OutputRating?'8^F^ „ , ^
ACFrequencyRegulation3.0HzNoLoad-FullLoad
BatteryChargingCurrent35Amps
CAPACITIES AND REQUIREMENTS
CoolingSystem(includingRadiatorandIntercooler)...16.5Gallons(62.5litres)
EngineOilCapacity(Filter,Lines,Crankcase)11-25Gallons(29.3litres)15Gallons(56.8litres)
ExhaustConnection(inchespipethread)6
AIRREQUIREMENTS(1800RPM)'
EngineCombustion648CFM(18.78 m'/m.n
RadiatorCooledEngine18,400CFM(521.08mVmm)
TotalforRadiatorCooledModel20,248CFM(539.86mVmm)
AlternatorCoolingAir(1800RPM)1.200CFM(33.96mVmin)
(1500RPM)1,000CFM(28.32mVmin)
FuelConsumptionatRatedLoad(No.2 Diesel)15.5-gph(58.7lit/hr)19.0-gph(68.22lit/hr)
Hek!htRAL72.875-inches(1851mm)70.00-inches(1778mm)
.width37.5-inches(950mm)44.00-inches(1117mm)
Lenath
r110.313-inches(2800mm)109.00-inches(2768mm)
Weight(Approx.')"7,060-lbs(3201kg)6,500-lbs(2951kg)

200kW
165kW 60Hz
50Hz
TABLE 1. GENERATORVOLTAGE OPTIONS
VOLTAGE PHASE
FREQUENCY
MAXIMUM
CURRENT
PARALLEL
WYE
SERIES
WYE CONNECT
WIRE W12
(YB17)
120/208
3
60Hz 694AMPS
X H3
127/220
3
60Hz 656AMPS
X
H4
139/240
3 60Hz 600AMPS
X
.H5
240/416 3
60Hz 347AMPS x H3
254/440
3
60Hz 328AMPS
X
H4
277/480
3
60Hz 300AMPS
X H5
(YB517)
110/190 3
50Hz 616AMPS
X
H3
115/200
3 50Hz 598AMPS
X
H4
120/208 3-50Hz 573AMPS
X
H4
127/220
3 50Hz 543AMPS
X
H5
220/380
3 50Hz 313AMPS
X H3
230/400
3 " 50Hz 294AMPS
X H4
240/416
3
50Hz 287AMPS
X
H4
254/440
3
50Hz 272AMPS
X H5

250kW
208kW 60Hz
50Hz
TABLE 1A. GENERATORVOLTAGE OPTIONS
VOLTAGE PHASE
FREQUENCY
MAXIMUM
CURRENT
PARALLEL
WYE
SERIES
WYE CONNECT
WIRE W12
(YB17)
120/208
3 60Hz 868AMPS
X
H3
127/220'
3 60Hz 820AMPS
X.
H4
139/240
3 60Hz 750AMPS
X
H5
240/416
3 60Hz 434AMPS
X
H3
254/440
3
60Hz 410AMPS
X
H4
277/480 3
60Hz 376AMPS
X H5
.(YB517)
110/190
3
50Hz 788AMPS
X
H3
115/200
3 50Hz 752AMPS
X
H4
120/208 3
50Hz 720AMPS
X
H4
•127/220
3 50Hz 688AMPS
X
H5
220/380
3 50Hz 394AMPS
X
H3
230/400
3 50Hz 376AMPS
X
H4
240/416
3 50Hz 360AMPS
X
H4
254/440
3 50Hz 344AMPS
X
H5

INDICATORLAMPSINDICATE
UPPER AND LOWERSCALE ON
VOLTMETER AND AMMETER
DUALRANGE
ACAMMETER
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT-
FREQUENCY
METER
EXCITER
CIRCUIT
BREAKER
1/4TURNFASTENERS - TURN
BOTHSCREWS TO OPENHINGED
CONTROLPANELDOORS
B1S4
PHASESELECTORSWITCH LOWATTMETER
(OPTIONAL)
.OIL
PRESSURE
GAUGE
•WATER
TEMPERATURE
GAUGE
FAULTLAMPS
(ISTANDARD -
5OPTIONAL)
-DC
AMMETER
RESETSWITCH
FORENGINE
MONITOR
RUN-STOP-REMOTE
SWITCH
TESTLAMPBUTTON
FIGURE 1. CONTROL PANEL
AC
VOLTMETER
VOLTAGE
REGULATOR
RHEOSTAT
VOLTMETER
ANDAMMETER
RANGESELECTOR
SWITCH
KILOWATT
METER
(OPTIONAL)
ENGINEMONITOR
PANEL
CYCLECRANKER
(OPTIONAL)
-TIMEDELAY
START-STOP
(OPTIONAL)
BITO
VOLTAGE REGULATOR
DAMPING ANDVOLTAGE
ADJ USTMENTS
OIL PRESSURE
GAUGE
WATER
TEMPERATURE
GAUGE
-5FAULT
LIGHTS
(OPTIONAL)
STANDARD-
ONELIGHT
FIGURE 2. CONTROL PANEL INTERIOR

DESCRIPTION
GENERAL
AnONANDYHserieselectricgeneratingsetisa
completeunitconsistingofanenginedrivenAC
generator,withcontrolsandaccessoriesasordered.
ENGINE
TheengineontheDYHisanAllisChalmers21000
MKIIasdescribedinenginemanual.Basic
measurementsandrequirementswillbefoundunder
Specifications.However,theengineusedforyourunit
mayhavevariationsduetooptionalequipment
available,thereforetheAllisChalmersmanualshould
beconsulted.
AC GENERATOR
The200and250kWsetsuseanOnanTypeYB17/I
12 lead, 4 polerevolving field, reconnectiblebus-bar
brushlessunit.Thealternatingcurrentisgeneratedin
thestatorwinding.Thealternatorrotor,attached
directlytotheengineflywheelturnsatenginespeed.
Therefore,thespeedatwhichtherotorturns,deter-
minesgeneratoroutputfrequency.The60hertzset
operatesat1800rpmandthe50hertzat1500rpm.
ExcitationisachievedbyfeedingACoutputtoa
voltageregulator,whereitiscomparedwitha
referencevoltageintheregulator,rectifiedand
returnedtothefieldoftheexciter,thentotheexciter
armature,rectifiedandfedtothegenerator field.
CONTROL PANEL
Thefollowingisa briefdescriptionofthestandard
controlsandinstrumentslocatedonthefaceofthe
panel. SeeFigure1.
DC PANEL
OllPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitlocatedonthe
engine).
WaterTemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeterIndicatesthe
batterychargingcurrent.
Run-Stop-RemoteSwitch:Startsandstopstheunit
locallyorfroma remotelocation.
ResetSwitch:Manualresetforenginemonitorafter
shut-down.
LampTest:Presstotestwarninglampbulbs(when
engineisrunningonly).
WamingLight:Indicates"Fault"inengineoperation.
AC PANEL
ACVoltmeter:IndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
ACAmmeter:IndicatesACgeneratoroutputcurrent.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
Voltmeter-AmmeterPhaseSelectorSwitch:Selects
thephasesofthegeneratoroutputtobemeasuredby
theACvoltmeterandACammeter.
VoltageRegulatorRheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreakerProvidesgeneratorexciter
andregulatorprotectionfromoverheatinginthe
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeter:Registersthetotalnumberof
hours, to 1/1 Oth thattheunithasrun.Useittokeepa
recordforperiodicservicing.Timeisaccumulative,
metercannotbereset.
FrequencyMeterIndicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30rpm).
OPTIONAL EQUIPMENT
DC Panel
WamingLights:Eliminatestheone"Fault"lightand
substitutesfiveindicatorlightstogivewarningof-
a.Overcrank
b.Overspeed
c.Lowoilpressure
d. Highenginetemperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.
ACPanei
KilowattMeter:IndicatesoutputoftheACgenerator
inkilowatts.Connectedintoa transducermountedin
thecontrolboxhousing.

CONTROL PANEL INTERIOR
Discussedbelowisequipmentwhichtheoperator
mayhavereasontoadjustorinspectforservice.
TerminalBoard(TB)21:Connectionofwandering
lead(W12)toterminalsH3,H4,H5ismadeatthis
point,tochangevoltageregulatortapwhen
reconnectinggeneratorfordifferentvoltages.Refer
toFigure15.
VoltageRegulatorSolidstateunitcontrolsACoutput
fromgeneratoratpredeterminedlevelregardlessof
load. Regulationplusorminus2%fromnoloadtofull
load, 0.8P.F.
EngineMonitorPrintedcircuitplug-inmodules
providethefollowingfunctions:
1. A 75-secondcrankingperiod.
2. Approximatelya 12.5-secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampand
shutdownthesetforalarmconditionssuchas:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Overspeed(enginespeedreaches2100r/min).
c.Lowoilpressure- 14psi(96.5kPa).
d. Highenginetemperature- 215°F (102oC).
CAUTION HighEngineTemperatureCutoffwillshut
downengineinanoverheatconditiononlyif
coolantlevelissufficientlyhightophysicallycontactshutdown
switch. Lossofcoolant will, allowenginetooverheatwithout
protectionofshutdowndevice,therebycausingseveredamageto
theengine.Adequateenginecoolantlevelsmustbemaintainedto
ensureoperationalshutdownprotectioncapabilityofengine
coolingsystem.
Onstandardcontrolpanels,allfouralarmserawiredIntoona
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperatura)lightsa fault
lamponly.RefertoTable2.
TABLE2.FAULTLAMPOPTIONS
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
SLIGHT 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
-Withadditionaloptionalsensors.

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.
Start-DisconnectandOverspeed:Plug-inmodule.
Operatesatapproximately100rpmabovemaximum
crankingspeedtopreventthestarterfrombeing
energizedwhileengineisrunning.Overspeed
operatesat2000-2200rpm.SeeFigure3.
TimeDelayStart/Stop:Operativefromremoteloca-
tiononly.Provides1-10secondstimedelayon
startingand30-secondsto5-minutesdelayonstop-
ping. Delayperiodadjustableonenginemonitor
panel.
Pre-Alarm: Givesadvancewarningforiowoil
pressureorhighenginetemperature.Requirestwo
sensorseachforenginetemperatureandoil
pressure.
AUTOMATIC OVERSPE
SHUTDOWNSENSOR
FIGURE3.OVERSPEEDSENSOR

SUPPORT
COOLINGAIRINLETMUSTBE
ATLEASTiy2TIMESLARGER
THANRADIATORDUCTOUTLET
AREAONRADIATORCOOLED
MODELS.
FIGURE 4.A TYPICAL STANDBY INSTALLATION
10

INSTALLATION
GENERAL
Installationsmustbeconsideredindividually.Use
theseinstructionsasa generalguide.Meet
regulationsoflocalbuildingcodes,fireordinances,
etc.,whichmayaffectinstallationdetails.SeeFigure
4.
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 rigidskid.base
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
metalbetweenthe rad iatorandthe ai routletopening.
Theductpreventsrecirculationofheatedair.
Providea meansofrestrictingtheairflowincold
weathertokeeptheroomorcompartment
temperatureata normalpoint.Keepinmind,
however,thattheenginemustgetadequatecooling
air.
Ashelterhousingwithelectricallyoperatedlouvresis
availableasanoption.Transformersconnected
acrossthegeneratoroutputsupplycurrenttothe
motors.
Whenthegeneratorisoperating,currentinthe
transformersactuatethemotorsandopenthe
louvres.Thelouvresareheldopenforthedurationof
thesetoperation,thenareclosedbyreturnsprings
whenthesetisshutdown.
Citywatercooledsetsdonotusetheconventional
radiator.A constantlychangingwaterflowcoolsthe
engine.Ventilationisseldomaproblem,butsufficient
airmovementandfreshairmustbeavailableto
properlycoolthegenerator,disperseheatconvected
offtheengineandsupportcombustionintheengine.
Forsmallcompartments,aductofequalorlargerarea
thangeneratoroutletisrecommendedtoremovethe
heatedairfromthegeneratorairoutlettotheoutside
atmosphere.Limitbendsanduseradiustypeelbows
whereneeded.A larger,wellventilatedcompartment
orroomdoesnotrequirea hotairduct.
Installationsmadeina smallroommayrequire
installationofanauxiliaryfan(connectedtooperate
onlywhentheplantisrunning)ofsufficientsizeto
assureproperaircirculation.
11

CITY WATER COOLING
Anoptionalmethodofenginecooling,inplaceofthe
conventionalradiatorandfan,usesa constant
pressurewatersupply.ThisisreferredtoasCITY
WATERCOOLING.Therearetwovarietiesofcity
watercooling;theHEATEXCHANGERSYSTEMand
STANDPIPESYSTEM.SeeFiguresSand6.
-—HEATEXCHANGER
:TO ENGINE
EXPANSION
TANK
=FROM
ENGINE
DRAIN
SOLENOID
VALVE
(OPENSWHEN
'PLANTISRUNNING)
ADJUSTABLE
VALVE
(RATE OF FLOW) Bx
zrf-l^WATER.
IN
STRAINER
ANTI-SIPHON—I
STAND
PIPE
SOLENOIDVALVE
(OPENSWHEN
PLANTISRUNNING)
WATER
-9?
DRAIN
-FROM
ENGINE
ADJUSTABLE
VALVE
(RATEOFFLOW)
ITOENGINE
STRAINER
FIGURE6.TYPICALSTANDPIPESYSTEM
TheSTANDPIPESYSTEMusesa mixingortemper-
ingtank.Coolingwaterthatcirculatesthroughthe
enginemixeswitha sourceofcool"raw"water.The
"raw"watersupplymustbefreeofscaleforminglime
orotherimpurities.
FIGURE5.TYPICALHEATEXCHANGERSYSTEM
Onbothsystemsuseflexiblepipeforconnecting
watersupplyandoutletflowpipestoengine.Pipethe
outletflowtoa convenientdrain.Installanelectric
solenoidvalveanda rateofflowvalveinthewater
supplyline.Theelectricsolenoidvalveopensand
allowswaterflowthroughthesystemonlywhenthe
plantoperates.Therateoffiowvalve,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.
Beforefillingcoolingsystenicheckallhardwareforsecurity.This
includeshoseclamps,capscrews,fittingsandconnections.Use
flexiblecoolantlineswithheatexchanger,standpipeorremote
mountingradiator.
WATER JACKET HEATER (Optional)
Thisheaterisinstalledtomaintainanelevatedengine
temperatureinlowerambienttemperature
applications.Itheatsandcirculatesenginecoolant,
andisthermostaticallycontrolled.
12

EXHAUST
WARNING"!Inhalationofexhaustgasescanresultin
death.
Engineexhaustgasmustbepipedoutsidebuilding or
enclosure. Donot terminateexhaustpipenearinlet
vents or combustiblematerials.Anapprovedthimble
(Figure 7) must be usedwhereexhaustpipespass
throughwalls or partitions.Pitchexhaustpipes
downward or install a condensationtrap(Figure8) at
thepointwhere a rise in theexhaustsystembegins.
Avoidsharpbends;usesweepinglongradiuselbows.
Provideadequatesupport for mufflers and exhaust
pipes. Refer to Figure4 fora typicalexhaustinstalla-
tion. Shield or insulateexhaustlinesifthereisdanger
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
FIGURE8.EXHAUSTCONDENSATIONTRAP
RAIN CAP
HOLES INENDOF
INNERSLEEVE
DRIP CAP
9MINIMUM
(230mm)
9MINIMUM
(230mm)
WALL OR PARTITION
NOTE: VENTILATEDTHIMBLEDIAMETER 6'
B4, (ISOmm) LARGERTHANEXHAUSTLINE.
7
- HOLESIN
END OF
iNNERSLEEVE
Donotconnectaflexiblelinetotheexhaustmanifold.
Minimumdiametersandmaximumlengthsofpipeare
asfollows:
SingleExhaustsystem:
5-inch(127 mm) pipe 50 feet (15ni)
6-inch(152.4mm)pipe150feet (46m)
8-inch(203.2mm)pipe 500 feet(152 m)
Maximumpermissibleexhaustrestriction(back
pressure) is 2-inchesHg.(6754N/m2).
FIGURE 7. EXHAUST THIMBLE
13

FUEL PUMP
RETURN LINE
FUEL
PUMP
7^
FUEL
FILTER
c
INJECTOR
y FUEL RETURN
^LINE
VENT LINE
Allmodal*raquirafualraturnUna from
injactor*totank.
VENTED
FILL CAP
FLOAT TYPE
VALVE
*•DAY'TANK
5 CALMIN.
CAPACITY
WARNING:Itisnecessarythatanoverflow
i3ipebeinstalledbetweenthedaytankand
Imamfueltank.A hazardousfirecondition
'existswithspilledfuel.
li I
SIZE LARGER.
OVERFLOW
*NOTE;Wharauaad.
Float-typa"Da/"Tank
and Llnas mustbabalow
.Injactorraturn outlat!
AWS
FUEL TRANSFER
PUMP- ELECTRIC
MOTORDRIVEN:
' SUPPLY LINE
-FILL
PIPE
FIGURE 9.DAYTANKINSTALLATION
14

FUEL SYSTEM
Allis-ChalmersenginesusedontheDYHsetsare
designedforusewithASTMNo.2 Diesel fuel. They
willhowever,operateondieselfuelswithinthe
specificationsdelineatedintheAllis-Chalmers
enginemanual.
FUEL CONNECTIONS
Checklocalregulationsgoverningtheinstallationof
afuelsupplytank.
Inanydieselengineinstallation,fuelsystemcleanlinessisof
utmostimportance.Makeeveryefforttoprevententranceof
moistureorcontaminantsofany kind. Donotuselinesorfittingsof
gaivanizedmaterial.
Afuelliftinexcessof8 feet(2.44m)isnot
recommendedwithouta daytankinstallation,
becauseoffueldrainage.Horizontalrun,ifthesupply
tankislevelwiththefuelpump,shouldnotexceed25-
feet(7.6m).However,a daytankisagain
recommended.
Thefuelinletistothetransferpumpandisthreaded
for3/8-inchpipe.Injectors'returnlinerequiresa 1/4-
inchlowpressurehoseconnection.
STARTINGMOTOR
SOLENOID BATTERYPOSITIVE
CONNECTION
CONNECTNEGATIVECABLETO
CONVENIENTBOLTONENGINE
TMECONNECTIONMUSTBECLEAN
ANDPAINTFREE
2-12VOLT,225AMP/HR
BATTERIES
FIGURE10.BATTERYCONNECTION
DAY TANK
Generatorsetinstallationsmaybeequippedwithan
optionalseparatefueldaytank.A floatoperatedvalve
controlsfuelflowintothefueltank.Thecorrectlevel
ismaintainedtdassurea constantsourceof fuel. Itis
necessarytoinstallanoverflowlinebetweentheday
tankandthemainfueltank.Refertotheinstallations
includedwiththetank.SeeFigure9foranexampleof
adaytankinstallation.
BATTERY
Startingtheunitrequires24-voltbatterycurrent.Use
two12-volt(seeSpecifications)batteriesforanormal
installation.Connectthebatteriesinseries(negative
postoffirstbatterytopositivepostofsecond)asin
Figure10.Necessarybatterycablesareonunit.
Servicethebatteriesasnecessary.Infrequentunit
use(asinemergencystandbyservice)mayallowthe
batteriestoself-dischargetothepointwherethey
cannotstarttheunit.Ifinstallinganautomatic
transferswitchthathasnobuilt-inchargecircuit,
connecta separatetricklecharger.Onanautomatic
transferswitchesincludesucha batterycharging
circuit.
WARMBNG
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. Continuechargingforlhourata4to6hourrate.
5.Testeach cell. Ifthespecificgravityisstillabove
1.255, repeatsteps2,3,and4 untilthereadingis
reducedto 1.225. Usually,repeatingstepstwiceis
sufficient.
"3:
15

REMOTE CONTROL CONNECTIONS
Provision is madeforaddition of remotestarting.This
isaccomplished ona 4 placeterminalblocksituated
within the control box. Connect one or moreremote
switchesacrossremoteterminal andB+ termin0i as
shown in Figure11. ifthe distancebetween theset
andremotestation is lessthan1000-feet, use No. 18
AWGwire,between 1000-and 2000-feet, useNo.
16AWGwire.
TERMINALBLOCK TB12FOR
REMOTECONNECTIONS AND
COMMONALARM(INSIDECONTROL)
COMMONREMOTE
A^AF^MSWITCH
FIGURE 11. REMOTESTARTING
WIRINGCONNECTIONS
Mostlocalregulationsrequirethatwiringconnec-
tions be made bya licensedelectrician and that the
installation be inspectedandapprovedbeforeopera-
tion. All connections,wiresizes,etc.mustconform to
requirements of electricaicodes in effect atthe
installationsite.
CONTROL BOXCONNECTION
Reconnectionlead W12on TB21 isa jumperwhich
connects a singlephaseoutputfrom the generator to
theappropriate taponthe voltagereference
transformer.Thislead is connected atoneendto
terminal 63onthe terminalboard. The otherendwill
beconnected toa terminalmarked H3,H4orH5
dependinguponthevoltageoptionrequired.Referto
Table 1 and Figure 15for voltagesavailable and
correcthookup.
(W12WIRE)
CONNECTLOOSEWIRE
FROMTERMINAL «63
TOEITHERM3,H4.M5 OR
H6DEPENDING ON
VOLTAGESELECTED.
FIGURE 13. CONTROL BOX CONNECTION
If the installation isfor standby'service, a double
throwtransferswitch(Figure 12) mustalways be
used. Connectthisswitch(eitherautomatic or
manual) so that itis impossibleforcommercialpower
andgeneratorpower tobe connected tothe load at
thesametime.Instructions for connecting an
automatictransferswitch are includedwithsuch
equipment.
GENERATOR-CONNECTIONS
ThemodelYB17generator isa 3-phase60-Hertz (or
50-Hertz) set which canbe connected in eitherseries
wye or parallel wye configuration to give the line to
neutral and line to linevoltageoptionsreferred toin
Table 1 and Figure 15. The line to neutralvoltage is
thelowervoltagenoted onthe unitnameplate,while
theline to linevoltage is the highernameplaterating.
Refer to Figurel4foranexample of 120/208voltage.
LINE LOAD GEN
NOTE: SHOWNWITHLINECONNECTED TO LOAD.
FIGURE 12. LOADTRANSFERSWITCH FIGURE
14.3 PHASE WYE CONNECTION
16

GENERATOR
CONNECTION
SCHEMATIC
OIASRAM
GENERATOR CONNECTION
^WIRING DIAGRAM
17
120/208
127/220
139/240
H3
H4
H6
317
110/190
113/200
120/208
127/220
H3
H4
H4
H5
CT22
L3-
L2-
Ll-
LO-
9^
1)3 \Z
^—r
II
10
12
220/380 60
H3
17
240/416
254/440
277/480
H3
H4
60 HS
517
220/380
230/400
240/416
254/440
H3
H4
H4
HS
7 NOT RECONNECTABLE
L3-
L2-
Ll-
LO-
6|0 0|9~i3 fo"
]e iz
4^"
SINGLEPHASE NOTAVAILABLE YB
SERIES GENERATORS
9.8-2579 (C)
FIGURE 15.
VOLTAGE CONNECTIONS
17

For 3-phaseloadsconnectseparateloadwiresto
each ofthe setterminals L1, L2andL3(Figure14).For
a largesinglephaseloadonly,connectbetween
terminalsL1andL2.Availablecapacityis2/3max-
imum output.
Bus barsandreconnection bars arealuminum,plated
with tintoretardelectrolyticcorrosion.Select con-
nectingcablesandterminallugs with care,tokeep
dissimilar metalsapart.Donotovertorquebolts.
The terminal LO canbegrounded.For1-phaseloads
connect theneutralwiretothe LO terminal.Connect
theloadwiretoeitherterminal— Ll, L2. Twoseparate
single phase circuits areavailable with a totai capaci-
tyofupto2/3ofthegeneratorrated3-phaseoutput.
If using 1 -phase and 3-phase cu rrentatthe same time,
ensure the1-phaseload is properly balanced. Donot
exceed ratedlinecurrent.
ONANrecommends that all connections from thegeneratortothe
bus-bars and from the bus-bars totheloadbemadebya qualified
electrician. Allapplicablelocalandstatelawsshouldbecomplied
with.
RECONNECTION
BAR STOWAGE
8178
FIGURE 16.LOADWIRECONNECTIONS
18