Onan EM Series Instruction Manual

•0(3

®•

RATOR'S

MANUA

AND

FOR

EK-EM

SERIES

ELECTRIC

GENERATING

BEGIN

SPEC.

't'-i

928-0302 PrintedinU.S.A

'..^0jS-.©^'Cf=75

(R e

pTa-c

e s..4C

ETIC.E.T

3 )

TABLE

CONTENTS

TITLEPAGE

Introduction1

SafetyPrecautions2

Specifications

Description.

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

symbol

manualto

alinjury.

rxrr^T^r?

This/Symbol>e|ers

possible

l£Ayi!ONiequ/pmentdamage.

MODEL

IDENTIFICATION

IdentifyyourmodelbyreferringtotheMODELand

SPECIFICATIONNO.asshownontheOnan

nameplate.Electricalcharacteristicsareshownon

thelowerportionofthenameplate.

30.0EK15R/ 1 G

•T

1 4 5

IndicatesKilowattrating(30kW).

FactorycodeforSERIESidentification.

3.15= 60Hz.Reconnectible

515= 50Hz.Reconnectible

R—Indicatesremotestartingfeature.

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

conditionsthatcouldresult

danger

you

the

equipment,

the

notice

ignored.

ONANrecommendsthat

you

readyourmanual

and

becomethoroughlyacquaintedwith

itand

your

equipmentbefore

you

startyourunit.

Theac-

cumulatedexperience

ONANengineers

available

you,enabling

you

operateyourset

themostefficientandsafestmannerpossible.These

recommendations

andthe

followingsafety

precautions

arefor

yourprotection.Studyandknow

them!

REMEMBER.Mostaccidentsarecaused

failure

followsimple

and

fundamentalsafetyrules

precautions.

MosX accidents

can be

prevented!

KNOW

YOUR

MANUAL—KNOW

YOUR

EQUIP-

MENT

not

stand

ona

wet

floorwhileworking

electricalequipment.Userubberinsulativemats

placed

ondry

woodplatforms.

WARNING Setforthbelow

area

number

potential

hazardswhichcouldresult

somedegree

personalinjury.Thesuggestedproceduresshould

adhered

to.

General

•Keepyourelectricgenerating

set

and

the

sur-

roundingareaclean

and

freefromobstructions.

Remove

alloil

deposits;keep

the

floorclean

and

dry.

•Provideappropriatefireextinguishersandinstall

them

convenientlocations.Consultyourlocal

firedepartment

forthe

correcttype

ofex-

tinguisher

use.

Donotuse

foam

electrical

fires.

Use

extinguisherrated

ABC

NFPA.

•Makesurethatallfastenersonthegenerating

set

aresecure.Tightensupports

and

clamps,keep

guards

positionoverfans,drivingbelts,

etc.

•

Donot

wearlooseclothing

inthe

vicinity

movingparts,

jewelrywhileworking

elec-

tricalequipment.Looseclothingandjewelrycan

becomecaught

movingparts.Jewelry

can

short

out

electricalcontacts;causeshock

burning.

•

necessary

makeadjustmentswhiletheunitis

running,

use

extremecautionwhenclose

hot

exhausts,movingparts,

etc.

FuelSystem

•

NOT

fillfueltankswhileengine

running,

unlesstanks

are

outsideenginecompartment.

Fuelcontactwith

hot

engine

exhaust

isa

potentialfirehazard.

•

DONOT

SMOKE

USE

OPENFLAME

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

approvedflexibleline.

Donotuse

copperpipingonflexiblelinesascopperwillwork

harden

and

becomebrittle.

•Yourengineinstallationshouldbeequippedwith

ameans

positivefuelshutoff

applications

whenfuel

conductedfrom

remotesource.

Fuelsunderpressure(e.g.naturalgas

liquefied

petroleumgas)shouldbecontrolledbya positive

shutoffvalve,preferablyautomatic,

addition

anyvalveintegralwith

the

carburetor

orgas

regulatorequipment.

ExhaustSystem

•Exhaustproducts

ofany

internalcombustion

engine

are

toxicand

can

causeseriouspersonal

injury,

inhaled.

All

engineinstallations,

es-

peciallythosewithin

confine,should

equippedwith

exhaustsystem

discharge

gases

tothe

atmosphere.

Donot

use

exhaust

gases

heat

compartment.

•Inspectexhaustsystemregularly

assurethat

system

free

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)

1-phase

1610Ib(730kg)

SERIES

EK"

TABLE

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

115/230 50Hz 1

136*

x H6

120/240 60Hz 1

156* X

110/190 50Hz

115/200 50Hz

120/208 50Hz

87,

120/208 60Hz

104

110/220 50Hz

127/220 50Hz

127/220 60Hz

115/230 50Hz

120/240 60Hz

139/240 60Hz

220/380 50Hz

230/400 50Hz

240/416 50Hz

240/416 60Hz

254/440 50Hz

254/440 60Hz

277/480 60Hz

9X H5—Not

347/600 60Hz

36 Reconnectible

3 H5—Not

120/240 60Hz 1 156 Reconnectible

30kW37.5kVA60Hz

25kW31.25kVA50Hz

-Thesecurrentvaluesareavailableonlyfromspeciallongstackunits(B125option).Whenstandard3 phase

unitisconnectedintoDoubleDeltaconfiguration,maximumcurrentis2/3thatofvaluegiven.

SERIES

TABLE

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

115/230 50Hz 1

204*

.H6

120/240 60Hz 1

234*

110/190 50 Hz

142- r

115/200 50 Hz

135 -

120/208 50 Hz

130

120/208 60 Hz

156*

110/220 50 Hz

123

127/220 50 Hz

123-

127/220 60 Hz

148

115/230 50 Hz

118-

120/240 60 Hz

135

139/240 60 Hz

135-

220/380 50 Hz

71-

230/400 50 Hz

68—

240/416 50 Hz

240/416 60 Hz

78 "

254/440 50 Hz

254/440 60 Hz

277/480 60 Hz

68-

9X H5—Not

347/600 60Hz

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,

PHASE,

HERTZ

347/600

VOLT,3PHASE,

HERTZ

NAMEPLATEVOLTAGECODE

•TO

CONNECTLEAD

FROM

TERMINAL

63TOH5

NAMEPLATEVOLTAGECODE

.T2

•)

CONNECTLEAD

FROM

T3|

TERMINAI63TOH5

THIS

DIAGRAM

APPLIES

TO12

LEADGENERATORSONLY

fe:

SIS

S15

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

T2T6TilT8

T12

T4T9TST7T3TIO

TIOT6T7T2TilT4TBT3T12TST9

CT22

T6Til

TIOT12

CT21

CT22

TlO

TilT12TlT7T4T2T8TST3T9T6

9BC2193

FIGURE

OPTIONAL

VOLTAGE

CONNECTIONS

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