Engine-Driven Generators XCR XDR XSD XAF XTP | | | | | contractor/rental diesel standard-duty alternative fuels three-phase Owner’s Manual April 2012
Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 1.2 1.3 1.4 1.5 2 1 1 2 3 3 3 3 4 4 4 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 2.2 2.3 3 Read before using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EPA certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 3.2 3.3 Operating the generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Ground-fault protection. . . . . . . . . . . . . . . . . . . 3.2.2 Electrical loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 First-time use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.4 Starting the generator . . . . . . . . . . . . . . . . . . . . 3.2.5 Stopping the generator . . . . . . . . . . . . . . . . . . . General maintenance . . . . . . . . . . . . . . . .
Contents List of Figures Figure 3.1 Figure A-1 Fuel mixture adjustment screw . . . . . . . . . . . . Formula for calculating wattage . . . . . . . . . . . 25 33 List of Tables Table 3.2 Table 3.1 Table A-1 Table A-2 Table A-3 Battery type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended oil grade . . . . . . . . . . . . . . . . . . Approximate current requirements for electric motors . . . . . . . . . . . . . . . . . . . . . . . Minimum extension cord gauge . . . . . . . . . . .
iv Voltmaster Engine-Driven Generators
1 Introduction 1.1 Read before using WARNING Improper use of equipment could cause serious injury or death. Prior to using this equipment, carefully read, understand, and observe all instructions in this manual and the engine manual. This is an industrial-type electric generator. This equipment is potentially hazardous and could cause physical injury or even death if improperly used.
Introduction: Generator models 1.
Introduction: Specifications 1.4 Specifications 1.4.1 XCR contractor/rental generators Model Max. watts Rated watts Rated voltage Rated amps Fuel Run time capacity 1/2 load (gal.) (hrs.)* Run time full load (hrs.)* XCR30 XCR55 XCR70 XCR80 XCR105 XCR150 XCR180 3000 5500 7000 8000 10,000 15,000 18,000 2400 4500 6500 7500 9500 12,000 15,000 120 120/240 120/240 120/240 120/240 120/240 120/240 20 37.5/18.8 54.2/27.1 62.5/31.3 79.2/39.6 100/50 125/62.5 3 5 10 10 10 10 18 7.9–8.6 5.7–8.3 9–11.
Introduction: Where to obtain service 1.4.4 XAF alternative-fuel generators Model Fuel Max. type* watts Rated watts Rated voltage Rated amps Run time 1/2 load Run time full load LP NG LP NG 8500 8000 11,000 10,500 120/240 120/240 120/240 120/240 70.8/35.4 66.7/33.3 91.7/45.8 87.5/43.8 1.2 gal./hr. 145 CFH 1.6 gal./hr. 190 CFH 1.6 gal./hr. 200 CFH 2.2 gal./hr. 264 CFH XAF105 XAF150 9000 8500 12,000 11,000 *LP=liquid propane NG=natural gas 1.4.
2 Safety 2.1 Operating safety DANGER Explosion hazard. ■ NEVER operate generator in an explosive atmosphere or near combustible materials. ■ Keep generator, engine, fuel, and other combustibles away from sparks, open flame, and burning objects. ■ Do not smoke near engine. ■ Never use generator to jump-start a vehicle. ■ Before filling or draining fuel, stop engine and allow it to cool. ■ Use correct fuel. ■ Replace fuel tank cap after refueling. ■ Do not mix lubricating oil with fuel.
Safety: Operating safety DANGER Asphyxiation hazard. Engine exhaust contains carbon monoxide, a poison gas you cannot see or smell. ■ NEVER operate engine indoors, EVEN IF doors and windows are open. ■ Operate the engine OUTSIDE, far away from doors, windows, and vents. ■ Refill and drain fuel tank only in a well ventilated area. ■ Perform maintenance in a well ventilated area. WARNING Shock hazard. 6 ■ Use extreme caution when working on or with electrical components.
Safety: Operating safety WARNING Fire hazard. ■ Before transporting generator, drain fuel and close fuel-shutoff valve. ■ A hot muffler can ignite flammable materials. Keep area around muffler free of debris such as leaves, paper, and cartons. ■ Remove all unnecessary grease and oil from generator surfaces. ■ Do not leave any flammable material on generator while it is running. CAUTION Risk of severe burn. Do not touch engine, exhaust pipes, or any engine component until cool.
Safety: Operating safety 8 ■ NEVER operate this equipment under the influence or drugs or alcohol. ■ When fueling electric-start engines, do not touch battery cables or posts to gasoline supply can. ■ Before operating, know the location of the nearest fire extinguisher, first aid kit, and emergency telephone. ■ Keep a fire extinguisher nearby and know its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications. For more information, consult your local fire department.
Safety: Engine safety 2.2 Engine safety 2.2.1 Operator safety Before using the generator, refer to engine manufacturer’s documentation for additional engine safety and operating information. 2.2.2 California Proposition 65 WARNING Health hazard. Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 2.2.
Safety: Maintenance and storage safety 2.3 Maintenance and storage safety DANGER Explosion hazard. Do not use gasoline, other fuels, or flammable solvents to clean parts. DANGER Corrosive material. Battery acid will cause severe burns and blindness. ■ Use extreme care when handling or servicing batteries. ■ Never service batteries while generator is operating. ■ Wear appropriate eye and hand protection. ■ Upon contact with skin or eyes, immediately flush with water and seek medical help.
Safety: Maintenance and storage safety ■ Before servicing, ensure power cannot be started inadvertently during service. ■ ALWAYS keep the generator in proper running condition. ■ ALWAYS fix damage to the generator immediately. Repair or replace broken or worn parts. Only use parts from original manufacturer. ■ Replace operation and safety decals when they become difficult to read. ■ When not in use, store equipment in a clean, dry location out of the reach of children.
12 Voltmaster Engine-Driven Generators
3 Operation 3.1 Before starting 3.1.1 Safety Before operating the generator: ■ Read and be familiar with this instruction manual. ■ Read and follow all safety instructions (see Section 2, page 5). ■ Read and follow instructions in the engine manufacturer’s documentation. 3.1.2 Fuel ■ For gasoline-powered models, use unleaded gasoline, 87 octane or higher ■ For diesel-powered models: ❑ In normal ambient temperatures, use No. 2 diesel fuel (DF2) ❑ In cold weather, use No.
Operation: Before starting 3.1.3 Oil CAUTION Crankcase pressure can blow hot engine oil out the fill tube, causing severe burns. ■ Before removing oil cap, stop engine. ■ Loosen cap slowly and with great care. CAUTION Overfilling oil will damage diesel engine beyond repair. ■ Fill the oil sump to the full mark on the dipstick. ■ Check oil level while filling and DO NOT overfill. ■ If accidentally overfilled, drain extra oil.
Operation: Before starting Table 3.1 Recommended oil grade Expected ambient temperature SAE viscosity grade 32°F (0°C) or higher 30 10 to 100°F (–12 to 38°C) 15W-40 0 to 80°F (–18 to 27°C) 10W-30 or 10W-40 –20 to 50°F (–28 to 10°C) 5W-30 Changing the oil Change the engine oil as specified in the engine manual. Oil should be drained while the engine is slightly warm. 3.1.4 Battery for electric-start models For electric-start models, the starter battery is user-supplied.
Operation: Before starting 3.1.5 Location Avoid placing the generator in locations where it will be exposed to high humidity, dust, high ambient temperature, or corrosive fumes. Moisture can condense on electrical components, causing corrosion and short circuits. Accumulation of dirt on components will retain moisture, accelerating wear on moving parts. Provide at least 2 feet (61cm) of space on all sides of generator, for ventilation and servicing. Ensure that the ventilator openings are not obstructed.
Operation: Before starting Fuel shutoff valve An external, manual fuel-shutoff valve is also required. The valve must be installed using the flexible fuel line included with the generator, which isolates the generator vibration from rigid pipeline. The shutoff valve must be installed within sight of the generator. Fuel line The incoming fuel line should be a 1-inch line. Fuel connections on the generator are 3/4-inch NPT.
Operation: Before starting 3.1.7 Standby installations WARNING Shock hazard. Failure to isolate generator from power utility can result in death or serious injury. When using the generator for backup power: ■ Never connect the generator output to any live home or commercial electric circuits. ■ Use a suitable power-transfer device to isolate the generator from the power utility. ■ Use a licensed electrician or electrical contractor to install the power-transfer device.
Operation: Before starting 3.1.8 Preparing for use 1. Ensure the generator is in proper working order: ■ Check the generator for damage and wear. ■ Secure all fuel and wiring connections. ■ Tighten loose screws, nuts, and bolts. ■ If applicable, ensure the starter battery is fully charged (see Section 3.3.3, page 28). If a trickle charger was used when the generator was not in use, disconnect the charger. 2. Read tags and labels, and follow all directions.
Operation: Operating the generator 3.2 Operating the generator 3.2.1 Ground-fault protection The generator features total ground-fault protection. When a ground fault occurs on any receptacle: ■ The ground-fault circuit interrupter (GFCI) fault-sensing module trips the generator’s main circuit breaker ■ Power to all receptacles is disengaged ■ A red LED on the control panel lights up, indicating a ground fault 1. With the engine running, remove all loads. 2.
Operation: Operating the generator 3.2.2 Electrical loads Ratings Complete ratings for the generator are listed on the generator serial number tag, which is attached to the generator housing. Large power tools and large electric motors require additional amperage for starting, as much as two to three times the ampere rating listed on their nameplates. NEVER increase the generator engine speed to get more output from the generator.
Operation: Operating the generator Model XDR diesel generators CAUTION Operating a diesel generator without the proper load will permanently damage the engine. Always operate the diesel engine under load, using at least 25% of its rated capacity. Diesel generators require a load of at least 25% of the generator’s rated output. Operating a diesel generator with insufficient load (referred to as “wet stacking”) will irreparably damage the engine and void the warranty.
Operation: Operating the generator Plugs and connected equipment Use only 3-prong grounded plugs, 3-wire extension cords, and 3-wire or double-insulated power tools with the generator. Full-power switch Some models are equipped with a switch that allows selection of 120-volt power only or both 120- and 240-volt power. ■ ■ ■ When using the generator to power only 120-volt equipment, put the full-power switch in the 120V position.
Operation: Operating the generator 3.2.3 First-time use Break-in period Controlled break-in helps to ensure satisfactory service from the generator. Model XDR diesel generators During the first 5 to 10 hours of operation, operate the generator with electrical loads from 25 to 50 percent of the generator’s rated capacity (indicated on the generator serial number tag). This will ensure the valves are properly seated. After the first 10 hours of operation, change the oil and oil filter.
Operation: Operating the generator Figure 3.1 Fuel mixture adjustment screw Fuel mixture adjustment screw Fuel mixture nut 3.2.4 Starting the generator Diesel recoil start Some diesel generators feature electric-start engines with auxiliary recoil starter. Before starting the engine on these models, if a battery is not available, move the red or black lever near the fuel pump to the up position. If a 12-volt battery is installed, the lever must be in the down position at all times.
Operation: Operating the generator Starting procedure CAUTION Load on generator at startup or shutdown can damage equipment. Remove all electric loads from the generator before starting or stopping the engine. 1. Before operating the generator, follow all instructions in Section 3.1 and Section 3.1.9. 2. Start the generator: 3. 26 a. Disconnect all loads. b. For models with an idler switch, turn the idler off. c.
Operation: Operating the generator 3.2.5 Stopping the generator Gradually remove all loads from the generator before stopping the generator engine. To stop the engine: ■ On models with an electric starter, rotate the key to the off position. ■ On all diesel models, you must keep pressure on the stop lever until the engine comes to a complete stop.
Operation: General maintenance 3.3 General maintenance The generator should be run at least once a month for a few minutes to keep all components in proper operating condition. For engine maintenance requirements, see the engine manual. For troubleshooting, see the Voltmaster troubleshooting manual, available at www.voltmaster.com. 3.3.1 Gasoline-fueled generators Model XCR, XSD, and XTP gasoline-fueled generators are EPA certified and require the following maintenance. 3.3.
Operation: General maintenance 3.3.4 Storage Store the generator in a warm, dry location. If the generator is used infrequently, the engine could become difficult to start. For gasoline-powered generators, a fuel additive can help prevent this situation from occurring. See “Fuel additive” on page 13. Before putting the generator into storage for 6 months or longer, follow these steps: 1. Run the generator until it reaches normal operating temperature (about 10 minutes) and then shut it down. 2.
Operation: General maintenance 3.3.5 Battery For generator models that have a battery, regular maintenance is necessary for the battery to function properly and for long battery life. Safety DANGER Explosive gases can cause blindness and severe injury. When working on or near batteries: ■ Wear eye protection. ■ Prevent sparks and open flames. ■ No smoking anywhere in the vicinity. ■ Keep children clear of the area. DANGER Sulfuric acid can cause blindness and severe burns.
Operation: General maintenance ■ Even when batteries are not in operation, self-discharge generates hydrogen gas that can explode. Always store and work on batteries in a well ventilated area. ■ Always wear proper eye, face, and hand protection when working on or near batteries. Battery acid will cause severe eye damage and skin burns. If contact with battery acid occurs, immediately flush with water and seek medical help. ■ Keep all sparks, flames, and cigarettes away from batteries at all times.
Operation: General maintenance Charging ■ Observe battery safety precautions (see “Safety” on page 30). ■ To lengthen battery life and to prevent freezing, always keep batteries fully charged. ■ The charging circuit is operational during engine cranking and running. The charging circuit is not designed to recharge a dead battery but only to maintain the charge in the battery. If the generator is not in regular, daily use, check battery voltage once a week.
Appendix A Power requirements The information provided in this appendix is for reference only. Values presented here are not necessarily representative of all such equipment. A.1 Sizing the generator In most applications, the generator will provide power to devices that use a total wattage rating up to the rated wattage output of the generator. For example, to power ten 100 watt light bulbs, the generator rated wattage output would need to be 1000 watts (10 × 100 = 1000).
Power requirements: Sizing the generator Table A-1 Approximate current requirements for electric motors Horsepower Running watts Universal motor* Starting watts Induction Capacitor motor motor Split-phase motor 1/6 275 400 600 850 1200 1/4 400 500 850 1050 1700 1/3 450 600 950 1350 1950 1/2 600 750 1300 1800 2600 3/4 850 1000 1900 2600 — 1 1000 1250 2300 3000 — 1 1/2 1600 1750 3200 4200 — 2 2000 2350 3900 5100 — 3 3000 — 5200 6800 — 5 4800 — 7500
Power requirements: Sizing the generator Table A-2 Minimum extension cord gauge Amps 2 3 4 5 6 8 10 12 14 16 18 20 22 25 30 35 40 50 60 Continuous load Watts Minimum gauge @ 120 volts @ 240 volts 0–50 foot length 50–100 foot length 100–150 foot length 240 360 480 600 720 960 1200 1440 1680 1920 2160 2400 2640 3000 3600 4200 4800 6000 7200 480 720 960 1200 1440 1920 2400 2880 3360 3840 4320 4800 5280 6000 7200 8400 9600 12,000 14,400 22 22 20 18 18 16 16 16 14 14 14 12 12 12 10 10 8 6 4 20 18 16
Power requirements: Sizing the generator Table A-3 Approximate equipment power requirements* Household and RV equipment Central air conditioner 10,000 BTU Clothes dryer, electric Clothes dryer, gas Running watts Starting watts 1500 2200 5200 5750 700 1800 Clothes washing machine 1150 2300 Coffee maker 1750 — Computer, desktop 600–800 Computer, laptop 200–250 — Computer monitor 200–250 — Computer printer 400–600 — Dishwasher, cool dry 700 1400 Dishwasher, hot dry 1450 1400
Power requirements: Sizing the generator Table A-3 Approximate equipment power requirements* (continued) Contractor equipment Running watts Air compressor (see Table A-1) 1/2 HP 975 Starting watts 1600 1 HP 1600 4500 1 1/2 HP 2200 6000 7700 2 HP 2800 Bench grinder 8 inch 1400 2500 Circular saw 6 inch 950 2200 7 1/4 inch 1200 2600 8 1/2 inch 1500 3000 10 inch 2000 3900 1/4 inch 300 400 3/8 inch 475 650 Drill Impact wrench 1/2 inch 750 900 1 inch 1000 1250 1/2 inc
Power requirements: Sizing the generator Table A-3 Approximate equipment power requirements* (continued) Farm equipment Running watts Battery charger Starting watts 4 amp 90 — 15 amp 380 — 1500/5750 — 2400/7800 — Electric fence 60 amp with 240-amp boost 100 amp with 300-amp boost 25 mile Grain cleaner 1/4 HP 650 1000 Grain conveyor, portable 1/2 HP 1000 2400 50,000 BTU 400 675 100,000 BTU 500 1260 625 1875 Heater, portable liquid-fuel type 150,000 BTU 250 — Heater, porta
Voltmaster is a Wanco brand. Voltmaster, Wanco, and the Voltmaster and Wanco logos are registered trademarks of Wanco Inc. All other trademarks are property of their respective owners. WANCO INC. 5870 Tennyson Street Arvada, Colorado 80003 800-730-3927 303-427-5700 303-427-5725 fax www.voltmaster.com ©2012 Wanco Inc. All rights reserved. Printed in the USA. | 207071 Rev.
