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
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(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