INSTALLATION GUIDE FOR DRY FUEL MODELS: (GM DRIVEN, DRY FUEL GEN-SETS) SP-200 SP-250 SP-300 SP-410 SP-520 SP-620 SP-800 SP-1000 SP-1250 SP-1400 GILLETTE GENERATORS AUTOMATIC POWER SYSTEMS OGU06-OWN795-20120824
TABLE OF CONTENTS Page Introduction, General Cautions, Warnings, Danger & Danger Points -------3-10 Receiving, Un-packing and Installation of your Generator Set ---------------11-14 Muffler Installation on Open (No Housing) Gen-Sets ---------------------------14-16 Engine Radiator Systems --------------------------------------------------------------16-17 Starting, Battery Requirements -------------------------------------------------------17 Engine Oil Requirements and Generator Housing Information -------
PRODUCT SAFETY INFORMATION SECTION 1 SAFETY RESPONSIBILITY Be sure that you are completely familiar with the safe operation of this equipment. Improper use can cause serious or fatal injury. GILLETTE Generator installation and repair procedures require specialized skills. Contact GILLETTE service department for repairs or any questions you may have about the safe installation and operation of this system. The precaution statements are general guidelines for the safe use and operation of this generator.
use by non-qualified operator can cause serious or fatal injury. clothing or extremities and cause serious of fatal injury. DANGER: Disconnect all electrical wires and load devices from generator power outlets before servicing the generator. Electrical shock can cause serious or fatal injury. DANGER: Do not put hands, feet, tools, clothing, or other objects near rotating parts such as cooling fan, drive shaft, pulley, belt, etc.
death. Symptoms of carbon monoxide poising include: dizziness, nausea, headaches, sleepiness, vomiting, or incoherence. If anyone experiences these symptoms, get out into fresh air immediately. Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or generator may need an increase in cooling air input and hot air output. DANGER: Never operate the generator set indoors in a poorly or non-ventilated area.
with the National regulations. Electrical Code and local WARNING: Parts of this generator are extremely hot during and after operation. To prevent severe burns, do not touch any part of the generator until you have first determined it has cooled down to a safe point to touch. WARNING: Be sure that you understand how to stop the engine quickly in case of an emergency situation. Become familiar with the engine controller and safety systems provided with this generator set.
This gen-set may have an all weather protected metal enclosure, MADE EXCLUSIVELY FOR OUTDOOR INSTALLATION, and will operate on its specific fuel. Read and understand the above listed safety alert symbols, plus the following symbols that are used through out this manual. GILLETTE GENERATORS has made every effort to present a modern, safe generator set that will give you a safe, clean supply of an alternative electrical source.
● Generator should not be exposed to excessive and constant moisture, dust, dirt, or corrosive environments. ● If connected loads cause over heating or excessive vibration, an overload condition exists. Remove loads until condition stabilizes. ● Do not sit, step, or load heavy items on generator roof. Added stress can cause breakage. ● Do not start generator with air cleaner, air cleaner cover, or oil dipstick removed, nor with oil drain hose in open drain position.
generator. Jewelry will conduct electricity, causing electric shock. ● If generator must be serviced while it is running, stand on a dry, insulated surface from ground to reduce shock hazard. Never service a generator in the rain or snow. ● Do not allow unqualified or ill-experienced persons to operate or service generator. ● Remain alert at all times. Never work on a generator when you are physically or mentally fatigued. ● This generator is equipped with a ground terminal.
can be ignited. Leaks in fuel system can be ignited. Both are conditions that can cause fire and/or explosion, leading to possible death. make sure that different procedure, work method, or operating method is totally safe, against harm and hazards to operators, buildings or environments. ● Do not operate generator if smell of fuel is detected. UNPACKING AND INSPECTION ● Wipe up any oil spills immediately. Remove any debris that has accumulated inside or around generator base and housing.
● Starting battery is not included. See page 17 for battery supply information. ● All gen-sets have the required vibration isolators between generator and steel mounting skid base. No further vibration isolation is required. ● Dry fuel input pipe is supplied for fuel connection. Installer must supply fuel line and a Stainless Steel Flexible Exhaust Hose at the point of muffler connection for pipe vibration damping. and NFPA-70 standards.
RECEIVING AND INSTALLATION TIPS When you receive your weather/sound housed generator, there are several items that require immediate attention. A) If gen-set is shipped open with protective wrap, remove wrap and carefully inspect gen-set for any shipping damage or missing optional equipment, before shipper leaves your premise. Note damage or missing parts on shipper’s Bill of Lading.
WARNING: An open bottom, stationary gen-set must be installed over a non-combustible material, such as a cement slab, and must be positioned to prevent combustible materials, rain, pooling water, sprinklers, etc. from entering into, and accumulating under gen-set. A) Installation should place gen-set as close as possible to the fuel supply, the transfer switch, and distribution/ circuit breaker panel. B) Service access must be provided to allow generator housing doors to fully open.
TYPICAL EMERGENCY GENERATOR INSTALLATION PRACTICES FOR “OPEN” (NON-SELF ENCLOSED) GENERATOR A standby emergency power systems will give years of dependable service when installed properly. Incorrect installations can cause continuing service problems and may result in harm to humans. It is the responsibility of the owner or operator to know and understand the correct installation methods. It is of particular importance to know safe methods especially, when installing an open generator inside a building.
It is, however, available as an option purchase. GILLETTE does not offer the “Industrial” grade muffler as it is very loud and is seldom satisfactory to the end user. Muffler selections are: Residential grade (reasonable quietness), “Critical” grade (very quiet) or “Hospital” grade for ultimate silencing. NOTE: The gen-set drawings on page 14 shows a horizontal Hospital grade muffler.
F) The exhaust piping system is subject to engine vibration, so it must be solidly installed to reduce potential for pipe cracks or breakage. G) It is very important to discharge exhaust gasses away from the engine and out of the generator building. If these gasses remain in the engine cylinders, poor engine performance and eventual engine damage may result.
circulate into the radiator core. Thermostat can also close, restricting the coolant flow, as necessary to prevent over cooling. The engine fan blows air, from the engine side, through the fins of the radiator. When a generator set is installed inside a building room, the radiator air discharge should be ducted outside the building, into the atmosphere. A typical installation is shown on page 14, Figure 5. Install a set of louvers, 1½ times the size of engine radiator perimeter.
RECOMMENDED ENGINE OIL GENERATOR MODEL SP-200 SP-250 SP-300 SP-410 SP-520 SP-620 SP-800 SP-1000 SP-1250 SP-1400 OIL CAPACITY WITH FILTER QT (L) SUMMER OIL GRADE K) “Intelligent” Battery conforming to NFPA-110. WINTER OIL GRADE Upgrade, L) “Command” Programmable Controller: Is standard equipment on all Gillette standby 4-pole generator sets, and has a vast array of options for almost any application. 4.3 (4.1) 6.5 (6.
1) “Standard” housing with standard interior sound deadening foam and mounted residential grade muffler. touch. This “Hot Pipe Burn” warning remains in effect for 60 minutes after shut-down of generator set. CORROSION TO GENERATOR AND HOUSING 2) “Super-Silent” housing with special interior foam having damping material included. 3) “Super-Silent” housing also has a “Critical” grade muffler included with a choice of “Hospital” grade muffler as an additional upgrade.
Cu. Ft., under column 11-20 Ft. runs = 470 Cu. Ft. Locate the required pipe diameter at left side of Table C = 1” Dia. TABLE A: ENGINE HORSEPOWER VERSUS FUEL CONSUMPTION, AT 100% LOAD 1800 RPM ENGINES GEN-SET KW 20 25 30 41 52 62 80 100 125 140 ENGINE HP FOR LPV FUEL 48 * 48 * 48 * 65 105 105 162 * 162 * 163 220 LPV GAS FUEL (CU. FT./HR) 155 168 203 237 286 345 490 595 875 1210 LPV GAS FUEL (CU. M./HR) 4.4 4.8 5.8 6.7 8.07 9.8 13.9 16.8 24.7 34.
THE GASEOUS DRY FUEL SYSTEM INSTALLATION causing a possible fire hazard. WARNING NATURAL GAS FUEL Propane (LPV) and natural gas (NG) is extremely flammable and explosive. Fire or explosion can cause serious burns or death. LPV is heavier than air and will settle in low areas. NG is lighter than air and will collect in high areas. The slightest spark can ignite either fuel and can cause fire or explosion. The following LPV and NG fuel information is provided to assist the fuel installer.
All new installations, plus any future repair or troubleshooting procedures must include a natural gas manometer test. This test should be conducted after all other natural gas appliances have been turned on. After all appliances are running, start the generator. If manometer stays within 7 inches water column with full load applied to a proper running generator, it’s a good installation.
LPV fuel pressure must be 6 ounce pressure (11-12 inches water column) delivered to the generator. Figure 11 Often new LPV tanks or existing LPV tanks already located at the installation site, have a preinstalled, primary regulator set for 250 PSI and intended for home heating and cooking. This is wrong for generator LPV fuel.
cables. Place the selected fully charged battery with full electrolyte in battery tray and secure with battery hold down strap. WARNING The high voltage access panels should only be removed by experienced licensed electricians, repair and service personnel, and installers. Electrical shock from mishandled battery. Toxic fumes from battery or engine exhaust may be inhaled. Hot surfaces may cause severe burns.
● Contact with battery acid will cause severe burns to the skin and eyes. BATTERIES CAN CAUSE DANGEROUS ELECTRICAL SHOCK BEFORE WORKING ON BATTERY: ● Always remove 10 amp fuse in control panel. ● Always turn the “auto-off-manual” switch to off position. A battery can cause an electrical shock. Before working on a battery, follow safe procedures: FINAL PREPARATIONS BEFORE INITIAL START-UP ● Remove the start/stop 10 amp fuse in control circuit.
for Buyer to know, that all ATS operating methods, parts supplied, operational services, warranties, etc. are the responsibilities of chosen ATS supplier. However, GILLETTE’S responsibilities are to ensure all such requirements are carried out, by the selected ATS vendor. A) When all connections, adjustments, and tests are completed, and the automatic transfer switch is installed and wired, the standby generator system is ready to be placed on standby duty.
OIL DRAIN: Remove oil drain hose from the holding clip. Remove the end cap from end of oil drain hose, and let oil drain into a separate container. Remove dipstick and oil fill cap to facilitate complete draining process. When oil is drained, replace dip stick, oil fill cap, oil hose drain cap and place hose in holding clip. OIL FILL: Replace oil with premium grade API SJ/10W-30 oil when ambient temperature is above 32º F (0º C).
TERMINAL CONNECTOR TORQUE TIGHTENING TORQUE FOR PRESSURE WIRE CONNECTORS WITH INTERNALDRIVE SOCKET-HEAD SCREWS Use the torque values shown for terminal connectors. Refer to UL-486A, UL-486B, and UL-486E for information on terminal connectors for aluminum and/or copper conductors. Comply with applicable national and local codes when installing a wiring system. SOCKET SIZE ACROSS FLATS, TIGHTENING TORQUE, mm (in.) Nm (in. lb.
FORMULAS THAT MAY BE OF USE TEMPERATURE ºC = (ºF – 32) x 0.55555 ºF = (ºC X 1.8) + 32 VELOCITY ft/sec x 0.3048 = m/sec miles/hr x 1.6093 = km/hr miles/hr x 0.44704 = m/sec m/sec x 3.2808 = ft/sec km/hr x 0.6214 = miles/hr m/sec x 3.2808 = ft/sec VOLUME inches3 x 16.388 = mm3 feet3 x 0.0283 = m3 gallons x 3.785 = liter gallons x 0.13337 = ft3 cc3 x 0.06102 = inches3 m3 x 35.315 = feet3 liter x 0.2642 = gallon PRESSURE pounds/ft2 x 0.006944 = pounds/in2 psi x 6.8948 = kPa psi = 0.
Gillette Generators, Inc. 1340 Wade Drive Elkhart, IN 46514 Phone: 574-264-9639 Fax: 574-262-1840 E-mail: sales@gillettegenerators.com www.gillettegenerators.com Call for Tech Support: 1-866-537-4388 Email: service@gillettegenerators.
