Onan EM Series Instruction Manual

•0(3 DO
®•
RATOR'S MANUA
AND
FOR
EK-EM
SERIES
ELECTRIC GENERATING
BEGIN SPEC. C
't'-i
928-0302 PrintedinU.S.A
'..^0jS-.©^'Cf=75
(R e pTa-c e s..4C ETIC.E.T 3 )

TABLE OF CONTENTS
TITLEPAGE
Introduction1
SafetyPrecautions2
Specifications 4
Description. 9
Installation13
Operation22
General Maintenance27
Parts Catalog35
Theneedforaninternationalstandardofmeasurementhasbeenincreasedby
today'simprovedcommunicationandtransportationbetweencountries.
ThishaspromptedformationofmodernizedmetricsknownastheInternational
SystemofUnits,officiallyabbreviatedSI.
ONANproductsappearontheworldmarket,thereforebothmetricandthepresent
Americansystemofunits(CU)willbefoundinthismanual.
Toassistinfamiliarization,refertothefollowingterms.
TERMMETRICENGLISH
Length' millimetre(mm)Inch(in)
Pressurekilopascalspoundspersquare
(kPa)inch(PSI)
Mass(Weight)kilogram(kg)pound(Ib)
Volume(Liquid)litregallon(gal)
Powerkilowatthorsepower(HP)
Frequencyhertz(Hz)cyclespersecond
(CPS)
EnergyJoules(J)BTU
BatteryCapacityCoulomb(C)AmpereHour(AH)
RevolutionsperMinute r/min rpm
TemperatureCelsius(0C)Fahrenheit(0F)
ThecustomaryunitofBrakeHorsepower(BHP)becomeskilowatts(kW)when
convertedtoSImetricunits.ThiskWratingshouldnotbeconfusedwiththekW
ratingofthegeneratorwhichwillalwaysbelowerduetolossesinherentwithany
electricalinductiondevice.
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
ThismanualisapplicabletotheEK/EMSerieselectric
generatingsetseachconsistingofanONANUR
generator,drivenbya FordC5PGGas/GasoEngine.
SeeSPECIFICATIONSforgeneratorsizes.
Themanualisdividedintotwosections.
Section1 providesinformationininstallation,opera-
tionandtroubleshooting.
Section2 isa PartsCatalogforONANoptionaland
standardequipment.
Themanualshouldbeusedinconjunctionwiththe
Fordenginemanual,forspecificengineinformation.
WARNII
Onan uses
warnof possible
iroughou
is symbol
manualto
alinjury.
rxrr^T^r? This/Symbol>e|ers to possible
l£Ayi!ONiequ/pmentdamage.
MODEL IDENTIFICATION
IdentifyyourmodelbyreferringtotheMODELand
SPECIFICATIONNO.asshownontheOnan
nameplate.Electricalcharacteristicsareshownon
thelowerportionofthenameplate.
30.0EK15R/ 1 G
•T
1 4 5
1. IndicatesKilowattrating(30kW).
2. FactorycodeforSERIESidentification.
3.15= 60Hz.Reconnectible
515= 50Hz.Reconnectible
R—Indicatesremotestartingfeature.
4. Factorycodefordesignatingoptionalequipment.
5.Specificationletter.(Advanceswhenfactory
makesproductionmodifications.)
Whencontactinga dealerorthefactoryregardingthe
set,alwaysmentionthecompleteModel,SpecNo.
andSerialNo.asgivenontheOnannameplate.This
nameplateinformationisnecessarytoproperlyiden-
tifyyourunitamongthemanymanufactured.Referto
theenginenameplatewhenrequestinginformation
fromitsmanufacturer.TheOnannameplateis
locatedontherightsideofthegenerator;theFord
nameplateisontherighthandsideonthevalvecover.
Leftsideandrightsideareconsideredwhenviewedfromthe
engineorfrontendofthegeneratorset.

±4J
0 •
SAFETY PRECAUTIONS
Throughoutthismanual you willfindeye-catching
flagscontainingWarnings and Cautions.Thesewill
alert you to conditionsthatcouldresult in danger to
you or the equipment, if the notice is ignored.
ONANrecommendsthat you readyourmanual and
becomethoroughlyacquaintedwith itand your
equipmentbefore you startyourunit. Theac-
cumulatedexperience of ONANengineers is
available to you,enabling you to operateyourset in
themostefficientandsafestmannerpossible.These
recommendations andthe followingsafety
precautions arefor yourprotection.Studyandknow
them!
REMEMBER.Mostaccidentsarecaused by failure to
followsimple and fundamentalsafetyrules or
precautions.
MosX accidents can be prevented!
KNOW YOUR MANUAL—KNOW YOUR EQUIP-
MENT
Do not stand ona wet floorwhileworking on
electricalequipment.Userubberinsulativemats
placed ondry woodplatforms.
WARNING Setforthbelow
area number of potential
hazardswhichcouldresult in somedegree of
personalinjury.Thesuggestedproceduresshould be adhered to.
General
•Keepyourelectricgenerating set and the sur-
roundingareaclean and freefromobstructions.
Remove alloil deposits;keep the floorclean and
dry.
•Provideappropriatefireextinguishersandinstall
them in convenientlocations.Consultyourlocal
firedepartment forthe correcttype ofex-
tinguisher to use. Donotuse foam on electrical
fires. Use extinguisherrated ABC by NFPA.
•Makesurethatallfastenersonthegenerating set
aresecure.Tightensupports and clamps,keep
guards in positionoverfans,drivingbelts, etc.
• Donot wearlooseclothing inthe vicinity of
movingparts, or jewelrywhileworking on elec-
tricalequipment.Looseclothingandjewelrycan
becomecaught in movingparts.Jewelry can
short out electricalcontacts;causeshock or
burning.
• If necessary to makeadjustmentswhiletheunitis
running, use extremecautionwhenclose to hot
exhausts,movingparts, etc.
FuelSystem
• DO NOT fillfueltankswhileengine is running,
unlesstanks are outsideenginecompartment.
Fuelcontactwith hot engine or exhaust isa
potentialfirehazard.
• DONOT SMOKE OR USE AN OPENFLAME in
thevicinity ofthe generator setor fueltank.
Internalcombustionenginefuelsarehighlyflam-
mable.
REMEMBER—IF YOUCAN SMELLFUMES-A
POSSIBLEEXPLOSIONANDFIRECONDITION
EXISTS!
•Makesurethatoilyragsare not leftonornearthe
engine. Oil soakedrags are combustible and
presenthazardouswalkingconditions.
•Fuellinesmust beof steelpiping,adequately
secured, andfreefromleaks.Pipingattheengine
should be approvedflexibleline. Donotuse
copperpipingonflexiblelinesascopperwillwork
harden and becomebrittle.
•Yourengineinstallationshouldbeequippedwith
ameans of positivefuelshutoff in applications
whenfuel is conductedfrom a remotesource.
Fuelsunderpressure(e.g.naturalgas or liquefied
petroleumgas)shouldbecontrolledbya positive
shutoffvalve,preferablyautomatic, in addition to
anyvalveintegralwith the carburetor orgas
regulatorequipment.
ExhaustSystem
•Exhaustproducts ofany internalcombustion
engine are toxicand can causeseriouspersonal
injury, if inhaled. All engineinstallations, es-
peciallythosewithin a confine,should be
equippedwith an exhaustsystem to discharge
gases tothe atmosphere. Donot use exhaust
gases to heat a compartment.
•Inspectexhaustsystemregularly to assurethat
system is free of leaks.

Coolant System
•Coolantsunderpressurehavea higherboiling
pointthanthatofwater.DONOTopena radiator
orheatexchangerpressurecaporbreaka system
whiletheengineisrunning,andinnocaseuntil
thesystempressurehasbeenbledoff.
•Radiatorfanbeltsareguardedforyourprotec-
tion. DONOTremovecoversorguards.
• Keep your hands away from movingparts.
Ventilation System
•Checkremoteradiatorsfrequently.Removeany
dirt,debris,birdnests,etc.
•Checkventilationlouvres.frequently.Makesure
thatfree-falllouvresandmotoroperatedlouvres
openandcloseproperlyandthatthereisno
restrictioninthefree-airflow.
Electrical System
•Theelectricalinstallationexteriortoyour
generatorshouldhavebeenperformedby
qualifiedlicensedelectricians.Alllocalandstate
codesshould-havebeenconsultedandcomplied
with. Itisessentialthatallloadcircuitbreakers
adequatelyprotectelectricalfunctions,allcir-
cuitsareproperlygroundedandwiringiscorrect
capacity.
Tagopen'switches."''"'
DON'Ttamperwithinterlocks.
Beforestartingworkonthegeneratingset,
disconnectbatteries.Thiswillpreventinadver-
tentstartingoftheset.
Useextremecautionwhenmakingadjustments
ontheelectricalcomponentsinthecontrol
cabinetwhiletheengineisrunning.Highvoltages
arepresentandcouldcauseseriouspersonal,
injury.
DONOTSMOKEwhileservicingbatteries.Verify
correctpolarityofbatterycablesbeforeconnec-
ting. Leadacidbatteriesgiveoffa highlyex-
plosivehydrogengaswhichcanbeignitedby
electricalarcingorbysmoking.Whenconnecting
batteries,connectthegroundleadlast.

SPECIFICATIONS
30kWEK
ENGINE DETAILS
EngineManufacturerFord
EngineSeries* C5PG
NumberofCylinders6
Displacement300-in3(4.9 litre)
BHP@ 1800 r/min 80(59.68kW)
CompressionRatio8.4:1
Bore4.00-inch(101.6mm)
Stroke3.98-inch(101.09mm)
FuelGas/Gaso
BatteryVoltage12
BatteryGroup—One12-Volt,74A.H.(266kC)Type60
StartingMethodSolenoidShift
GovernorRegulation5%Max.NoLoad—FullLoad
BatteryChargingCurrent35-Amperes
GENERATOR DETAILS
TypeUR1560Hz
UR51550Hz
Rating(Watts)
60HertzContinuousStandby30000(37.5kVA)
50HertzContinuousStandby25000(31.25kVA)
ACVoltageRegulation±2%
60Hertz r/min ! 1800
50Hertz r/min 1500
OutputRating0.8PF
ACFrequencyRegulation3 HzMax
CAPACITIES AND REQUIREMENTS
CoolingSystem,EngineandRadiator20-quarts(19litres)
EngineOilCapacity(Filter,Lines,Crankcase)7-quarts(6.6litres)
ExhaustConnection(inchespipethread)2
AIR REQUIREMENTS (1800 r/min)
EngineCombustion100ftVmin(0.05m3/s)
RadiatorCooledEngine5 335ftVmin(2.52m3/s)
TotalforRadiatorCooledModel5 435ftVmin(2.6mVs)
AlternatorCoolingAir(1800r/min)1 000ftVmin(0.5mVs)
(1500r/min)833ftVmin(0.4mVs)
FuelConsumptionatRatedLoad
Gasoline(Regular)4.9gal/hr(5.15cmVs)
NaturalGas(1000BTU/ft3[37.25MJ/m3])600-ft3/hr(0.28mVmin)
LPG(2500BTU/ft3[93.1MJ/m3])245-ftVhr(0.12mVmin)
GENERAL
Height45.56-inches(1.16m)
Width33.00-inches(0.84m)
Length71.81-inches(1.82m)
ApproximateWeight(Mass)1395-lb(633kg)
1550-lb(703kg)

SPECIFICATIONS
45kWEM
ENGINE DETAILS
EngineManufacturerr^pr
EngineSeries6
Number of Cylinders • •• •• • •;:'':' .
DisplacementSOO-m3(49 l.tre
BHP@ 1800 r/min
98( ^
Compression Ratio ; •• • •; • •; • 8-[
Bore4.00-inch(101.6mm)
Stroke3.98-inch(101.09mm)
Fuei Gas/Gaso
BatteryVoltage•• •'
Battery Group-One 12-Volt, 74 A.H. (266 kC) vj**™
Starting Method ••••• So}erl0i^M'
GovernorRegulation5%Max.NoLoad-FullLoad
BatteryChargingCurrent35-Amperes
GENERATOR DETAILS
Type• UR1560Hz
yP: " UR51550Hz
"^'eoSzContinuousStandby45000(56.25kVA)
50HertzContinuousStandby37500 (46-87
ACVoltageRegulation±2J^
60Hertz r/min
1°JJj
50Hertz r/min ^5°°
OutputRating• 0^PF
ACFrequencyRegulation3 HzMax
CAPACITIES AND REQUIREMENTS
CoolingSystem,EngineandRadiator20-quarts(19litres)
EngineOilCapacity(Filter,Lines,Crankcase)7-quartsc(6.6litres)
ExhaustConnection(inchespipethread)2
AIR REQUIREMENTS (1800 r/min)
Engine Combustion -J^TVlo"Yfl
RadiatorCooledEngine^f'^/T-^ " *
TotalforRadiatorCooledModel; 5 460-ft3/min(2.6m3/s)
AlternatorCoolingAir(1800r/min)1000-ft3/min(0.5m3/s)
(1500r/min)833-ftVmin(0.4m3/s)
FuelConsumptionatRatedLoad-
Gasoline (Regular) J^T^T
NaturalGas(1000BTU/ft3[37.25MJ/m3]).690ft3/hr(0-32mVmin)
LPG(2500BTU/ft3[93.1MJ/m3])290ft3/hr(O-14mVmin)
GENERAL
Heiqht• ' 45.56inches(1.16m)
Wjd^h33.00inches(0.84m)
Length73.19inches(1.86m)
ApproximateWeight(Mass)3-phase1455Ib(660kg)
MM
1-phase 1610Ib(730kg)
5

SERIES EK"
TABLE 1
GENERATORVOLTAGE/CURRENT OPTIONS
DOUBLE
SERIES
PARALLEL
SERIES REF VOLTAGE
VOLTS FREQ
PHASE AMPERES DELTA DELTA WYE WYE
WIRE (W12)TAP
110/220 50Hz 1
142* X
H6
115/230 50Hz 1
136*
x H6
120/240 60Hz 1
156* X
H5
110/190 50Hz 3
95
X
H3
115/200 50Hz
3 90
X H4
120/208 50Hz
3
87,
X H4
120/208 60Hz
3
104
X
H3
110/220 50Hz
3 82
X H6
127/220 50Hz 3
82
X H5
127/220 60Hz
3 98
X H4
115/230 50Hz
3 78
X H6
120/240 60Hz
3 90
X
H5
139/240 60Hz
3 90
X H5
220/380 50Hz
3 47
X H3
230/400 50Hz
3 45
X
H4
240/416 50Hz 3 43
X H4
240/416 60Hz 3 52
X H3
254/440 50Hz
3
41
X
H5
254/440 60Hz
3 49
X
H4
277/480 60Hz
3 45
X
H5
9X H5—Not
347/600 60Hz
3
36 Reconnectible
3 H5—Not
120/240 60Hz 1 156 Reconnectible
30kW37.5kVA60Hz
25kW31.25kVA50Hz
-Thesecurrentvaluesareavailableonlyfromspeciallongstackunits(B125option).Whenstandard3 phase
unitisconnectedintoDoubleDeltaconfiguration,maximumcurrentis2/3thatofvaluegiven.

SERIES EM
TABLE IA
GENERATORVOLTAGE/CURRENT OPTIONS
DOUBLE
SERIES PARALLEL
SERIES
REF VOLTAGE
VOLTS
FREQ PHASE AMPERES DELTA DELTA WYE WYE
WIRE (W12)TAP
110/220 50Hz 1
213* X
H6
115/230 50Hz 1
204*
X .H6
120/240 60Hz 1
234* -
X
H5
110/190 50 Hz
3
142- r
X
H3
115/200 50 Hz
3
135 -
X H4
120/208 50 Hz
3
130
X H4
120/208 60 Hz 3
156*
X H3
110/220 50 Hz 3 123
X
H6
127/220 50 Hz
3
123-
X H5
127/220 60 Hz
3
148
X
H4
115/230 50 Hz
3 118-
X
H6
120/240 60 Hz 3
135
X H5
139/240 60 Hz 3
135-
X H5
220/380 50 Hz 3
71-
X
H3
230/400 50 Hz
3
68—
X
H4
240/416 50 Hz
3
65
X
H4
240/416 60 Hz
3 78 "
X
H3
254/440 50 Hz
3 62
X
H5
254/440 60 Hz 3 74
X
H4
277/480 60 Hz
3
68-
X
H5
9X H5—Not
347/600 60Hz
3 54 Reconnectible
3 H5—Not
120/240 60Hz 1 234 Reconnectible
45kW56.25kVA60Hz
37.5kW46.87kVA50Hz
-Thesecurrentvaluesareavailableonlyfromspeciallongstackunits(B125option).Whenstandard3 phase
unitisconnectedintoDoubleDeltaconfiguration,maximumcurrentis2/3thatofvaluegiven.

120/240 VOLT, 1 PHASE, 60 HERTZ
347/600 VOLT,3PHASE, 60 HERTZ
NAMEPLATEVOLTAGECODE 3
Tl
•TO
T2
CONNECTLEAD FROM
TERMINAL 63TOH5
+
NAMEPLATEVOLTAGECODE 9X
TK .T2
TO
•) CONNECTLEAD FROM
T3|
TERMINAI63TOH5
THIS DIAGRAM APPLIES TO12 LEADGENERATORSONLY
fe:
13
SIS
IS
S15
IS
12C/240
115/230
110/220
120/208
12^220
139/240
110/190
115/200
129/208
127/^20
240/416
254/140
277/180
515
22(^)80
230/400
240/416
25V440
Mm/'
GENERATOR
CONNECTION
SCHEMATIC
DIAGRAM
GENERATOR CONNECTIONWIRINGDIAGRAM
(WITH CURRENTTRANSFORMERS WHEN USED)
60 H5
H6
H6
H3
H4
H5
H3
H4
H4
H5
H3
H4
HS
H3
H4
H4
H5
Tl T2T6TilT8 T12 T4T9TST7T3TIO
Tl TIOT6T7T2TilT4TBT3T12TST9
LO Ll
L2
CT22
T4 T6Til
TS TIOT12
Tl T7 T2 T8
T3 T9
LO Ll L2
CT21
TT
CT22
n
TlO TilT12TlT7T4T2T8TST3T9T6
9BC2193
FIGURE 1. OPTIONAL VOLTAGE CONNECTIONS
8

DESCRIPTION
GENERAL
AnOnanEKorEMserieselectricgeneratingsetisa
completeunitconsistingofanenginedrivenAC
generator,withstandardandoptionalcontrolsand
accessoriesasordered.
ENGINE
Theengineontheseunitsisa FordC5PGas
describedintheenginemanual.Basicmeasurements
andrequirementswillbefoundunder
SPECIFICATIONS.Foroperation,maintenanceand
serviceinformation,consulttheFordmanual.
AC GENERATOR
ThegeneratorisanONANTypeUR,12 lead, 4-pole
revolving field, reconnectible,brushlessunit.The
mainrotorisattacheddirectlytotheengineflywheel,
thereforeenginespeeddeterminesgeneratoroutput
frequency.The60Hzsetoperatesat1800r/min,the
50Hzat1500r/min.Excitationisachievedas
fol lows-
Residualalternatingcurrentfromthestatorwinding
isappliedtothevoltageregulator,whereitis
comparedwitha referencevoltage,rectifiedand
returnedtothefieldwindingoftheexciter.Current
theninducedintheexciterrotorisrectifiedandfed
intothegeneratorrotor.Thisinducesa currentin
generatorstatorwhichisappliedtothe load.
CONTROL PANEL
Thefollowingisa briefdescriptionofeachofthe
standardcontrolsandinstrumentslocatedonthe
faceofthepanel.SeeFigure2.
DC PanelQ_
Pai^y§fofr«nd-SwHehUWujnjm
OilPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitlocatedonthe
engine).
WaterTemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeter:.Indicatesbattery
chargingcurrent.
RunStop/Reset-RemoteSwitch:Startsandstopsthe
unitlocallyortransferscontroltoa remotelocation.
ResetsenginemonitorrelayinStop/Resetposition.
WarningLight:Indicates"Fault"inengineoperation.
AC Panel
ACVoltmeter:IndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
VoltageRegulator:Rheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreakerProvidesgeneratorexciter
andregulatorprotectionfromoverheating,inthe
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeter:Registersthetotalnumberof
hours, to1/10th,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. Highenginetemperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.
ResetSwitch:Manualresetforenginemonitorafter
shut-down.
LampTest:Presstotestwarninglampbulbs(when
engineisrunningonly),onfivelightpanels.
AC Panel
•/ACAmmeter:,IndicatesAGvgene.ratoroutput-current./
Dualrangeinuseshownonindicatorlights.
FrequencyMeter:Indicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30r/min.)

RUNNINGTIME
METER
INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER—,
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
PHASESELECTOR
SWITCH
%TURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
P&yELiXI.G.HXANDSWITCH
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
•RUN-STOP-REMOTESWITCH
(ALSOA RESETSWITCHFOR
ENGINEMONITOR)
FIELDCIRCUITBREAKER FAULTLAMP
FIGURE 2. TYPICAL CONTROL PANEL (ONE FAULT LAMP)
DUALRANGEACAMMETER
INDICATORLAMPS
INDICATEUPPERANDLOWERSCALE
ONVOLTMETERANDAMMETER—,
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
FREQUENCY
METER
RUNNINGTIME
METER
VSTURNFASTENERS-TURNBOTH
SCREWSTOOPENHINGEDCONTROL
PANELDOORS
I Et-blG-HT-A'N-D-SWTTtm*.
FIELDCIRCUITBREAKER
PHASESELECTORSWITCH
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
RUN-STOP-REMOTESWITCH
(ALSOA RESETSWITCHFOR
ENGINEMONITOR)
FAULTLAMPS
TESTLAMPBUTTONAND
ENGINEMONITORRESETSWITCH
USEDONLYONCONTROLPANELS
WITHFIVEFAULTLAMPS
FIGURE 3.OPTIONAL CONTROL PANEL (FIVE FAULT LAMPS)
10

CONTROL PANEL INTERIOR
Theonlyequipmentsdiscussedinthissectionwillbe
thosewhichtheoperatormayhavereasontoadjustor
inspectforservice.
TerminalBoard(TB)21:ConnectionofwireW12to
terminalsH3,H4,H5,andH6ismadeatthispoint,to
changereferencevoltagewhenreconnecting
generatorfordifferentvoltages.RefertoFigure1.
VoltageRegulator,BeginSpecF:Solidstateunit,
consistingofprintedcircuitboardVR21;anSCR
bridgeCR21,witha commutatingreactorL21are
locatedinthecontrolpanelaspartofthevoltage
regulatorsystem.ACoutputfromgeneratoris con-
trolledatpredeterminedlevelregardlessof load;
regulationisplusorminus2%fromnoloadtofull
load, at0.8P.F.
VoltageRegulator,PriortoSpecF:Solidstateunit
consistingofprintedcircuitboardVR21.
Anexciter-regulatorassemblydesignatedVR22containinganSCR
bridgecircuitandcommutatingreactorismountedonthe
generatorendbell(seeFigure4)andworksinconjunctionwith
VR21.
EXCITER-REGULATOR
CHASSIS ASSEMBLY
\ NDBELL
OVERSPEEDSWITCH ROTATINGEXCITER
WITHRECTIFIERS
EngineMonitor:Printedcircuitplug-inmodules
providethefollowingfunctions:
1. A 75secondcrankingperiod.
2. Approximatelya 12.5-secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampahd
shutdownthesetforalarmconditionssuchas:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Overspeed(enginespeedreaches2100r/min).
c.Lowoilpressure14psi(96.
d. Highenginetemperature|fT5°F(102oC).
p^^^JJ^HighEngineTemperature(
L^x^^^-^Z^J'downengineinanoverheati
Cutoffwillshut
iengineinanoverheatconditiononlyif
coolantlevelissufficientlyhightophysicallycontactshutdown
switch. Lossofcoolantwillallowenginetooverheatwithout
protectionofshutdowndevice,therebycausingseveredamageto
theengine.Itisthereforeimperativethatadequateenginecoolant
levelsbemaintained,toensureoperationalintegrityofcooling
systemandenginecoolantoverheatshutdownprotection.
Onstandardcontrolpanels,allfouralarmsarewiredintoone
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperature)lightsa fault
lamponly.RefertoTable2.
StandardCrankingModule:Limitsenginecranking
timeto75seconds.Ifenginefailstostartafter75
secondstheenginemonitorlightsa faultlampand
opensthecrankingcircuit.
FIGURE4.REGULATORASSEMBLY
(PriortoSpecF)
OPTIONAL MODULES
CycleCranker:Plug-in'modulereplacesstandard
crankingcircuit.Automaticallyprovidesa 15-second
cranktimeanda 10-secondresttimeforth ree ONand
twoOFFcyclesin65seconds.Ifenginefailstostart,
after75secondstheenginemonitorlightsafaultlamp
andopensthecrankingcircuit.TheONandOFF
cycletimesarenominalandcanbeadjustedat
potentiometersonthecrankermoduleboard.
Pre-Alarm: Givesadvancewarningforlowoil
pressureorhighenginetemperature.Requirestwo
sensorseachforenginetemperatureandoilpressure.
11

TABLE 2. FAULT LAMPOPTIONS
FAULT STOP EXTERNAL PRE-
SYSTEM FAULT
LAMP
ENGINE
ALARM ALARM
PENNSTATE Overcrank
X X X
SINGLELIGHT' Overspeed
X X X
LowOilPressure
X X
HighEngineTemperature
X X
STANDARD Overcrank
X X X
SINGLELIGHT Overspeed
X X X
LowOilPressure
X X X
HighEngineTemperature X X X
5LIGHT Overcrank
X X X
Overspeed X X X
LowOilPressure X X X
HighEngineTemperature
X X X
LowEngineTemperature
X
5LIGHT Overcrank
X X X
PRE-ALARM Overspeed
X X X
LowOilPressure X *
X X
HighEngineTemperature X
*
X
X
LowEngineTemperature X
*- Withadditionaloptionalsensors.
ENGINE SENSORS
Resistanceunitsandswitchesintheengine
temperatureandoilpressuremonitoringandshut-
downsystemsaresealedunitsandarenotrepairable.
Forlocation,refertoFigures5 and6.Whenreplacing
asensor,donotsubstitute,userecommendeditems.
Resistanceunitsarematchedtothegaugethey
supply,andcut-offswitchesareclose-tolerance
actuationparts,madefora specificapplication.
HIGH
ENGINETEMPERATURE
CUT-OFFSWITCH
(HETCO)
LOWOIL
PRESSURE
SWITCH
(LOPKO)
B374 OILPRESSURE
GAUGESENDER
FIGURE5.OILPRESSUREMONITORS FIGURE6.ENGINETEMPERATUREMONITORS
12

INSTALLATION
GENERAL
Installationsmustbeconsideredindividually.Use
theseinstructionsasa generalguide.Allinstallations
mustmeetregulationsofstateandlocalbuilding
codes,fireordinances,etc.,whichmayaffectinstalla-
tiondetails.SeeFigures7 and8.RefertoONAN
TechnicalBulletinT-030forfurtherinstallationinfor-
mation.
Requirementstobeconsideredpriortoinstallation:
1. Levelmountingsurface.
2. Adequatecoolingair.
3.Adequatefreshinductionair.
4. Dischargeofcirculatedair.
5.Dischargeofexhaustgases.
6.Electricalconnections.
7.Fuelinstallation.
8.Watersupply(citywatercooling).
9.Accessibilityforoperationandservicing.
10. Vibrationisolation.
11. Noiselevels.
VENTILATION
Generatorsetscreateconsiderableheatwhichmust
beremovedbyproperventilation.Outdoorin-
stallationsrelyonnaturalaircirculationbutindoor
installationsneedproperlysizedandpositionedvents
fortherequiredairflow.SeeSPECIFICATIONSfor
theairrequiredtooperatewithratedloadunder
normalconditionsat1800r/min.
Radiatorsetcoolingairtravelsfromtherearoftheset
andisremovedbya pusherfanwhichblowsout
throughtheradiator.Locatetheairinlettotherearof
theset.
Locatethecoolingairoutletdirectlyinfrontofthe
radiatorandascloseaspossible.Theopeningfree
areamustbeatleastaslargeastheradiatorarea.
Lengthandshapeoftheairoutletductshouldoffer
minimumrestrictiontoairflow.Usea ductofcanvas
orsheetmetalbetweentheradiatorandtheairoutlet
opening. Theductpreventsrecirculationofheated
air.
LOCATION
Providea locationthatisprotectedfromtheweather
andisdry,clean,dustfreeandwellventilated.If
practical, installinsidea heatedbuildingforprotec-
tionfromextremeweatherconditions.
MOUNTING
Generatorsetsaremountedona rigidskidbase
whichprovidespropersupport.Theengine-
generatorassemblyisisolatedfromtheskidbaseby
rubbermountswhichprovideadequatevibration
isolationfornormalinstallations.Forinstallations
wherevibrationcontroliscritical,installadditional
spring-typeisolatorsbetweenskidbaseandfounda-
tion.
Forconvenienceingeneralservicingandchanging
crankcaseoil,mountsetonraisedpedestalatleast6-
inches(150mm)high.
Foroperationoutsidea building,a shelterhousing
withelectricallyoperatedlouvresisavailableasan
option. Transformersconnectedacrossthegenerator
outputsupplycurrenttothemotors.
Whenthegeneratorisoperating,currentinthe
transformersactuatethemotorsandopenthe
louvres.Thelouvresareheldopenforthedurationof
thesetoperation,thenareclosedbyreturnsprings
whenthesetisshutdown.
Citywatercooledsetsdonotusetheconventional
radiator.A constantlychangingwaterflowcoolsthe
engine.Sufficientairmovementandfreshairmustbe
availabletoproperlycoolthegenerator,disperseheat
convectedofftheengineandsupportcombustionin
theengine.• • • - "v.-•
Installationsrequireanauxiliaryfan(connectedto
operateonlywhentheunitisrunning)ofsufficient
sizetoassureproperaircirculationandevacuationof
fumes.
13

FILLPIPE
HOODEDVENT
^^^"^FUELLINE
FUELRETURNLINE
.^"'-Jf"' (FROMDAYTANKIFUSED)
FIGURE 7. TYPICAL INSTALLATION
•OASFUELREGULATOR
ELECTRICFUELSOLENOID
FUELSTORAGETANK
DRYFUELFILTER
SHUTOFFVALVE
1 |f
FIGURE 8. TYPICAL INSTALLATIONOFLPGWITHDRAWAL SYSTEM
14

COOLING SYSTEM
StandardRadiatorCooling,usesa setmounted
radiatorandenginedrivenpushertypefantocool
enginewaterjacket.Airtravelsfromthegenerator
endoftheset,acrosstheengineandoutthroughthe
radiator.Anintegraldischargeductadapterflange
surroundstheradiatorgrille.
HeatExchangerCooling(optional),usesa shelland
tubetypeheatexchangerinsteadofthestandard
radiatorandfan.Enginejacketcoolantcirculates
throughtheshellsideoftheheatexchanger,while
rawcoolingwaterispumpedthroughthetubes.
Enginecoolantandrawwaterdonotmix.Thistypeof
coolingseparationisnecessarywhentherawwater
containsscaleforminglime,orotherimpurities.
Thissystemreducessetenclosureairflowre-
quirementsandnoiselevels.Properoperation
dependsupona constantsupplyofrawwaterforheat
removal. Theenginecoolantsideofthesystemmay
beprotectedfromfreezing;therawwatersidecannot.
SeeFigure9 fortypicalinstallation.
EXPANSION
TANK
-»— HEATEXCHANGER
TnENGINE
FROM
ENGINE
J
DRAIN
SOLENOID
VALVE
(OPENSWHEN
SETISRUNNING)
ADJUSTABLE
VALVE
(RATEOFFLOW)ase
I^- CRATER
IN
STRAINER
FIGURE 9. TYPICAL HEAT EXCHANGER SYSTEM
StandpipeCooling(optional)substitutesa mixing
(tempering)tankforthestandardradiatorandfan.
Coolingwatercirculatingthroughtheenginejacketis
mixedwithrawwaterinthetank.Becauserawwater
flowsthroughtheenginejacket,itmustnotcontain
scaleformingimpuritiesorfoulingoftheengine
waterpassageswilloccur.Foulingresultsinengine
overheatingandcostlyrepairbills.
Thissystemreducessetenclosureairflowre-
quirementsandnoiselevels.Properoperationis
dependentonaconstantsupplyofcoolingwater.The
systemcannotbeprotectedfromfreezing.SeeFigure
10.
ANTI-SIPHON— r
MIXING
TANK-
STAND
PIPE
SOLENOIDVALVE
(OPENWHEN
SETISRUNNING)
WATE
I
DRAIN
FROM
ENGINE
•TOENGINE
•ADJUSTABLEVALVE
(RATEOFFLOW)
STRAINER
FIGURE 10. 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.Itiselectricallyoperatedandther-
mostaticallycontrolled.
15

Oirect FlowInstallation
Withthissystem,a cityorrawwatercoolingsupply
underpressureforceswaterdirectlyintotheengine,
throughtheengineandtotheoutlet.Anadjustable
valvecontrolstheincomingwaterflowratetoobtain
correctenginewatertemperature,asmeasuredat
enginecoolantwateroutletwhilethegeneratorsetis
operatingunderfull load. A solenoidvalveiscoor-
dinatedwiththegeneratorsetsystemtoopenduring
setoperation.
Restrictinletwaterpressuretoa maximumof
7psior48.3kPa,otherwiseenginegaskets
CAUTION
andsealswillleak.
Rawwatercoolingisoftenundesirablebecause:
1. Thewatersupplymustbeverycleanorengine
depositswillresult.
2. A hightemperaturedifferentialbetweenthecold
incomingwaterintotheengineandwarmdis-
chargedwatercanputdamagingstresseson
enginecomponents(nooveralluniformengine
temperature).
COOLING CONNECTIONS
Theradiatorcooled(standard)setdoesnotrequire
anyexternalconnectionsexceptasdiscussedunder
Ventilation.Allowclearancearoundthesetforaccess
toservicetheradiatorandfanbelts.SeeFigure7.
HeatExchangerandStandpipecooledsetsmustbe
connectedtoa pressurizedsupplyofcoldwater.
Makeconnectionstothesetwithflexiblepipeto
absorbvibration.Onthecoolwaterlineinstalla
solenoidvalvetoshutofftheflowwhenthesetisshut
downanda rateofflowvalvetocontrolengine
temperature.Thisvalvecanbeeithermanualor
automatic.Actualrateofflowwilldependoninlet
watertemperatureandapplied load.
Adjusttheflowtomaintainwatertemperature
between1650Fand195° F (73.9°C and90.6°C)while
viewingthewatertemperaturegauge.
Beforefillingcoolingsystemcheckallhardwareforsecurity.This
includeshoseclamps,capscrews,fittingsandconnections.Use
flexiblecoolantlineswithheatexchanger,standpipeorremote
mountingradiator.
Remoteradiatorplumbingwillvarywithinstallation.
Allsystemsmustcomplywiththefollowing
conditions—
1. Makeallconnectionstothesetandtotheradiator
withflexiblepipe.
2. Installanauxiliarycirculatingpumpifthe
horizontaldistancebetweentheengineand
pumpexceeds15-feet(4.65m).
3.Installa hot-wellsystemtorelieveexcessengine
waterjacketpressureifthetopoftheradiatoris
morethan15-feet(4.65m)abovethecenter-line
oftheenginecrankshaft.
16

EXHAUST
IWARNING
Inhalationofexhaustgasescanresultin
death.
Engineexhaustgasmustbepipedoutsidebuilding or
enclosure. Donot terminateexhaustpipenearinlet,
vents or combustiblematerials. An approvedthimble
(Figure 11) must be usedwhereexhaustpipespass
throughwalls or partitions.Pitchexhaustpipes
downward or install a condensationtrap(Figure 12)
atthepointwherea riseintheexhaustsystembegins.
Avoidsharpbends;usesweepinglongradiuselbows.
Provideadequatesupport for mufflers and exhaust
pipes. Refer to Figure 7 fora typicalexhaustinstalla-
tion. Shield or insulateexhaustlines 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 engine.
Suspend the pipefrom the enclosurestructure and
attach to enginewitha flexiblesection.Placemuffler
asclosetoengineaspossibletoreducecondensation
damage and carbonfouling.
IFEXHAUSTLINEMUST BE PITCHEDUPWARD.'
•CONSTRUCT A TRAP OF PIPEFITTINGS AT
POINT OF RISE
DRAINCONDENSATIONTRAP
PERIODICALLY
FIGURE 12.EXHAUSTCONDENSATIONTRAP
RAIN CAP
DRIP CAP
HOLES INENDOF
INNERSLEEVE
WALL OR PARTITION -"Jl
INNERSLEEVE
FIGURE 11. TYPICAL EXHAUSTTHIMBLE
Minimumdiameters and maximumlengths of pipe
(withcriticalmuffler[s]) areas follows:
SingleExhaustsystem:
2.5-inch (67 mm)pipe9-feet (3m)
3.0-inch (76 mm)pipe89-feet (27m)
3.5-inch (90 mm)pipe...... / 168-fee't(51 m)
Maximumpermissibleexhaustrestriction(back
pressure) is 20.4-inches(508 mm) H2Omanometer,
or11.8ounces(5.1kPa)gauge.
17

FUEL SYSTEM
FordenginesusedonEK/EMsetsaredesignedto
operateongasoline(averageregulargradeof93
octane), naturalgaswiththermalratingof1000
BTU/ft3(37.25MJ/m3)orliquefiedpetroleumgas
(LPG)Propaneat2500BTU/ft3(93.13MJ/m3).
FUEL CONNECTIONS
Beforestartinganytypeoffuelinstallation,ONAN
recommendsthattheregulationsdescribedin
Pamphlet58oftheNationalFirePreventionAssocia-
tion(NFPA)bestudied.Allpertinentstateandlocal
codes,mostofwhicharegovernedbyNFPA58,must
becomplied with, andtheinstallationmustbe
inspectedbeforetheunitisputinservice.
Fuelsunderpressure(e.g.naturalgasorLPG)must
becontrolledbya positiveshutoffvalve,preferably
automatic,inadditiontoanyvalveintegralwiththe
carburetororgasregulatorequipment.
Connectionofgasolinefuelinletlinerequiresa 1/8-
inchpipefittingtoanadapteronskidbase.
Lifttofuelpumpshouldnotexceed6 feet(2m),
horizontaldistancebetweensetandfueltankshould
notexceed50feet(15m).Use3/8-inchtubingupto
25feet(12.5m), 1/2-inch upto50feet(15m).
OptionalDayTank:Theenginemaybeequippedwith
aonequartreservoirtanktoreplenishfuellostfrom
thecarburetorbyevaporationduringshutdown.See
Figure13.Connecta 5/16-inchreturnlinebetween
thereservoiruppersidefitting(thisfittinghasa
restrictedorificeandmustbeused)andthemain
supplytank.Besurethereturnlinehasa continuous
droptothemainsupplytankwithnodip-and-nse
wherefuelcouldcollectandformavent seal. Seethat
thetopcenteropeningofthetankistightlyplugged.
NaturalorManufacturedGas:Onsetsequippedwith
anImpcocarburetor,gaspressureatthecarburetor
mustbesetat3-ounces(1.3kPa)gauge,or5-inch
(127mm)watercolumn,manometer,withtheengine
runningat1800 r/min onno load.
Thermaeregulatorisdesignedfora maximumlinepressureof6-
ounces(2.6kPa)gauge,or10.38-inches(263.6mm)watercolumn,
manometer.
Iflinepressureisexcessive,installasuitablepressure
reducingregulator.Besuretocomplywithalllocal
regulationssuchas:
•Recommendedelectricshutoffvalve.
•Handshutoffvalveatthefuelsource.
•Supplylinefilter.
Usea shortlengthofapprovedflexibleconnection
betweenthesupplypipeandthesetregulatorinlet.
CombinationGas-Gasoline:Combinationgas-
gasolinesetsaredesignedfornormaloperationon
gas fuel, withprovisionforemergencyoperationon
gasoline.Bothgasandgasoproceduresmustbe
followed. A reservoirtankissometimesprovided,soa
fuelreturnlinemaybenecessaryasdescribedfor
gasoline fuel.
BATTERY
Startingtheunitrequires12-voltbatterycurrent.Use
one12-volt(seespecification)batteryfora normal
installation.ConnectthebatteryasinFigure14.
Necessarybatterycablesareonunit.Servicebattery
asnecessary.Infrequentsetuse(asinemergency
standbyservice)mayallowbatterytoself-discharge
tothepointwhereitcannotstarttheunit.Ifinstalling
anautomatictransferswitchthathasnobuilt-in
chargecircuit,connecta separatetricklecharger.
Onanautomatictransferswitchesincludesucha
batterychargingcircuit.
WARNING\ Dono,snlokewhileservicingbatteries.Lea«S
^HMi^M^iacidbatteriesgiveoffexplosivegaseswhile
beingcharged.
RESERVOIR(DAY)TANKINSTALLATION
RESERVOIRTANK
RESTRICTED
OUTLET
RETURN_UNETO
UNDERGROUND
FUELTANK
LINEFROM
FUELPUMP
LINETO
CARBURETOR
STARTER
(AUTOMOTIVE) ENGINE
GROUND
12V.BATTERY(TYPE3EE)
72A.H.(25gkc)
FIGURE13.DAYTANKINSTALLATION FIGURE14.BATTERYCONNECTION
18