Gillette Generators SP-1200 Installation Manual Download Page 1

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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-8005N

SP-960

SP-1200
SP-1500

GILLETTE GENERATORS

AUTOMATIC POWER SYSTEMS

OGU06-OWN795-20131219

Summary of Contents for SP-1200

Page 1: ...STALLATION GUIDE FOR DRY FUEL MODELS GM DRIVEN DRY FUEL GEN SETS SP 200 SP 250 SP 300 SP 410 SP 520 SP 620 SP 8005N SP 960 SP 1200 SP 1500 GILLETTE GENERATORS AUTOMATIC POWER SYSTEMS OGU06 OWN795 20131219 ...

Page 2: ...ry Fuel Pipe Sizing Instructions 19 21 Gaseous Dry Fuel System Natural Gas 21 22 Gaseous Dry Fuel System Liquid Propane Vapor Gas LPV 22 23 12 VDC Starting Battery Installation 24 25 Engine Oil and Engine Radiator Service 25 26 Automatic Transfer Switch ATS 26 27 Engine Spark Plug Service 27 Terminal Connector Torque Tightening Information 28 Electrical Mechanical Formulas That May Be Useful 29 Se...

Page 3: ...o ensure that any person operating this generator has access to all GILLETTE manuals and information required for the safe use and operation of this generator It is the responsibility of the owner of this generator to ensure that any person operating this generator has been properly trained It is the responsibility of the owner of this generator to ensure that it is properly maintained at regular ...

Page 4: ...s situations because they can catch loose clothing or extremities and cause serious of 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 Rotating parts can snag loose clothing or extremities and cause serious or fatal injury DANGER Disconnect the battery s ground terminal before working in the vicinity of t...

Page 5: ...nerator may cause illness injury or death DANGER Do not dispose of battery or batteries in a fire or mutilate the battery The battery is capable of exploding If the battery explodes electrolyte solution is caustic and can cause sever burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly WARNING Never permit anyone to opera...

Page 6: ...de heat generating equipment water or steam discharge systems or in the vicinity of corrosive substances or vapors metal particles and dust Heat can cause engine problems to develop and unwanted substances can cause rust or generator failure over time Steam or water penetration will destroy generator windings CAUTION Do not operate generator in tropical ambient conditions without a special protect...

Page 7: ... FORM THAT IS TO BE RETURNED TO GILLETTE GENERATORS INC IMPORTANT SAFETY RULES The safety alert symbol is used as a signal for possible danger caution warning or general hazard DANGER Indicating a hazard that if not avoided will result in death or serious injury WARNING Indicating a hazard that if not avoided could result in a serious injury CAUTION Indicating a hazard that if not avoided might re...

Page 8: ...by generator requires a 12 VDC or 24 VDC fully charged battery Released battery electrolyte can burn your skin and eyes and is toxic When electrolyte touches skin wash it off immediately with water and seek medical attention When electrolyte contacts eyes flush thoroughly with water and seek medical attention Spilled electrolyte must be washed away with an acid neutral agent Use a solution of one ...

Page 9: ...r s home or any buildings that house animals POTENTIAL BURN OR FIRE CONDITIONS Contact with exhaust muffler and exhaust pipe can result in serious burns Exhaust heat may ignite combustibles such as leaves or other such debris that is allowed to accumulate around base or interior of generator where exhaust exits Do not touch hot exhaust or engine parts and avoid hot exhaust gases Keep at least a th...

Page 10: ...ally safe against harm and hazards to operators buildings or environments UNPACKING AND INSPECTION After receiving the generator note that it is mounted on a heavy wood skid base and protected by clear plastic wrap While the transportation carrier is still present note the condition of skid and generator set If damage occurs make a note of damage on carrier s freight bill and have truck driver sig...

Page 11: ...circumstances and to plan the best installation possible First Federal State and local codes may be a factor The local fire department can be of help on learning these codes As with all generators your generator must be installed in accordance with current NFPA 37 and NFPA 70 standards Contact your local electrical inspector or city hall to insure you are aware of all codes and regulations Contact...

Page 12: ...e and crate appears damaged note this crate damage on shippers Bill of Lading indicating product damage may be possible due to crate damage C If gen set is to stored for a long period before use the storage area should conform to published storage temperature and humidity specifications When lift or hoist equipment is used to lift the gen set be careful not to contact overhead power lines or any o...

Page 13: ...36 34 86 1070 485 47 119 1470 667 SP 300 14 6 34 49 1 2 62 68 7 36 36 34 86 1120 508 47 119 1520 689 SP 410 16 6 4 1 4 51 1 2 72 78 8 39 42 36 91 1326 601 53 134 1806 819 SP 520 16 6 4 1 4 51 1 2 72 78 8 39 42 38 97 1670 757 53 134 2150 973 SP 620 16 6 4 1 4 51 1 2 72 78 8 39 42 38 97 2097 951 53 134 2411 1094 SP 8005N 24 6 4 1 4 55 74 1 2 104 98 12 45 48 50 127 2097 943 72 1 2 183 2829 1283 SP 96...

Page 14: ... double walled room sound deadening materials on wall hospital grade muffler etc 5 Building code and safety requirements for open gen set operation within a building are important to know and compliance to the codes are essential National Electric Code Articles 230 250 245 517 and 700 National Fire Protection Association NFPA 37 Stationary Combustion Engines and Gas Turbines 99 Essential Electrica...

Page 15: ...SAFE EXHAUST SYSTEM A Do not allow engine exhaust gases to re circulate into engine s cooling air input B Use an exhaust pipe rain cap on vertical pipe ending Rain getting into exhaust pipe system will cause eventual corrosion and damage to the entire exhaust system C The remote muffler must be mounted as close to the engine as possible or it will carbon up if its operating temperature is too low ...

Page 16: ... 200 SP 250 SP 300 2 CR 2 RESIDENTIAL GRADE 15 CC 2 CRITICAL GRADE 19 SP 410 SP 520 SP 620 2 CR 2 RESIDENTIAL GRADE 20 CC 2 CRITICAL GRADE 32 SP 8005N SP 960 3 CR 3 RESIDENTIAL GRADE 32 CC 3 CRITICAL GRADE 52 SP 1200 SP 1500 3 CR 3 RESIDENTIAL GRADE 38 CC 3 CRITICAL GRADE 63 MUFFLER MOUNTING TO GENERATOR GILLETTE uses a 50 50 mix of glycol di ionized water When replacing coolant in radiator DO NOT...

Page 17: ... difference between the two thermometers should be no more than 20º F STARTING BATTERY All generator models have a fixed position for installer furnished 12 VDC starting battery A corrosion free battery tray is furnished with woven hold down strap Positive and Negative battery cables are installed and ready for connection to installed battery While installing the battery notice the Positive batter...

Page 18: ...5 RECOMMENDED ENGINE OIL SP 1200 8 5 8 1 K Intelligent Battery Charger Upgrade conforming to NFPA 110 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 M Command Elite Controller Upgrade for complete remote access controlling or monitoring generator from anywhere in the world with interne...

Page 19: ...tration of salt water exposure USA Coastal Regions and Tropics will require frequent washings and a final waxing of generator housing much like an automobile s special care in these areas Salt corrosion may enter the generator interior which may have to be removed by special detergents Every 3 months spray the engine governor linkage springs and other engine control moving parts with a light spray...

Page 20: ...EL 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 3 ENGINE HP FOR NATURAL GAS FUEL 42 42 42 59 95 95 138 138 184 228 NATURAL GAS FUEL CU FT HR 387 431 539 554 685 807 1115 1275 1750 2420 NATURAL GAS FUEL CU M HR 10 9 12 2 15 3 15 7 19 4 22 8 31 6 36 1 49 5 68 5 GEN SET KW 20 25 30 41...

Page 21: ...r is extended in length its ability to carry the volume of gas diminishes in direct proportion INSTALLER S RESPONSIBILITY Use chart Table A on page 20 to learn fuel cubic feet hour value of generator to be installed Use Natural Gas fuel chart Table C to learn minimum pipe size diameter and maximum distance from gas meter to insure sufficient fuel volume from natural gas meter to generator set CRIT...

Page 22: ...ROPER LPV VAPOR WITHDRAWAL INSTALLATION This generator system has been set up at the factory for natural gas fuel unless it has been specifically ordered for vapor withdrawal liquid propane gas LPV This installation operation guide will explain the factory LPV system Additional information is available upon request for field conversion from one fuel to the other LPV fuel is typically at farms or r...

Page 23: ...operly it may indicate fuel line length is too long or fuel line diameter is too small to deliver proper volume of fuel Check fuel line diameters on page 20 NOTE After completion of all gas tests remove manometer and replace blank plug using fresh pipe sealant Climates that have snow and ice build up along with sub zero temperatures should have LPV fuel pipe protection against freezing The generat...

Page 24: ...ls 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 Explosions from battery or dry fuel fumes being ignited by careless smoking or sparks from mishandled tools All hinged or bolted panel contains access to A C ...

Page 25: ...emove the oil dipstick wipe it clean re install oil dipstick then remove it again to check the oil level See diagram below Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the gen set before removing oil dipstick or oil fill cap NOTE A typical oil dip stick is shown in figure 12 where as proper oil level should be between Upper Limit and Lower Limit ...

Page 26: ...L LOAD TO BE APPLIED TO GENERATOR IN WATTS NEVER EXCEED 75 OF GENERATOR RATING IN ACTUAL ing on the specific setup at this location The auto transfer switch will switch the connected load from utility to emergency generator power Note that engine generator set must start under an immediately applied load In most cases the gen set is strong enough to perform under this demanding scenario However if...

Page 27: ...quid cooled with a radiator Inspect the debris guard on engine air intake to insure no obstructions have accumulated Inspect radiator to insure no debris accumulation has occurred Some generator models have bug rodent screens Inspect and clean off any aluminum screens that may collect debris EXHAUST SYSTEM Engine end of generator set will be the hot exhaust discharge Keep any combustibles building...

Page 28: ...LOT HEAD 4 7 mm NO 10 OR LARGER HEXAGONAL HEAD EXTERNAL DRIVE SOCKET WRENCH AWG kcmil mm2 SLOT WIDTH 1 2 mm 0 047 in SLOT LENGTH 6 4 mm 0 25 in SLOT WIDTH 1 2 mm 0 047 in SLOT LENGTH 6 4 mm 0 25 in SPLIT BOLT CONNECTORS OTHER CONNECTIONS 18 10 0 82 5 3 2 3 20 4 0 35 9 0 80 8 5 75 8 8 4 2 8 25 4 5 40 9 0 80 8 5 75 6 4 13 3 21 2 4 0 35 5 1 45 18 6 165 12 4 110 3 26 7 4 0 35 5 6 50 31 1 275 16 9 150 ...

Page 29: ...hes Hg kPa 0 1333 x inches Hg MISCELLANEOUS Watt x 0 00134 hp Watts x 3 4122 BTU hr BTU hr x 0 293 Watts hp x 2545 177 BTU hr BTU hr x 0 0003929 hp AREA inches2 x 6 451 cm2 cm2 x 0 394 inches2 feet2 x 0 0929 m2 m2 x 10 764 feet2 TORQUE oz in x 0 007062 Nm Nm x 141 6029 oz in lb in x 0 11296 Nm Nm x 8 8495 lb in lb ft x 1 356 Nm Nm x 0 7376 lb ft SINGLE PHASE ELECTRIC Single Phase Power Factor is t...

Page 30: ...6 OWN 795 20131219 Gillette Generators Inc 2921Thorne Drive Elkhart IN 46514 Phone 574 264 9639 Fax 574 262 1840 E mail sales gillettegenerators com www gillettegenerators com Call for Tech Support 1 800 777 9639 Email service gillettegenerators com ...

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