User's Manual

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Owner’s Manual

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

This manual should remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model No. ASPAS1BBL025 (25kW)

Summary of content (56 pages)

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Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model No. ASPAS1BBL025 (25kW) This manual should remain with the unit.
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INTRODUCTION Thank you for purchasing a Bryant home standby generator system. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
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Table of Contents Bryant Liquid-cooled 25 kW Generator INTRODUCTION ................................................IFC Section 3 — OPERATION ................................12 Read this Manual Thoroughly......................................IFC 3.1 Engineered GTS Transfer Switch ........................12 Operation and Maintenance ........................................IFC 3.2 Control Console Components..............................14 How to Obtain Service ........................................
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Important Safety Instructions Bryant Liquid-cooled 25 kW Generator ! 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. ! SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
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Important Safety Instructions Bryant Liquid-cooled 25 kW Generator • • • • • • • • • place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard. Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.
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Section 1 - General Information Bryant Liquid-cooled 25 kW Generator 1.1 GENERATOR 1.3 AUTOMATIC SYSTEM OPERATION This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only.
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Section 1 - General Information Bryant Liquid-cooled 25 kW Generator 1.6 GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is preferred, refer to Section 1.12, Reconfiguring the Fuel System for LP Vapor. Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges. 1.7.1 LOW OIL PRESSURE SWITCH This switch is normally-closed (N.C.
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Section 1 — General Information Bryant Liquid-cooled 25 kW Generator Figure 1.6 - Low Coolant Level Sensor 1.9 ! LIFTING THE GENERATOR When lifting or hoisting equipment is used, be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking. 1.10 SPECIFICATIONS 1.7.
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Section 1 — General Information Bryant Liquid-cooled 25 kW Generator * Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors. Engine power will decrease about 2.5% for each 1000 feet above 500 feet and will decrease an additional 2.5% for each 10°F above 104°F. Maximum output power of the generator is limited by maximum engine power. Figure 1.8 — Reconfigure the Fuel System Port 2 Port 1 PLUG 1.
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Section 2 — Installation Bryant Liquid-cooled 25 kW Generator 1.14 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti-freeze and half deionized water. Cooling system capacity is about 8 U.S. quarts (7.6 liters). Use only deionized water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.
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Section 2 — Installation Bryant Liquid-cooled 25 kW Generator • AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 909 University Avenue, Columbia, MO, 65201. • ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085. • A52.
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Section 2 — Installation Bryant Liquid-cooled 25 kW Generator 2.6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed, the “Total Circuit Isolation Method” may be used. The following apply to the transfer switch in this type of system. • Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service.
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Section 2 — Installation Bryant Liquid-cooled 25 kW Generator Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated.
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Section 3 - Operation Bryant Liquid-cooled 25 kW Generator 2.11.2 TRANSFER SWITCH If this generator is used to supply power to any electrical system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems, (for additional information, see the applicable transfer switch manual for this unit).
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Section 3 - Operation Bryant Liquid-cooled 25 kW Generator 3.1.3 15 AMP FUSE 3.1.6 SYSTEM READY LED This fuse protects the control console’s DC control circuit against electrical overload and is located inside the control panel. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse (type ATO). The System Ready LED (green) has two main proposes.
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Section 3 - Operation Bryant Liquid-cooled 25 kW Generator 3.2 MANUAL TRANSFER AND START-UP To transfer electrical loads to the Standby (EMERGENCY) power source side and start the engine manually, refer to the Owner’s Manual of the particular transfer switch. 3.3 ENGINE GOVERNOR ADJUSTMENTS Engine speed governing is also controlled by the engine control board. The engine governor has been set by the factory during final testing of the generator and should not be adjusted.
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Section 3 - Operation Bryant Liquid-cooled 25 kW Generator 2. Press and hold the “Set Exercise” switch for five seconds, then release. At this time all five red LEDs will flash for approximately 10 seconds, then the engine will start and run for it’s 12 minute exercise period, then shut down. The generator will now start and run each week at the same time. 3.7 CONTROL BOARD DIP SWITCH SETTINGS Located on the control board is an eight position DIP switch (see Figure 3.2).
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator 4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHS 1. 2. 3. 4. 5. 6. Check battery condition. Inspect and test fuel system. Check transfer switch. Inspect exhaust system. Check engine ignition system. Check fan belts. B. ONCE EVERY SIX MONTHS 1. Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature). 4.3 INTAKE MANIFOLD PROCEDURE 1.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator 4.5 COOLING SYSTEM Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.) • Remove oil dipstick and wipe dry with a clean, lint-free cloth.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator 4.8.5 CHECK ENGINE COOLANT LEVEL See “Checking Fluid Levels”. 4.8.6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks. 4.8.7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator 4.8.13 COOLANT CHANGE 4.9.3 Every year, have a Bryant dealer drain, flush and refill the cooling system. See “Specifications” for cooling system recommendations. The battery should be inspected per Section 4.7, Scheduled Maintenance. The following procedure should be followed for inspection: 4.9 MISCELLANEOUS MAINTENANCE 4.9.1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator 4.9.4 BATTERY REPLACEMENT When replacing batteries, use the same number and the type of battery that follows: BCI Group No. 26 CCA 525 @ 0 deg. F NOTE: The BCI number should be located directly on the battery.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator 4.10 SCHEDULED MAINTENANCE 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. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator Maintenance Tasks 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level. Correct as necessary. 5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary. 6. Check the air inlets and outlets for debris. Clean as necessary. 7.
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Section 4 — Maintenance Bryant Liquid-cooled 25 kW Generator Maintenance Tasks Level 1 Recommended to be done monthly Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in Level 3 Task Comp. (DateInitials) Required to be done Semiannually Level 4 Task Comp. (DateInitials) Required to be done Annually Task Comp. (DateInitials) 13.
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Section 5 — Troubleshooting Bryant Liquid-cooled 25 kW Generator TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5. Remove, change or replace battery. 6. Replace fuse.
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Section 6 — Notes Bryant Liquid-cooled 25 kW Generator Bryant 25
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Section 6 — Notes Bryant Liquid-cooled 25 kW Generator 26 Bryant
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Section 6 — Notes Bryant Liquid-cooled 25 kW Generator Bryant 27
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine — Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine — Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L Engine — Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L Engine — Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No.
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Section 7 - Electrical Data Bryant Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No.
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36 Bryant 3 2 PANEL BOTTOM 3 15 14 13 12 11 1 4 5 35 3 1 10 36 10 REAR BEARING CARRIER 15 14 13 12 11 3 2 6 8 3 9 21 22 27 23 1 26 33 20 25 24 34 3 29 28 3 30 29 6 TO STARTER BOLT TO ENGINE BLOCK 19 17 32 2 O MOUNT 16 HARNESS WIRE TO STARTER Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Mounting Base — Drawing No.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Mounting Base — Drawing No. 0E9964-E ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 PART NO. 0D9336 0E9939 0C2454 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0E9941 025507 059980 046526 022131 021991 038805J 050331 050331A 038804J 045771 022129 027482 075763 0E9748 0E9940 065852 024469 QTY.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Enclosure — Drawing No. 0F4568-B WELD STUD UNDER ROOF PANEL FOR ACCESS COVER CABLE 21 4 29 36 1 13 14 15 11 41 16 11 "Y" 26 10 10 2 37 3 34 40 26 "Y" 17 18 3 35 20 19 11 4 35 3 33 2 29 11 9 15 8 26 15 24 10 19 6 25 11 17 24 18 3 30 26 17 10 32 25 5 38 31 7 11 38 Bryant NOTE: USE DOOR LATCH FASTENER TO SECURE GROUND WIRE. NOTE: USE LOCTITE ON NUTS ITEM #26.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Enclosure — Drawing No. 0F4568-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 PART NO.
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5 19 40 40 Bryant 14 32 15 1 14 4 10 1 44 13 2 TO "A" 26 14 48 41 33 4 24 52 50 7 27 3 36 9 35 34 43 54 21 35 34 "A" 31 33 29 22 65 30 17 34 3 23 37 16 56 5 0 12 35 36 34 35 6 54 64 18 14 11 38 39 Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Control Panel — Drawing No.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Control Panel — Drawing No. 0E9719-E ITEM PART NO. QTY.
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30 42 Bryant 41 20 30 19 20 29 27 60 39 59 28 38 19 20 14 39 16 52 40 25 38 4 10 13 2 0 17 15 22 31 5 19 45 19 3 47 FOR HARNESS GROUND 20 HSG. 20 3 68 34 17 22 15 1 50 35 49 39 16 65 33 15 8 66 67 18 20 12 61 37 "A" 57 16 11 18 62 17 58 38 TO RADIATOR CAP 39 24 23 STEPPER MOTOR UNITS ONLY Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Engine — Drawing No.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Engine — Drawing No. 0E9918-F ITEM PART NO. QTY.
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44 Bryant 12 TO VALVE 1 COVER 17 20 28 TO ENGINE 10 32 31 8 33 18 42 30 6 26 7 35 22 21 38 34 16 24 25 13 9 41 PORT "OUT 2" 3 11 4 15 29 CARBURETOR ASSY. 0E1028A (I/N 19) L.P. VAPOR CONVERSION 40 5 27 1 4 6 3 40 11 2 PORT "OUT 1" 6 7 Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Fuel System — Drawing No.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Fuel System — Drawing No. 0E9980-D ITEM 1 2 3 4 5 6 7 8* 9 10 11 12 13 14 15 16 * 17 18 19 20 21 * 22 * 23 24 25 26 27 28 29 30* 31* 32* 33* 34* 35* 36* 37* 38* 39* 40 41 42 PART NO.
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Section 8 - Exploded Views and Parts 12 8 7 5 18 46 Bryant LOCKTIGHT 15 7 17 1 4 16 31 30 LEADS 2 6 9 21 13 LOCKTIGHT 3 10 11 20 19 14 Bryant Liquid-cooled 25 kW Generator Alternator — Drawing No.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Alternator — Drawing No. 0F5092 ITEM PART NO. QTY.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Muffler — Drawing No. 0F2930-B 1 5 4 24 6 7 11 3 17 19 20 13 15 20 12 11 20 5 7 4 6 18 6 15 14 16 9 8 10 2 21 22 23 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. 0F2912 0F2869 0F2823 036434 036449 022129 022259 0E0170A 044149 0E8816 0F2925 0F2926 48 Bryant QTY. 1 1 1 2 2 6 4 1 1 1 2 1 DESCRIPTION PIPE MUFFLER OUT PIPE EXHAUST 2.5L FORD MUFFLER 2.5L FORD BOLT U 5/16-18 X 2.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Stepper Motor — Drawing No. 0E9979-C 5 4 3 ITEM (13) NEOPRENE COATING 2 1 14 6 7 10 WIRE HARNESS 15 12 9 "A" 10 7 CARBURETOR ARM (REF.) 6 SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN. 7 16 17 TO "A" INTAKE MANIFOLD (REF.) 11 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NO. 098290 098941A 0F0454 098942A 098225 043146 022097 0E7358 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694 QTY.
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Section 8 - Exploded Views and Parts Bryant Liquid-cooled 25 kW Generator Radiator — Drawing No. 0E9965-D 1 19 18 12 5 11 2 18 14 8 10 TO BASE OF WATER INLET 7 25 5 9 7 24 15 3 16 4 17 6 9 10 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. 0E9769 0F0779 0E9837 0F0123 0F0118 099502 0C2454 052250 022097 022473 022127 046627 060035 50 Bryant QTY. REF REF 1 1 1 4 REF. 2 8 12 8 1 4 DESCRIPTION SUPPORT,RADIATOR 2.5L FORD SUPPORT RADIATOR 2.5L AL RADIATOR, 2.5L FORD VENTURI, 16" FAN 2.
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Section 9 — Installation Diagram Bryant Liquid-cooled 25 kW Generator Installation Diagram — Drawing No.
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Section 10 – Warranty Bryant Liquid-cooled 25 kW Generator CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards.
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Section 10 – Warranty Bryant Liquid-cooled 25 kW Generator EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
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Section 10 – Warranty Bryant Liquid-cooled 25 kW Generator BRYANT "TWO YEAR" LIMITED WARRANTY FOR "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Bryant warrants that its generator will be free from defects in material and workmanship for the items and period set forth below. Bryant will, at its option, repair or replace any part which, upon examination, inspection and testing by a Bryant Dealer, is found to be defective.