Onan Ensign 4500 User manual

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MCE
Ensign Series 4500/6500
Printed in U.S.A. 927-0600
8-93

Safetv Precautions
Before operating the generator set, read the Operator's
Manualandbecomefamiliarwithitandyour
unit. Safe andeffl-
cient operation can be achieved only if the unit is properly
operated
and maintained. Many accidentsarecaused byfail-
ure to follow fundamental mles and precautions.
Thruugkout
this manualyou will noticesymbolswhichalert you
to potenliaHy dangerousconditions to theoperator,service per-
sonnel, or the equipment itself.
. l' This symbd warns of immediate haz-
ards which wiil result in severe personal fnjury or
death,
EWARtMG, This symbol refersto a hazardorunsafe
practicewhichcanresuitinseverepersonalinjury
or
death.
l%~cAu-tror\l Thls symbol refers to a hazard or unsafe
practh? whichcanresultinpersonalInjuv or prod-
oct
or property damage.
FUEL, ENGINE OIL, AND FUMES ARE FLAMMABLE AND
TOXIC.
Fire, explosion,andpersonalinjurycan resultfrom im-
proper practices.
Benzene and lead, found
in some gasoline, have been
identified
by some state and federal agencies as causing
cancer
Or reproductive toxicity. When checking,draining
or adding gasoline, take care not
to ingest, breathe the
fumchs, or contact gasoline.
Used engine oils have been identified by some state or
federal agencies as causingcancgr or reproductive toxic-
ity.
When checkingorchangingengine oil, take care not to
ingest, breathe the fumes, or contactused oil.
Do not fill fueltankswiththeengine running. Do not smoke
around
the generator set area. Wipe up any oil or gas
spills.
Do not leave oily rags in enginecompartment or on
the generator set. Keep this and surrounding area clean.
InsprxAfuel
system beforeeachoperationand periodically
while running.
Equip the engine fuel supply with a positive fuel shutoff.
Always disconnect the battery ground (-) lead first and re-
conmct it last. Make sure you connect the batlery cor-
rectly.
A direct short across the battery terminals can
CPUSCI anexplosion. Do not smokewhile servicingbatter-
ies. Hydrogen gasgiven off during charging is very explo-
sive.
Keep a fire extinguisher available in or near the engine
cornpa-tment and
in other areas throughout tke vessel.
Use the correct
ex?inguisher for the area. For most types
of fires, an extinguisherrated AB6 by the NFPA is avail-
able ancl suitablefor use on all types of firesexceptalco-
hol.
EXHAUST GASES ARE DEADLY
e Provide adequateventilation. Equipthebilge with a power
exhauster.
Be surepropuhion and generatorset engineexhaust zys-
ternsare free of leaks. Perform thorough, pcriodrc in:pec-
tions
of the exhaust system and repair leaksimmedistsly.
E:<haust
gases are deadly.
Never sleep in the vessel with the generator set running
unless the vessel is equipped with an operating carbon
monoxide detector.
,
HOT COOLANT CAN CAUSE SEVERE PERSONAL
INJURY
Hot coolant is under pressure. Do not loossn the coolant
pressure
cap while the engine is hot. Let the engina coal
before opening the pressure cap.
MOVING PARTS CAN CAUSESEVERE PERSONAL
INJURY OR DEATH
Do not remove any belt guardsor covers with the genm-
tor set
running.
Keep hands and loose clothing awayfrom moving parts.
Do not wearjewelry while servicing any part of the genera-
tor set.
Never step
on thegsneratorset(aswhenentering or leav-
ing the enginecompartment). It canstressand break unit
components, possible resulting in dangerous operating
conditions.
. from leaking fud, leaking exhaust fumes,
etc.
Before performing any maintenanceon thegerierator cet,
disconnect its batteriesto prevent accidentalstarting. do
not disconnector connectbattery cables if fuel vapors are
present. Ventilatethe generator set compartmentor bilge
thoroughly with the power exhauster.
ELECTRICAL SHOCK WILL CAUSE SEVERE
PERSONAL INJURY OR BEATH
Do not make adjustments in the controlpanel or on engine
with
unit running. High voltages are present. Work that
must be done while unit is running should be doneonly by
qualified service personnel standing on dry surfaces to re-
duce shock hazard.
.
DO NOT CONNECT THE GEldEFWTOR SET TO THE
PUBLIC UTILllY OR TO ANY OTHER ELECTRICAL
POWER SYSTEM. Etectrocuti n or damage to property
can occur
at a sita remote from the boat where line cor
equipmentrepairs are being made if the st is connected
tothe
power system. An approved bander switch mu3 be
used if more than one power source iz to be made avail-
able to servicethe boat.
Do not workonthisequiprnentwhen ~enfa:llyor physically
fatigued,
or after consuming any alcohol or drug that
makes
the operation of equipmmt unsafe.
bit 8
Copy and post these suggestloris in potential hazard areas of the vessel.

Table of Contents
SECTION TITLE PAGE
1 .
2 .
3 .
4 .
5 .
6 .
7 .
8 .
9 .
10 .
SAFETY PRECAUTIONS ............................... Inside Front Cover
INTRODUCTION ................................................... 1-1
General ......................................................... 1-1
Installation Codes and Safety Recommendations ........................ 1-1
Generator Details ................................................. 2-1
Engine Details
................................................... 2-1
Location ........................................................ 3-1
Mounting
........................................................ 3-1
General
......................................................... 4-1
Requirements .................................................... 4-1
Coast Guard and NFPA Requirements ................................ 4-1
General ......................................................... 5-1
Heat Exchanger Cooling ............................................ 5-1
SPECIFICATIONS .................................................. 2-1
LOCATIONAND MOUNTING ......................................... 3-1
VENTILATION ..................................................... 4-1
COOLING SYSTEM ................................................. 5-1
SeaWater Cooling
................................................ 5.3
Combined Cooling Systems ......................................... 5.3
EXHAUST SYSTEM ................................................ 6.1
General
......................................................... 6. 1
Below Load Waterline Installation
.................................... 6-3
Above Load Waterline Installation .................................... 6-4
FUELSYSTEM .................................................... 7.1
General ......................................................... 7-1
Installation
...................................................... 7.1
Fuelianks ...................................................... 7.2
Fuel tines
........................................................ 7.3
SiphonProtection
................................................. 7-3
FuelSystemTest ................................................. 7-3
ELECTRICALSYSTEM .............................................. 8-1
General
......................................................... 8-1
Load Connections .................................................. 8-1
Remote Starting Controls ........................................... 8-4
Batteries ........................................................ 8-4
Installation
Checks ................................................ 9.1
Initial Starting and Checks .......................................... 9-1
FINAL INSTALLATIONCHECKS ...................................... 9.1
DC WIRING DIAGRAM ............................................. 10-1
i

Section 1. Introduction
GENERAL
Eachmarinegeneratorset mustbeinstalledproperly if it
is to operate reliably, quietly, and most important -
safely. Therefore, readthisentire manual beforestarting
the installation. The manual should be used only as a
guide as each installation must be considered on an
individualbasis. Foroperationand maintenanceproce-
dures, refer to the MCE Operator‘s Manual 927-0124
which accompanieseach unit
Proper installation is very important Requirements to
consider should include:
Adequate cooling air
a Adequate combustionair
a Discharge of exhaust gases
a Discharge of circulatedair
Electricalconnectionsand bonding
Fuelconnections
Seawater connections
a Accessibility for operationand servicing
a Level mountingsurface
a Adequate support under mounting points
a Noiselevels
INSTALLATION CODESAND SAFETY
RECOMMENDATIONS
The insthation must follow recommendations of the
American Boat and Yacht Council (ABYC) and the
National FireProtectionAssociation (NFPA).
The installer should be familiar with and follow the
appropriate guidance found in the following
publications:
ABYC
“Safety Standards for Small Craft”from:
ABYC
15 East 26th St
NewYork, NY 10010
NFPA302 “Fire Protection Standard for Motor Craif”from:
NFPA
470 AtlanticAvenue
Boston, MA
02210
USCG 33CFR183from:
U.S. GovernmentPrintingOffice
Washington, D.C. 20404
~AWARNING 1
INCORRECT SERVICE OR REPLACEMENTOF PARTSCANRESULT IN SEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENTDAMAGE. SERVICE PER-
SONNELMUSTBE QUALIFIEDTOPERFORMELECTRICALAND/OR MECHANI-
CALSERVICE.
1 =I

Section 2. Specifications
GENERATOR
Type ................................................ RevolvingField,4-Pole, Self-Excited
Standby Ratings:
60 Hertz, 6.5 MCE
........................................... 6.5 kW, (6.5 kVA @ 1.0 PF)
60 Hertz, 4.5 MCE
........................................... 4.5 kW, (4.5 kVA @ 1.0 PF)
50 Hertz, 5.0 MCE ........................................... 5.0 kW, (5.0 kVA @ 1.0 PF)
AC VoltageRegulation
............................................................. +5%
Frequency Regulation ...................................................... .5% (3 Hertz)
ENGINE
EngineType ............................................ Onan@MCE, 2-Cylinder Opposed
EngineSpeed (r/min)
......................................................... I800/1500
Exhaust Outlet HoseSize
............................................... .2.0 in. (50.8 mm)
Fuel..
.............................................................. Unleaded, 88 octane
FuelInletSize..
............................................................ .1/4-18 NPT
FuelConsumption, Average
@ FullLoad:
60 Hertz, 6.5 MCE
.................................................... 1.3 gph (5.0 Lph)
60 Hertz, 4.5 MCE
.................................................... 1.6 gph (6.1 Lph)
50 Hertz, 5.0 MCE .................................................... 1.1 gph (4.2 Lph)
FuelInletSize..
......................................................... 1/4-18 NPTF
FuelReturnOutletSize
................................................... .1/8-27 NPT
MinimumColdCrankingAmps
@ 0°F (-18°C). ...................................... 360
Voltage
........................................................................... 12
Capacity, Heat ExchangerSystem.. .................................... .10 Quarts(9.4 L)
Heat Rejection:
60 Hertz
@ Load, Block & Exhaust Manifold.. ............................ 800 BTU/min
50 Hertz @ Load, Block & ExhaustManifold.. ............................ 650 BTU/min
HeatExchangerSystem,ThermostatOpen
......................... .2.2 gpm (8.3 L/min)
Sea Water, HeatExchangerSystem
.............................. .3.0 gpm (11.4 L/min)
SeaWater CoolingSystem
...................................... -3.0 gpm (1 1.4 L/min)
Heat ExchangerSystem,ThermostatOpen
......................... .2.2 gpm (8.3 L/min)
SeaWater, HeatExchangerSystem
............................... .2.5 gpm(9.5 L/min)
SeaWater CoolingSystem
....................................... .2.5 gpm (9.5 L/min)
SeaWater Pump
Dry Lift, Maximum ............................................ 3 ft (0.9 m)
TotalAir Required(Generator Coolingand Combustion):
60 Hertz..
.................................................... .146 ft3/min (4.1 m3/min)
50 Hertz .................................................... 120cu. ft./min (3.4 m3/min
EngineOil Capacitywith Filter
............................................ .3Quarts (2.8 L)
Battery Requirements:
CoolingSystem:
CoolingFlow Rate, 60 Hertz:
CoolingFlow Rate,
50 Hertz:
2-1

Section 3. Location and Mounting
LO CAT1 ON
Generatorsetlocationispreferableinthesameroomor
compartmentasthepropulsionengine,asthisisusually
a
well ventilatedarea,insulated,closetothefuelsupply
andisthecenterofelectricalloaddistribution. However,
a generator set cannot be installed in the propulsion
enginecompartmentunlessspecificconditionsaremet.
USCG regulation 33CFR183 pertainsto gasoline fuel
systems, and requiresa generator set operating in a
gasoline fuel environment to be “ignition protected.”
This means aset capableof operatinginan explosive
environmentwithoutignitingthatenvironment. Properly
installed and operated, the
MCE generator set can
operate inan explosive environment.
Gasolinefireorexplosioncanresult
inseverepersonaliniuryordeath.
Do
notinstallagasolinegeneratorsetinthesameroomor
compartment
of a dieselpropulsionengineorgenerator
set. Thediesel unitmay not be ignifionprotected and
mayignitegasolinefumes.Besure
a gasolinegenerator
set
is insfalledin its own room or compartment.
MOUNT1 NG
Thefloormustbeflatandgivesupportdirectlyunderthe
genset mounting points (Figures
3-1 and 3-2). A one
inch
(25 mm) clearance aroundthe unit is requiredto
permit rockingon its mounts without restraint; and
4.2
inches (106 mm) for servicingthe oil filter. Additional
spacemustbeallowedforproperventilationforcooling
and combustion,as well as serviceaccess.
Also allow
accessfor periodicmaintenancesuchasoilfill,coolant
fill, spark plug replacement, etc. The entire exhaust
system must be accessible
so a periodic visual and
audiblecheckfor leakagecanbemadebytheoperator.
Install
two hold-downclampsortwothroughboltstothe
drippanon bothsidesof thegeneratorset.Tightenthe
clamps securelyto the mounting base with bolts and
flatwashers.
Selecta locationthat will allow adequate space on all
sidesfor ventilationand servicingtheset, preferablyon
andparallelwiththekeelorvessel center line. Keepthe
generator set awayfrom livingquarters, andaway from
bilgesplash and vapors.
3-1