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Carrier ASPDS1CCL045 Owner's Manual

2.4l standby generator
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Serial Number

2.4L
45kW
Models: ASPDS1CCL045
ASPDA1CCL045
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
Not intended for use in critical life support applications.
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Catalog Number OMASPDS, A045-1

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Summary of Contents for Carrier ASPDS1CCL045

  • Page 1: Serial Number

    Serial Number 2.4L 45kW Models: ASPDS1CCL045 ASPDA1CCL045 STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability   Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Standby Generator Sets Table of Contents OPERATION ............9-1 SECTION PAGE SAFETY RULES ..........1-1 Generator Control and Operation ........9-1 Operating Unit with Automatic Transfer Switch ...9-1 INTRODUCTION .............1-3 MAINTENANCE .............10-1 Read this Manual Thoroughly ........1-3 Maintenance Performed by Service Facilities ....10-1 Operation and Maintenance ........1-3 Every Three Months ..........10-1 How to Obtain Service ..........1-3...

  • Page 3: Safety Rules

    Standby Generator Sets Important Safety Instructions   SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. ...

  • Page 4: Fire Hazards

    Standby Generator Sets Important Safety Instructions • Before performing any maintenance on the gen- • Generators installed with an automatic transfer erator, disconnect its battery cables to prevent switch will crank and start automatically when accidental start-up. Disconnect the cable from the normal (utility) source voltage is removed or is battery post indicated by a NEGATIVE, NEG or (–) below an acceptable preset level.

  • Page 5: Introduction

    Four commonly used safety symbols accompany the The Carrier Dealer is: DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows: Dealer Name ...

  • Page 6: Identification Record

    Standby Generator Sets General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular DATA LABEL model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data Every generator set has a DATA LABEL that contains label affixed to the unit.

  • Page 7: Equipment Description

    Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol rent generator set. It is powered by a gaseous fueled base anti-freeze and deionized water. Cooling system engine operating at 1800 rpm for 4-pole direct drive capacity is listed in the specifications.

  • Page 8: Engine Protective Devices

    Standby Generator Sets Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The standby generator may be required to operate for After a prespecified duration of cranking, this func- long periods of time without an operator on hand to tion ends the cranking if the engine has failed to monitor such engine conditions as coolant tempera- start.

  • Page 9: Fuel Systems

    Standby Generator Sets Fuel Systems FUEL SYSTEM • It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator. FUEL REQUIREMENTS • Gas pressure at the inlet to the fuel shutoff sole- The standby generator may be equipped with one of noid should not exceed approximately 14 inches the following fuel systems:...

  • Page 10: Specifications

    Standby Generator Sets Specifications SPECIFICATIONS COOLING SYSTEM Type ...........Pressurized Closed Recovery GENERATOR Water Pump ..............Belt Driven Type ................Synchronous Fan Speed .................2150 rpm Rotor Insulation ..............Class H Fan Diameter ..............22 inches Stator Insulation ..............Class H Fan Mode ................Puller Total Harmonic Distortion ............<5% Air Flow (inlet air including alternator and Telephone Interference Factor (TIF) ..........<...

  • Page 11: Cold Weather Kit

    Standby Generator Sets Specifications Figure 1 — Interconnections Utility In Transfer Switch CONTROL PANEL NEUTRAL ALTERNATOR NEUTRAL GENERATOR Load 4- # 14 GA CONNECTION CIRCUIT WIRES TO BREAKER GENERATOR CONNECTION Battery Charger Input GROUND TO GENERATOR 120 Volt + CONNECTION BOX Neutral To Generator Control Panel FRAME RAIL...

  • Page 12: General Information

    Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS FOUR-LEAD, SINGLE-PHASE STATOR Four-lead generators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were con- nected at the factory to the main circuit breaker as shown in Figure 7.1.

  • Page 13: Installation

    Standby Generator Sets Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide” supplied with the unit.  Prior to initially starting the generator, it must PREPARATION BEFORE START-UP be properly prepared for use. Any attempt to The instructions in this section assume that the crank or start the engine before it has been standby generator has been properly installed, ser- properly serviced with the recommended types...

  • Page 14: Start-Up Checklist

    Standby Generator Sets Installation START-UP CHECKLIST • Open the generator main line circuit breaker. • Connect a manometer to the gas line and record the static pressure. It must be as listed in the Specifications.  Before working on the generator, ensure the fol- •...

  • Page 15: Operation

    Standby Generator Sets Operation GENERATOR CONTROL AND OPERATING UNIT WITH AUTOMATIC OPERATION TRANSFER SWITCH Refer to the appropriate control panel operator’s If the generator has been installed with an automatic manual for this unit. transfer switch, such as an RTS, HTS, or GTS-type transfer switch, the engine may be started and stopped automatically or manually.

  • Page 16: Maintenance

    Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY COOLING SYSTEM Air intake and outlet openings in the generator com- SERVICE FACILITIES partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions as high grass, weeds, brush, leaves and snow. ...

  • Page 17: Battery Fluid

    Standby Generator Sets Maintenance EXERCISE SYSTEM Figure 10.1 - Oil Dipstick and Oil Fill Cap Start the generator engine at least once every seven Oil Fill Cap days and let it run at least 20 minutes. See “Weekly Exercise Cycle”. INSPECT COOLING SYSTEM Dipstick •...

  • Page 18: Changing Engine Oil

    Standby Generator Sets Maintenance CHANGING ENGINE OIL Figure 10.3 – Engine Air Cleaner Refer to maintenance performed by service facilities Air Cleaner for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning.

  • Page 19: Miscellaneous Maintenance

    Standby Generator Sets Maintenance MISCELLANEOUS MAINTENANCE BATTERY MAINTENANCE The battery should be inspected per the "Scheduled CLEANING THE GENERATOR Maintenance" section. The following procedure should be followed for inspection: Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- 1.

  • Page 20: Service Schedule

    Standby Generator Sets Service Schedule SERVICE SCHEDULE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 21 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date-...
  • Page 22 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date-...

  • Page 23: Troubleshooting

    Standby Generator Sets Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3.
  • Page 24 Standby Generator Sets Notes...
  • Page 25 Standby Generator Sets Notes...
  • Page 26 Standby Generator Sets Notes...
  • Page 27 Standby Generator Sets Notes...
  • Page 29 0F3137 PAN CB CONN BOX 0F3188 STAND RH CONTROL UL CIRCUIT BREAKER (JD+LD) 0F3189 STAND LH CONTROL 0F3329 COVER JD/LD CB SHRT STAND 023484N BUSHING SNAP SB-2.5-31 065469 DECAL DANGER HIGH VOLTAGE (3) 5 0F6366B 1 / 2 XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS) 0D5577 CB 0300A 3P 600V S JD6 LL 0F6366A...
  • Page 31 UL CIRCUIT BREAKER (QJ-2P) NEUTRAL BLOCK 390 / 200-400A 0F8137 COVER QJ 2P FRM CB 0D5466 BUS BAR NEUTRAL BLOCK 390 065469 DECAL, DANGER HIGH VOLTAGE 039287 SCREW HHC M8-1.25 X 45 G8.8 FT 0E7994 CB 0225A 240V 2P S QJ22 022145 WASHER FLAT 5/16-M8 ZINC 0F8136...
  • Page 33 INSTR HYPOT TEST (NOT SHOWN) SEE ENGINE EV ENGINE ADAPTER SEE ENGINE EV FLEXPLATE 0F5767B ASSY FLYWHEEL CPL W/40MM FAN B 0E5706 REAR BEARING CARRIER 390/DRCT 0F7874 ASSY BRUSH HOLDER 390/HSB 0G0587 GUARD REAR BEARING CARRIER 038150 WASHER FLAT #8 ZINC 023454...
  • Page 35 COMPONENTS INCLUDED IN 0G1290E 0F1823A ENCL HSB CONTROL PANEL 0F3078 COVER CONTROL PANEL 0F2606 HINGE CONTINUOUS H-PANEL 036261 RIVET POP .125 X .275 SS 043181 SCREW PHM M3-0.5 X 10MM 052777 WASHER FLAT M3 0G1303B ASSY PCB CPL2A CTRLR 3600 RPM 0F1262 HOLDER, FUSE WICKMANN 178.6150 0F1263...
  • Page 37 0F9517 WELDMENT FRAME 2.4L C2 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 39 0F3408B BATTERY TRAY C1 CPL 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 052212 SCREW HHC M10-1.25 X 25 G8.8 046526 WASHER LOCK M10 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLACK - 038805Y CABLE BATTERY BLACK #1 X 18.00 03880400AE...
  • Page 41 0E6586 GASKET BOSCH 32 & 40 0E0519A ADAPTER CARBURETOR W/PVC CONN 0C8127 ELEMENT AIR CLEANER 052619 SCREW HHC M5-0.8 X 20 G8.8 022127 NUT HEX 1/4-20 STEEL 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 0G0190 PLATE, AIR CLEANER TOP 2.4L 037561 NUT WING 1/4-20 NYLK 022097...
  • Page 43 0G1008 ENGINE 2.4L G2 (REWORK) 046526 7 (REF) WASHER LOCK M10 039414 4 (REF) SCREW HHC M8-1.25 X 35 G8.8 0G0149 1 (REF) SCREW SHC M14-1.5 X 35 G10.9 0E9868A 1 (REF) ALTERNATOR DC W/OUT PULLEY 0F3217 1 (REF) SPACER DC ALTERNATOR PULLEY 042574 1 (REF) ADAPTOR 1/8NPTF TO 1/8BSPT...
  • Page 45 0F9529 WELDMENT RADIATOR SUPPORT 2.4L 0F2572 ARM TENSIONER 0F2608 RADIATOR 598 X 568 X 49 CPL RH 045757 SCREW HHC M6-1.0 X 25 G8.8 0F5263 V-BELT 31/64" X 57-3/8" 0F2862 SPRING TENSION CPL 046526 WASHER LOCK M10 0F2560 PULLEY V-BELT 4" FLANGED 059981 SCREW HHC M10-1.5 X 30 G10.9 022131...
  • Page 47 026915 NIPPLE CLOSE 3/4 X 1.375 075580 FLANGE FUEL INLET 0F6390B REGULATOR ASSY 2.4L 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16-M8 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 040173 CLAMP HOSE #5.5 .62-.62 0E8286 STREET EL 45D 1/2 NPT BRASS 026812...
  • Page 49 0G0045 (XX) REAR WRAP C2 CPL 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F5849 (XX) DOOR C2 087233 RIVET POP .1875 X .450 SS 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W 0F5852 (XX) DISCHARGE DUCT LH & RH SIDE C2 0F9833 (XX) FRONT CORNERS C2 0F5851 (XX)
  • Page 51 0F9794 MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT 0G0113 EXHAUST ELBOW 2 1/4 OD 2 1/2OD 0G1007 BRACKET MUFFLER 0F2830 MUFFLER BRACKET STIFFENER 0F2962 MUFFLER STRAP 080762 BOLT U 3/8-16 X 2.62 0E0170A EXHAUST BLANKET 988MM (C2) 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G0776 PIPE EXHAUST G2 0G0007...
  • Page 63 C2 UNITS 0F9832 SHIELD CONN BOX C2 0F9832GGS0R SHIELD CONTROL STAND C2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS C3 UNITS 0F9832B SHIELD CONTROL STAND C3 0F9832KGS0R SHIELD CONTROL STAND C3 0C2454 SCREW THF M6-1 X 16 N WA Z/JS C4 UNITS 0F9832A SHIELD CONTROL STAND C4...
  • Page 64 "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Carrier warrants that its generator will be free from defects in material and workmanship for the items and period set forth below. Carrier will, at its option, repair or replace any part which, upon examination, inspection and testing by a Carrier Dealer, is found to be defective.

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