Lennox RGEN12 Generator Installation Manual
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E 2009 Lennox Industries Inc.
Dallas, Texas 75379-9900
This manual provides installation instructions for models RGEN12 and RGEN17/18 generator sets.
Refer to XP-6515, Operation Manual, for generator set operation and maintenance instructions.
The generator set is approved for use in stationary standby applications in locations served by a reliable utility power source. Do not install this generator set indoors.
Have a Lennox dealer who is approved to sell and install
Lennox generator sets (hereinafter referred to as a
Lennox dealer) install the generator set outdoors according to the instructions in this manual.
The generator set installation must comply with the National
Electrical Code (NEC) and local code requirements. If the generator set is installed in Canada, the installation must comply with the Canadian Electrical Code (CEC) and all applicable local codes.
Information in this publication represents data available at the time of print. The manufacturer reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section.
INSTALLATION
INSTRUCTIONS
RGEN12, RGEN17/18
RESIDENTIAL GENERATOR SET
XP-6514 4/09c
Table of Contents
1.1
1.2
1.3
1.4
Product Identification Information . . . . . . . . . . . . . . .
Safety Precautions and Instructions . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
Lifting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Inspection
Location and Mounting
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
1.4.1
Exhaust Requirements
1.4.2
Air Requirements
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
1.5
1.6
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Requirements
1.6.1
Fuel Supply
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
Fuel Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . .
1.7
Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.1
Fuel Conversion, RGEN12 . . . . . . . . . . . . . .
1.7.2
Fuel Conversion, RGEN17/18 . . . . . . . . . . .
1.8
Electrical Connections
1.8.1
AC Connections
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1.8.2
Remote Start Connection
1.8.3
Grounding
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.4
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . .
1.9
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.1 Carburetor Heater . . . . . . . . . . . . . . . . . . . . . .
1.11
Prestart Installation Check . . . . . . . . . . . . . . . . .
1.12
Startup Notification . . . . . . . . . . . . . . . . . . . . . . .
1.13
Controller Configuration . . . . . . . . . . . . . . . . . . .
1.14
Voltage and Frequency Adjustments . . . . . . . .
1.14.1 Voltage Adjustment . . . . . . . . . . . . . . . . . . . .
1.14.2 Frequency Adjustment . . . . . . . . . . . . . . . . . .
Section 2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . .
24
27
27
28
32
21
22
22
24
24
19
20
20
20
20
16
16
17
18
14
14
14
15
15
9
9
9
9
7
9
2
3
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Shipping and Packing List
1 -- Generator Set
Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.
506087-01
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Product Identification Information
Generator Set Identification Numbers
Record the product identification numbers from the generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer
Model Designation
Serial Number
Controller Identification
Record the controller description from the generator set operation manual, spec sheet, or sales invoice.
Controller Description
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety precautions and instructions.
SAVE
THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death , or substantial property damage .
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage .
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage .
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.
The decals are shown throughout this publication to improve operator recognition.
Replace missing or damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death.
Battery acid can cause blindness and burn skin.
Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.
Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
XP-6514 4/09 Safety Precautions and Instructions 3
Battery gases. Explosion can cause severe injury or death.
Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.
Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits.
Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Disconnect the battery before generator set installation or maintenance.
Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the air cleaner. A sudden backfire can cause severe injury or death.
Do not operate the generator set with the air cleaner removed.
Servicing the fuel system. A flash fire can cause severe injury or death.
Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
Catch fuels in an approved container when removing the fuel line or carburetor.
Combustible materials. A fire can cause severe injury or death.
Generator set engine fuels and fuel vapors are flammable and explosive.
Handle these materials carefully to minimize the risk of fire or explosion.
Equip the compartment or nearby area with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as recommended by the local fire code or an authorized agency.
Train all personnel on fire extinguisher operation and fire prevention procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause severe nausea, fainting, or death.
Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death.
Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.
Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
Gas fuel leaks.
Explosive fuel vapors can cause severe injury or death.
Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
4 Safety Precautions and Instructions XP-6514 4/09
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Engine noise. Hazardous noise can cause hearing loss.
Generator sets not equipped with sound enclosures can produce noise levels greater than
105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.
Hazardous Voltage/
Moving Parts
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
CAUTION
Welding the generator set.
Can cause severe electrical equipment damage.
Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death.
Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
Welding on the generator set. Can cause severe electrical equipment damage.
Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module
(ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection close to the weld location.
Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
Short circuits.
Hazardous voltage/current can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage .
Do not contact electrical connections with tools or jewelry while making adjustments or repairs.
Remove all jewelry before servicing the equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can cause severe injury or death.
Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.
Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
WARNING
Airborne particles.
Can cause severe injury or blindness.
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
Heavy Equipment
WARNING
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
XP-6514 4/09 Safety Precautions and Instructions 5
Hot Parts
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system. Hot parts can cause severe injury or death.
Do not touch hot engine parts.
The engine and exhaust system components become extremely hot during operation.
Servicing the engine heater.
Hot parts can cause minor personal injury or property damage.
Install the heater before connecting it to power.
Operating the heater before installation can cause burns and component damage.
Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.
Notice
NOTICE
Canadian installations only .
For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
6 Safety Precautions and Instructions XP-6514 4/09
Introduction
See Figure 1 and Figure 2 for generator set component locations.
1 2 3 4
5
Control detail
9
8
7
See control detail
6
16
7
6
17 18 19 20
21
22
15
10
24
14 13 12 11
1. Muffler
2. Oil check
3. Oil fill
4. Air cleaner
5. Controller user interface
6. Generator set master switch (RUN-OFF/RESET-AUTO)
7. Load circuit breaker
8. Fuses
9. RS-232 connector (for application program updates)
10. Field-connection terminal block location
11. Spark plug locations (both sides)
12. Oil drain hose
Figure 1 Generator Set Component Locations, RGEN12
13. Oil drain valve
14. Oil filter
15. Exhaust
16. Equipment ground
17. Battery charger
18. DSAI lead location
19. Fuel block
20. Gas regulator assembly
21. Fuel solenoid valve
22. Fuel inlet
23. Air intake
24. Engine starting battery location (battery purchased separately)
23
ADV-7466-
XP-6514 4/09 7
1 2 3 4
8
Control detail
12
11
9
10
5 6 7 See control detail 18 19 20 21
22
23
29
28
27
26
17 24
ADV-7341A-B
16 15 14 13
25
1. Muffler
2. Oil check
3. Oil fill
4. Air cleaner
5. Spark plug locations (both sides)
6. Oil filter
7. Oil cooler location
8. Controller user interface
9. Generator set master switch (RUN-OFF/RESET-AUTO)
10. Line circuit breaker
11. Fuses
12. RS-232 connector (for application program updates)
13. Engine starting battery location (battery purchased separately)
14. Oil drain hose
15. Nameplate location (on base)
16. Oil drain valve
17. Exhaust
18. Carburetor heater access opening
19. LP fuel orifice location (inside hose fitting)
20. Gas regulator assembly
21. DSAI leads
22. Fuel solenoid valve
23. Fuel inlet
24. Air intake
25. Battery cables
26. Battery charger
27. Field-connection terminal block location
28. 120 VAC receptacles for battery charger and optional carburetor heater
29. Field connections inside junction box if optional terminal block is not used
Figure 2 Generator Set Component Locations, RGEN17/18
8 XP-6514 4/09
Section 1 Installation
1.1 General
Have a Lennox dealer install the generator set outdoors according to the instructions in this manual. Do not install this generator set indoors.
Use the specifications provided here only in the initial planning. Use the generator set and transfer switch dimension drawings and wiring diagrams for installation.
1.2 Lifting
1.3 Generator Set Inspection
Complete a thorough inspection of the generator set.
Check for the following:
1. Inspect the generator set for loose or damaged parts or wires. Repair or tighten any loose parts before installation.
2. Check the engine oil. Fill, if necessary, with the recommended viscosity and grade of oil.
Use synthetic oil, API (American Petroleum Institute)
Service Class SG or higher.
See XP-6515,
Operation Manual, for additional information.
WARNING
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
Model
RGEN12
RGEN17/18
Figure 1-1 Approximate Weights
Weight, kg (lb.)
186 (410)
227 (500)
Approximate generator set weights are shown in
Figure 1-1. Use lifting bars inserted through the holes in the skid to lift the unit. See Figure 1-2 or Figure 1-4 for lifting hole locations.
1.4 Location and Mounting
See Figure 1-2 or Figure 1-4 for the generator set dimensions and fuel and electric inlet locations. The drawing dimensions are shown in millimeters, with inches in brackets.
Install the generator set outdoors. Provide the minimum clearance around the generator set shown in Figure 1-3 or Figure 1-5. Locate the generator set so that the hot exhaust does not blow on plants or other combustible materials.
Do not install the generator set where exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building.
The generator set is shipped on a plastic mounting pad.
Prepare a flat, level mounting area covered with a weed barrier and gravel as shown in Figure 1-3 or Figure 1-5.
Set the plastic mounting pad directly on the gravel. Do not install the mounting pad directly on grass.
XP-6514 4/09 Section 1 Installation 9
Figure 1-2 Generator Set Mounting Details and Dimensions, RGEN12, ADV-7466A-
10 Section 1 Installation XP-6514 4/09
Figure 1-3 Generator Set Clearances, RGEN12, ADV-7466B-
XP-6514 4/09 Section 1 Installation 11
Figure 1-4 Generator Set Mounting Details and Dimensions, RGEN17/18, ADV-7341A-B
12 Section 1 Installation XP-6514 4/09
Figure 1-5 Generator Set Clearances, RGEN17/18, ADV-7341B-B
XP-6514 4/09 Section 1 Installation 13
1.4.1
Exhaust Requirements
WARNING
3
1
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death.
Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.
The exhaust system is complete for generator sets installed outdoors.
Do not install this generator set indoors.
Figure 1-6 gives the exhaust flow and temperature at rated load.
The engine exhaust mixes with the generator set cooling air at the exhaust end of the enclosure.
Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials. Maintain the clearances shown in Figure 1-3 or Figure 1-5.
Exhaust System
Exhaust flow at rated kW, m
3
/min. (cfm)
RGEN12
RGEN17/18
60 Hz
3.8 (135)
5.3 (187)
Exhaust gas exiting the enclosure at rated kW,
_ C ( _ F)
Figure 1-6 Exhaust Flow and Temperature
216 (420)
1.4.2
Air Requirements
The generator set requires correct air flow for cooling and combustion. The inlet and outlet openings in the sound enclosure provide the cooling and combustion air. Figure 1-7 shows the locations of the cooling air intake and exhaust vents. Inspect the air inlet and outlet openings inside and outside the housing to ensure that the air flow is not blocked.
3
2
1. Exhaust outlet
2. Alternator air intake (both sides)
3. Engine air intake tp6195
Figure 1-7 Cooling Air Intake and Exhaust, Typical
Model
Air Requirements, m 3 /min. (cfm)
Hz
Cooling
Air
Combustion
Air
Total
Inlet Air
RGEN12 60 26.9 (950) 1.1 (39.2) 28.0 (990)
RGEN17/
18 60 28.0 (989) 1.62 (57.3) 29.6 (1045)
Figure 1-8 Air Requirements
1.5 Power Supply
Power must be supplied from a source that is GFCI protected to the generator set location for the battery charger and the optional carburetor heater. Connect power from a circuit on the essential loads panel to the
120-VAC receptacles.
Figure 1-9 lists the power requirements for the battery charger and accessories.
Equipment
Battery charger
Optional carburetor heater:
RGEN12
RGEN17/18
Power Requirement, Max.
Watts Amps Volts
192 1.6
38
40
Figure 1-9 Power Requirements
0.32
0.34
120
14 Section 1 Installation XP-6514 4/09
1.6 Fuel Requirements
The generator set operates using natural gas or LP vapor fuel. The generator set is EPA-certified for both natural gas and LP vapor fuels.
The fuel system installation must comply with the NEC and local codes.
1.6.1
Fuel Supply
Because of variable climates and geographical considerations, contact the local fuel supplier for fuel system planning and installation. Figure 1-10 lists the recommended fuel ratings and other fuel supply information for natural gas and LP vapor fuels.
Fuel type
Fuel supply inlet
Fuel supply pressure, kPa (in. H
2
RGEN12
O)
Fuel supply pressure, kPa (in. H 2 O),
RGEN17/18
Fuel flow rate, Btu/hr.
RGEN12
RGEN17/18
Nominal Fuel Rating, Btu/ft.
3
Natural gas
LP vapor
Figure 1-10 Fuel Supply
Natural
Gas
LP
Vapor
1/2 NPT
1.3--2.7
(5--11)
1.7--2.7
(7--11)
1.7--2.7
(7--11)
193000 203000
242000 280000
1000
2500
Verify that the output pressure from the primary gas utility (or LP tank) pressure regulator is 1.7--2.7 kPa
(7--11 in. water column) and that the utility gas meter flow rate is sufficient to supply the generator set at rated load plus all other gas-consuming appliances.
See
Figure 1-11 or Figure 1-12 for fuel consumption.
Contact the fuel supplier for flow rate information or a gas meter upgrade.
Figure 1-2 or Figure 1-4 shows the location of the fuel inlet connection. Use flexible sections to prevent fuel line breakage caused by vibration.
Hold the fuel solenoid valve with a wrench when tightening the fuel connections. Protect all fuel lines from machinery or equipment contact, adverse weather conditions, and environmental damage.
Fuel Consumption, at % load m
3
/hr. (cfh)
Natural Gas, m
3
/hr. (cfh)
100%
75%
50%
25%
LP Vapor, m
3
/hr. (cfh)
100%
75%
50%
25%
LP vapor conversion factors:
8.58 ft.
3
0.535 m
36.39 ft.
3
3
= 1 lb.
= 1 kg
= 1 gal.
Nominal fuel rating:
Natural gas: 37 MJ/m
3
LP vapor: 93 MJ/m
3
(1000 Btu/ft.
(2500 Btu/ft.
3
3
)
)
Figure 1-11 Fuel Consumption, RGEN12
60 Hz
5.9 (209)
4.8 (168)
3.6 (127)
2.4 (85)
3.1 (108)
2.5 (87)
1.9 (65)
1.2 (44)
Fuel Consumption, at % load m
3
/hr. (cfh)
Natural Gas, m
3
/hr. (cfh)
100%
75%
50%
25%
LP Vapor, m
3
/hr. (cfh)
100%
75%
50%
25%
LP vapor conversion factors:
8.58 ft.
3
0.535 m
36.39 ft.
3
3
= 1 lb.
= 1 kg
= 1 gal.
Nominal fuel rating:
Natural gas: 37 MJ/m
3
LP vapor: 93 MJ/m
3
(1000 Btu/ft.
(2500 Btu/ft.
3
3
)
)
Figure 1-12 Fuel Consumption, RGEN17/18
60 Hz
6.9 (242)
5.8 (204)
4.4 (155)
3.4 (120)
3.2
(112)
2.7
(96)
2.1
(74)
1.6
(57)
1.6.2
Fuel Pipe Size
Ensure that the natural gas pipe size and length meet the specifications in Figure 1-13 or Figure 1-14.
XP-6514 4/09 Section 1 Installation 15
Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow. Compare the total pipe length with the chart in Figure 1-13 or Figure 1-14 to find required pipe size.
Contact local LP provider for LP installation information.
Pipe Size
3/4 in. NPT
1 in. NPT
1 1/4 in. NPT
Maximum Pipe Length, m (ft.)
9.2
(30)
30 (100)
68.6 (225)
Figure 1-13 Fuel Pipe Size, Natural Gas, RGEN12
Minimum Gas Pipe Size Recommendation, in. NPT
Pipe Length, m (ft.)
8 (25)
Natural Gas
(242,000 Btu/hr.)
1
LP Vapor
(280,000 Btu/hr.)
3/4
15 (50)
30 (100)
46 (150)
61 (200)
1
1 1/4
1 1/4
1 1/4
1
1
1 1/4
1 1/4
Figure 1-14 Fuel Pipe Size, RGEN17/18
1.7 Fuel Conversion
The multi-fuel system allows conversion from natural gas to LP vapor (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or a Lennox dealer can convert the fuel system.
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
16 Section 1 Installation XP-6514 4/09
1.7.1
Fuel Conversion, RGEN12
Two fuel connections on the fuel block allow fieldconversion between natural gas and LP vapor. The fuel metering valves are factory-set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting.
Note: Do not adjust the factory-sealed fuel-metering adjustments on the fuel block. Changing the fuelmetering adjustments may violate federal or state laws.
Use the following procedure to convert from natural gas
(NG) to LP vapor, moving the fuel connection from the natural gas to the LP port, plugging the natural gas port, and connecting the leads to the digital spark advance ignition (DSAI). See Figure 1-15 for the fuel system component locations.
1 2
5. Remove the hose clamp and fuel hose from the hose fitting in the fuel block. See Figure 1-16.
4
5
1
2
Natural gas setup shown
3
3
1. DSAI connector location
2. Fuel block
3. Fuel inlet, 1/2 in. NPT female
Figure 1-15 Fuel System Locations, RGEN12
GM29253
Procedure to convert from NG to LP, RGEN12
1. Place the generator set master switch in the OFF position.
2. Disconnect the power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Turn off the fuel supply.
tp6195
1. Fuel block
2. Fuel metering valves— factory-sealed, do not adjust
3. Fuel inlet, 1/2 in. NPT
4. Hose fitting
5. Plug
Figure 1-16 Fuel Block, RGEN12
6. Remove the hose fitting from the natural gas outlet port in the fuel block. See Figure 1-16.
7. Remove the plug from the LP port in the fuel block.
See Figure 1-16. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install the plug into the natural gas outlet port.
8. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install the fitting into the LP port.
Note: Do not adjust the fuel metering valves.
9. Slide the hose onto the hose fitting and secure it with the clamp.
10. For the RGEN12: Disconnect the DSAI leads for
LP; connect the DSAI leads for natural gas. See
Figure 1-17 and Figure 1-18.
Fuel
Natural Gas
LP
DSAI Leads
Connect
Disconnect
Figure 1-17 DSAI Connection,12/17/18 kW Models
XP-6514 4/09 Section 1 Installation 17
1
2
3
4
Fuel System Detail
5 2
6
3
4 tp6195
1
1. DSAI leads (12 kW model only)
Figure 1-18 Digital Spark Advance Module Leads
(located in generator set air intake area)
11. Connect and turn on the new fuel supply.
12. Check that the generator set master switch is in the
OFF position.
13. Reconnect the generator set engine starting battery leads, negative (--) lead last.
14. Reconnect power to the battery charger.
15. Start the generator set by moving the generator set master switch to the RUN position.
16. Check for leaks using a gas leak detector.
17. Run the generator set and check the operation.
Use the controller to adjust the output and stability if necessary. See Section 1.14 for instructions.
18. Move the generator set master switch to the OFF/
RESET position to shut down the generator set.
To convert from LP vapor to natural gas, follow the same fuel conversion procedure, moving the hose fitting to the natural gas port and plugging the LP port.
For the
RGEN12 model, disconnect the DSAI leads for LP vapor. See Figure 1-17 and Figure 1-18.
1.7.2
Fuel Conversion, RGEN17/18
For LP vapor fuel, an orifice is used in the fuel line. The unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel line. To convert to LP vapor, install the orifice and disconnect the spark advance leads as described below. See Figure 1-19 for the fuel system component locations.
GM51561A-D
1. Hose fitting (LP orifice fits inside; see Figure 1-20)
2. Regulator
3. Fuel valve
4. Fuel inlet, 1/2 in. NPT female
5. Fuel hose with clamp
6. DSAI connector location (see Figure 1-21)
Figure 1-19 Fuel System Components, RGEN17/18
Procedure to Convert from NG to LP, RGEN17/18
1. Place the generator set master switch in the OFF position.
2. Disconnect the power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Turn off the fuel supply.
5. Remove the hose clamp and fuel hose from the hose fitting. See Figure 1-19.
18 Section 1 Installation XP-6514 4/09
6. Place the orifice into hose fitting. See Figure 1-20.
7. Slide the hose onto the hose fitting and secure it with the clamp.
1
2
3
12. Reconnect power to the battery charger.
13. Start the generator set by moving the generator set master switch to the RUN position.
14. Check for leaks using a gas leak detector.
15. Run the generator set and check the operation.
Use the controller to adjust the output and stability if necessary. See Section 1.14 for instructions.
16. Move the generator set master switch to the OFF/
RESET position to shut down the generator set.
To convert from LP vapor to natural gas, remove the fuel orifice and connect the DSAI leads together.
1. LP orifice (remove for natural gas)
2. Hose fitting
3. Regulator
Figure 1-20 LP Fuel Orifice, RGEN17/18 tp6514
8. Disconnect digital spark-advance module (DSAI) leads 65 and N5 for LP. (Connect the leads for natural gas.) See Figure 1-21 and Figure 1-22.
1 tp6514
1. DSAI leads 65 and N5: connect for natural gas, disconnect for LP.
Figure 1-21 Digital Spark Advance Ignition (DSAI)
Leads 65 and N5, RGEN17/18
Fuel
Natural Gas
LP
Figure 1-22 DSAI Connections
DSAI Leads 65 and N5
Connect
Disconnect
9. Connect and turn on the new fuel supply.
10. Check that the generator set master switch is in the
OFF position.
11. Reconnect the generator set engine starting battery leads, negative (--) lead last.
1.8 Electrical Connections
WARNING
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death.
Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death.
Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
NOTICE
Canadian installations only . For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.
XP-6514 4/09 Section 1 Installation 19
Have a Lennox dealer or a licensed electrician make the following electrical connections.
The electrical installation must comply with the National Electrical
Code (NEC) and all applicable local codes. Canadian installations must comply with the Canadian Electrical
Code (CEC) and applicable local codes.
Ground the generator set from the GRD terminal inside controller compartment according to applicable codes.
1.8.1
AC Connections
Refer to the transfer switch specifications and
Figure 1-23 for the acceptable cable sizes. Route AC leads through flexible conduit. Ensure that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas.
GM54820
GM58022
Figure 1-23 Field-Connection Terminal Block
See Figure 1-23.
Leads have been factory-installed from the junction box to the terminal block for easy field wiring. Make field connections to the other side of the terminal block. Refer to the decal near the terminal block for connections and cable sizes.
1. Connect the leads from the transfer switch emergency source lugs to the L1 and L2 connections on the generator set terminal block.
2. Connect the neutral (L0) and ground (GRD) leads from the ATS and the main panel to the corresponding connection points on the terminal block.
See Section 1.8.3, Grounding.
See
Section 1.8.2 for remote start connections.
3. The terminal block kit includes 120 VAC receptacles for the battery charger and optional carburetor heater.
Connect utility power to the terminal block as shown. Connect to a circuit that is supplied by the generator set if utility power is lost.
See Section 1.5 for more information about the
120 VAC power requirement.
1.8.2
Remote Start Connection
Connect leads 3 and 4 from the controller to the automatic transfer switch’s engine start terminals or to an optional remote start/stop switch. Route the engine start leads through separate conduit from the AC power and load leads.
1.8.3
Grounding
Ground the generator set. The grounding method must comply with NEC and local codes.
Connect the grounding strap to the generator set ground lug, terminal GND inside the controller compartment.
Generator sets are shipped with the generator neutral attached to the generator in the junction box.
At installation, the neutral can be grounded at the generator set or lifted from the ground stud and isolated if the installation requires an ungrounded neutral connection at the generator.
The generator set will operate properly with the neutral either bonded to ground or isolated from ground at the generator.
Various regulations and site configurations including the
National Electrical Code (NEC), local codes, and the type of transfer switch used in the application determine the grounding of the neutral at the generator. NEC 2002
Section 250.20 is one example that has a very good explanation of the neutral grounding requirements for generators.
1.8.4
Battery Charger
A 6-amp battery charger is factory-installed in the battery compartment to keep the starting battery fully charged. The battery charger’s DC leads are factoryconnected.
Plug the battery charger’s power cord into the receptacle on the bottom of the controller junction box.
Refer to the generator set operation manual for battery charger operation information.
20 Section 1 Installation XP-6514 4/09
1.9 Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death.
Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup.
Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases.
Explosion can cause severe injury or death.
Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire.
To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
Use a 12-volt battery with a minimum rating of 525 cold cranking amps at 0
_
F.
The generator set uses a negative ground with a 12-volt engine electrical system.
See Figure 1-24 for battery connections. Make sure that the battery is correctly connected and the terminals are tight.
1 2
EZ-273000-J
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor.
Figure 1-24 12-Volt Engine Electrical System Single
Starter Motor Typical Battery Connection
Note: The generator set will not start and circuit board damage may occur if the battery is connected in reverse.
XP-6514 4/09 Section 1 Installation 21
Figure 1-25 shows the location of the engine starting battery.
Standard battery cables provide easy connection to the battery. Use the following procedure to install and connect the battery.
1
If there are no accessories, proceed to Section
1.11,Prestart Installation Check.
1.10.1 Carburetor Heater
An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0
_
C (32
_
F). The carburetor heater prevents condensation and carburetor icing. The heater turns on when the temperature at the thermostat falls below approximately 4 _ C (40 _ F) and turns off when the temperature rises above approximately 16 _ C
(60 _ F). See Figure 1-26 through Figure 1-28.
The heater requires a continuous source of 120 VAC power.
The heater power cord and thermostat are located in the generator set housing air intake area/ battery compartment.
See Figure 1-25.
Plug the carburetor heater into an outlet on the load side of the
ATS.
1. Engine starting battery location
Figure 1-25 Battery Location, Air Intake End
ADV-7341A-B
Battery Installation Procedure
1. Ensure that the starting battery is fully charged before placing the battery in service.
2. Clean the battery posts and/or adapters if necessary.
3. Install the battery post adapters, if needed.
4. Place the battery in the housing.
5. Verify that the controller master switch is in the OFF position.
6. Connect the positive (+) lead to the engine starting battery.
7. Connect the negative (--) lead to the engine starting battery.
Refer to the generator set operation manual and the battery manufacturer’s instructions for battery maintenance instructions.
1
2 tp6195
1. Carburetor heater (air cleaner removed to show heater)
2. Carburetor heater power cord
Figure 1-26 RGEN12 Carburetor Heater Location
1.10 Accessories
Have accessories installed by a Lennox dealer or a licensed electrician. Follow the installation instructions provided with each kit. Use separate conduit for AC and
DC leads to reduce the possibility of electrical interference. Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. Verify that the electrical installation complies with the National Electrical Code
(NEC) and all applicable local codes. See Section 2,
Wiring Diagrams, for more information regarding generator set electrical connections.
22 Section 1 Installation XP-6514 4/09
1
2
3
4
GM57969
1
1. Thermostat
2. Bulkhead opening for carburetor heater access
3. Carburetor heater cord with thermostat
4. 120 VAC receptacles for carburetor heater and battery charger
Figure 1-27 RGEN17/18 Carburetor Heater Location
(air intake side of generator set)
1 2 tp6514
1. Carburetor heater location
Figure 1-28 RGEN17/18 Carburetor Heater Location on Engine (bulkhead removed to show heater location)
The heater thermostat is installed in the cord.
Figure 1-29 shows the location of the thermostat on the power cord.
Note: Do not place the heater thermostat inside the generator set engine compartment.
The thermostat must be exposed to the ambient air.
Thermostat will shut off power to the heater when ambient temperature reaches approximately
16 _ C (60 _ F).
3
RGEN12 Carburetor Heater
1
1. Thermostat
Figure 1-29 Carburetor Heaters
RGEN17/18 Carburetor Heater
2. Connector 3. Heater
2 3
GM19463
GM57968
XP-6514 4/09 Section 1 Installation 23
1.11 Prestart Installation Check
Review the entire installation section. Inspect all wiring and connections to verify that the generator set is ready for operation. Check all items in the following Prestart
Checklist.
Prestart Checklist
Air Cleaner.
Check that a clean air cleaner element is installed to prevent unfiltered air from entering the engine. See the generator set operation manual for instructions.
Air Inlets.
Check for clean and unobstructed air inlets.
Battery.
Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.
Exhaust System.
Check for exhaust leaks and blockages. Check the muffler condition.
D Inspect the exhaust system components for cracks, leaks, and corrosion. Check for tight exhaust system connections.
D Check for corroded or broken metal parts and replace them as needed.
D Check that the exhaust outlet is unobstructed.
Oil Level.
Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating Area.
Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.
1.12 Startup Notification
Complete the startup and installation checklists supplied with the startup notification form. Complete and sign the startup notification form and submit copies as instructed on the form.
Standby systems not registered within 60 days of startup are automatically registered using the manufacturer’s ship date as the startup date.
24 Section 1 Installation
1.13 Controller Configuration
1.13.1 System Parameters
The controller configuration for each generator model is set at the factory and should not normally require changes. The controller’s configuration mode allows adjustment of the system parameters listed in this section. Use the instructions in this section to check the configuration after installation and change them to match the settings shown in Figure 1-30, if necessary.
Parameter
Unit’s system voltage and frequency
Engine type
Setting
Uu01
Definition
Single phase, 120/240 VAC
Communication setting *
Ec00
Ec12
RGEN12
RGEN17/18
Cn00 No J1939 communication.
Sleep mode enabled
(48-hour power down in
AUTO).
Cn01 [ J1939 communication enabled. Sleep mode disabled (no power down in
AUTO).
* Controller application code version 1.13 or higher.
[ Default setting for application code version 1.13 or higher.
Figure 1-30 Controller Configuration Parameters
The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed.
Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved.
Follow the instructions in Figure 1-31 to enter the configuration mode while the engine is not running and then step through the following parameters. Use the up
(
∧
) and down (
∨
) arrow buttons to select the appropriate setting for the application.
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.
Voltage/frequency setting (Uu).
Select the system voltage and frequency from the table in Figure 1-30.
Note: The Uu parameter sets the system’s rated voltage and frequency.
To adjust the output
(measured) voltage and frequency, see Section
1.14, Voltage and Frequency Adjustments.
Engine configuration (Ec).
The engine configuration must match the generator set engine type.
XP-6514 4/09
Communication/Sleep Mode Setting (Cn).
(Available on controllers with application code version 1.13 or higher.) The communication setting enables or disables
J1939 communication, and also disables or enables the sleep mode. When J1939 communication is enabled, the sleep mode is turned off to allow uninterrupted communication with a personal computer running remote monitoring software. If remote monitoring is not used, the communication can be turned off, enabling the sleep mode which causes the controller to power down after 48 hours of inactivity. The generator set master switch must be in AUTO for the sleep mode to function.
The default setting for controllers with application code version 1.13 or higher is Cn01, communication on/sleep mode off.
Controllers with earlier application code versions have communication disabled and the sleep mode enabled. The Cn setting is not adjustable on these earlier versions.
1.13.2 Application Code Version
To check the application code version number, HOLD the select button while moving the generator set master switch to RUN. (The engine will not start when the select button is held.) Wait about 5 seconds for the application code version number to appear on the display. See
Figure 1-31.
XP-6514 4/09 Section 1 Installation 25
Controller Configuration Mode:
Hold the Select button:
Move the generator set master switch to the RUN position. (The generator set engine will not start.)
Wait about 5 seconds until the display shows the program version number. (The number may be different than the one shown here.)
Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.
(This is the controller “password.”)
Display:
.
0 v 1 1 3
U u 0 1
Now release the Select button.
Press: or
To change the voltage/frequency setting, if necessary. See Figure 1-30.
U u 0 x
To enter setting and step to the next parameter, engine type Ec.
or
To change the engine type, if necessary.
RGEN12
RGEN17/18 or
To enter setting and step to the next parameter, communication setting Cn.
To change the communication setting, if necessary. See Figure 1-30.
E c 0 0
E c 1 2
C n 0 x
To enter setting and step to SAVE.
S A V E
Press:
To SAVE CHANGES .
Y E S
OR
To DISCARD CHANGES without saving.
n o
“Yes” or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours.
x x x x
Now move the master switch to OFF/RESET.
Note: Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed.
X in the runtime hours display above denotes any number from 0 to 9.
Figure 1-31 Configuration Mode (system voltage/frequency, engine type, and communication parameters)
26 Section 1 Installation XP-6514 4/09
1.14 Voltage and Frequency
Adjustments
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Short circuits.
Hazardous voltage/current can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage .
Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
The controller’s adjustment mode allows adjustment of the output voltage and frequency, if necessary. Have adjustments performed by a Lennox dealer or service technician.
Note: A digital multimeter that measures voltage and frequency is required for these adjustments.
Use a digital multimeter to check the output voltage and frequency. If output voltage or frequency is not within specifications, use the ADC controller to adjust the output voltage and engine speed (frequency) while the generator set is running.
See Figure 1-32.
The flowcharts in Figure 1-34 through Figure 1-36 outline the adjustment procedures.
Note: Be sure to save your changes as instructed in
Figure 1-36 before exiting configuration mode.
1
1. Select button 2. Arrow buttons
Figure 1-32 Advanced Digital Control
2 tp6514
Changes in voltage and speed adjustments are lost if not saved before the generator set shuts down. The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup if the changes have not been saved.
1.14.1 Voltage Adjustment
Note: Refer to the flowcharts in Figure 1-34 through
Figure 1-36 during the following procedure.
Voltage Adjustment Procedure
1. With the generator set off, connect a digital multimeter to the output leads or an electrical outlet on the load side of the generator set. Set the meter to measure AC voltage.
2. Start the generator set by moving the generator set master switch to the RUN position.
3. Use the ADC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the desired value.
Refer to the flowcharts in
Figure 1-34 through Figure 1-36 for instructions to adjust the output voltage. See Figure 1-33 for the approximate change in voltage per step.
Measured
Voltage, VAC
85--132
180--251
ADC
Display
1P00--99
1P00--99
Voltage Change per
Step, VAC
Coarse
5
7
Fine
0.5
0.7
Figure 1-33 Voltage Adjustment (approximate)
4. Adjust the voltage stability (gain, parameter 2P) to minimize light flicker.
5. Readjust the voltage, if necessary.
6. Set the multimeter to measure frequency.
7. Adjust the engine speed to the cut-in frequency of
57.5 Hz by adjusting the engine governor speed
(parameter 4P).
8. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the multimeter begins to drop.
When the volts/Hz is set correctly, the generator
(as load is applied) attempts to maintain normal output until the engine speed drops below the cut-in frequency set in step 7.
XP-6514 4/09 Section 1 Installation 27
9. Reset the engine speed to the operating frequency by adjusting the engine governor speed
(parameter 4P).
10. Readjust the voltage stability (gain, parameter 2P), if necessary.
11. Readjust the voltage (parameter 1P), if necessary.
12. Save settings. See Figure 1-36.
13. Stop the generator set.
1.14.2 Frequency Adjustment
The engine speed determines the generator output frequency; 60 Hz units operate at 3600 rpm. Adjust the engine governor speed and gain to set the output frequency and stability using the following procedure.
Note: Refer to the flowcharts in Figure 1-34 through
Figure 1-36 during the following procedure.
Frequency Adjustment Procedure
Note: Refer to the flowcharts in Figure 1-34 through
Figure 1-36 during the following procedure.
1. Attach a frequency meter to the AC output leads or an electrical outlet on the load side of the generator set.
2. Start and run the generator set until it reaches normal operating temperature (at least 10 minutes).
3. Adjust electronic governor speed (parameter 4P) to obtain a frequency reading of 60 Hz. Each step changes the engine speed about 3.6 rpm, which changes the output frequency about 0.06 Hz.
4. Check stability with the generator set running and with no load applied. If the generator set speed is unstable, hunts, or surges, adjust the governor stability (gain, parameter 5P) until the generator set becomes stable with no hunting or surging.
(Increasing the gain slows the governor response.)
5. Check the frequency reading. Repeat steps 3 and
4 if necessary to obtain the rated frequency and stable operation.
6. Save settings. See Figure 1-36.
28 Section 1 Installation XP-6514 4/09
Output Voltage and Frequency Adjustment Mode:
Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours.
Hold:
Wait about 5 seconds until the display changes from runtime hours to the program version number.
Display :* x x x x x
.
x x
Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode. (This is the controller “password.”)
1 P x x
The controller is now in the voltage coarse adjustment mode.
Press: or
To raise or lower the voltage in large increments
(approximately 5--7 volts per step). (Parameter 1P) or or
To enter fine voltage adjustment mode.
To raise or lower the voltage in smaller increments
(approximately 0.5--0.7 volts per step). (Parameter 1P)
To enter coarse voltage stability (gain) adjustment mode.
To raise or lower the voltage stability (gain) in large increments. (Parameter 2P) or
To enter fine voltage stability (gain) adjustment mode.
To raise or lower the voltage stability (gain) in smaller increments. (Parameter 2P)
1 P
1 P
2 P
2 P x x x x x x x x
To enter volts/Hz adjustment mode.
(Parameter 3P)
To raise or lower the volts/Hz: 00=low; 09= high
3 P x x or
Continued on Figure 1-35.
* Shaded boxes show which character in the controller display changes for each adjustment.
X in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.
Figure 1-34 Output Voltage and Frequency Adjustments
XP-6514 4/09
TP6196
Section 1 Installation 29
Continued from Figure 1-34:
Press:
To enter engine governor speed coarse adjustment mode. (Parameter 4P) or
To raise or lower the engine speed in large increments.
or or or
To enter engine governor speed fine adjustment mode. (Parameter 4P)
To raise or lower the engine speed in smaller increments.
To enter engine governor stability (gain) coarse adjustment mode. (Parameter 5P)
To raise or lower the engine governor stability (gain) in large increments.
To enter engine governor stability (gain) fine adjustment mode. (Parameter 5P)
To raise or lower the engine governor stability (gain) in smaller increments.
To enter SAVE mode. Go to Figure 1-36.
Display : *
4 P x x
4 P
5 P
5 P x x x x x x
S A V E
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.
* Shaded boxes show which character in the controller display changes for each adjustment.
X in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.
Figure 1-35 Output Voltage and Frequency Adjustments, Continued
30 Section 1 Installation XP-6514 4/09
There are 3 options when the display says SAVE:
Press:
To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 1-34.
or
To save changes.
or
To discard changes without saving.
Y E S n o x x x x
“Yes”or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours.
Now move the master switch to OFF/RESET.
Figure 1-36 Save Mode
S A V E
1 P x x
XP-6514 4/09 Section 1 Installation 31
Section 2 Wiring Diagrams
Figure 2-1 lists the wiring diagram numbers and locations.
Wiring Diagram Description
Schematic Diagram, RGEN12
Point-to-Point Wiring Diagram, RGEN12
Schematic Diagram, RGEN17/18
Point-to-Point Wiring Diagram, RGEN17/18
Figure 2-1 Wiring Diagrams and Schematics
Drawing Number Page
ADV-7592 33
GM62285
ADV-7353
GM52541
34
35
36
32 Section 2 Wiring Diagrams XP-6514 4/09
Figure 2-2 Schematic Diagram, Single Phase, RGEN12, ADV-7592
XP-6514 4/09 Section 2 Wiring Diagrams 33
-
Figure 2-3 Point-to-Point Wiring Diagram, Single Phase, RGEN12, GM62285
34 Section 2 Wiring Diagrams XP-6514 4/09
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Figure 2-4 Schematic Diagram, Single Phase, RGEN17/18, ADV-7353-F
XP-6514 4/09 Section 2 Wiring Diagrams 35
-
Figure 2-5 Point-to-Point Wiring Diagram, Single Phase, RGEN17/18, GM52541-E
36 Section 2 Wiring Diagrams XP-6514 4/09

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