CP10WE Technical Book (English)

CP 10WE
10
Control
Yanmar Cogeneration Package
Installation Work Manual

CP10WE
This Installation Work Manual describes how to install the YANMAR Cogeneration Package
CP10WE, and includes work procedures and points to note during installation.
Single installation covered by G83/1 notification at or before day of commissioning
followed by G83/1 paperwork (G83/1 appendix 3) within 30 days.
Multiple installation covered by G83/1 application to proceed (G83/1 appendix 2). On
commissioning notification and appendix 3 as above.
1) Introduction
This Installation Work Manual employs the following symbols to ensure safe installation work of
the product. As these instructions are very important, ensure they are observed.
Warning
Denotes a case in which operating errors may cause dangerous
Caution
conditions leading to serious injury or death.
conditions leading to light or moderate injury and conditions where

only equipment damage may occur.
Note that there are cases where

serious consequences.
(1)
Caution markings can also indicate conditions that can have
Warning
Do not perform installation yourself. Ask your dealer or a qualified technician to install the system. If the
unit is not installed correctly this could lead to issues such as poisoning if exhaust gas enters buildings,
water leakage, electric shock, or fire.
(2)
Warning
Carefully follow the instructions in this manual when performing installation. If the unit is not installed
correctly this could lead to issues such as poisoning if exhaust gas enters buildings, water leakage,
electric shock, or fire.
(3)
Warning
Confirm that the fuel gas supplied is the same as the category specified on the unit. Use of a fuel gas other
than the specified category could cause incomplete combustion, leading to carbon monoxide poisoning.
64
2) Selection of Installation Locations

(1)
Warning
When the unit is installed outside a building, it should be located so that exhaust gas does not enter the
building via windows or ventilation ducts and piping connected to the building, etc. Inflow of exhaust gas
into buildings could cause poisoning or other problems. When extending the exhaust piping, install the
exhaust piping extension kit (option) with reference to the Exhaust Piping Work Manual.
(2)
Warning
When the unit is installed inside a building, the exhaust gas piping should be routed so that it discharges into
the open air outside the building. Locate the exhaust gas outlet with care so that exhaust gas does not enter
the building via windows or ventilation ducts and piping connected to the building, etc. The accumulation of
exhaust gas inside the building could cause poisoning or other problems. When extending the exhaust piping,
install the exhaust piping extension kit (option) with reference to the Exhaust Piping Work Manual.
(3)
Warning
When the unit is installed inside a building, install a gas leakage alarm and an incomplete combustion
alarm (CO detector) in the vicinity of the unit. If leaked gas accumulates inside the building, it could
cause an explosion or fire. The signal lines of the alarms should be connected to the terminals for the
external stop signals of the unit.
(4)
Warning
When the unit is installed inside a building, maintain the required ventilation level for the unit. If the
ventilation level is inadequate, it could cause incomplete combustion, resulting in poisoning or
performance degradation and malfunctioning of the unit. Connect a ventilation fan so that it is linked to
the operation signal of the unit and thus runs during operation of the unit.
(5)
Warning
Install the unit in an open space so that exhaust gas does not accumulate. If the exhaust gas enters a
building, it could cause poisoning, etc.
(6)
Warning
Discharge the exhaust gas into the open air at a location where it will not negatively affect the
surrounding area. (Exhaust gas must not be discharged into drainage gullies or ditches.) If the exhaust
gas enters a building, it could cause poisoning, etc.
(7)
Warning
Install the unit in a place that can fully support the weight of the unit. If the location is not strong enough,
the unit could topple over or fall, causing injuries, etc.
(8)
Caution
When the unit is installed near a parking lot or in similar places where there is a possibility of it being
accidentally hit by a car, take preventative measures such as positioning a car barrier.
65
(9)
Caution
Maintain the specified distance between the unit and flammable substances. If the distance is
insufficient, the unit could cause a fire.
(10)
Caution
Do not install the unit in a place where there is a possibility of the generation, inflow, accumulation, or
leakage of flammable gases, or where volatile flammable substances are handled. This could result in a
fire due to the ignition of flammable materials or gases.
(11)
Caution
Do not install the unit in a place where exhaust gas or air expelled by the fan will hit garden trees, etc.
This exhaust gas or air discharge could cause damage to the trees, etc.
(12)
Caution
Maintain the specified space for inspection and maintenance work. If the space is insufficient, personnel
could fall from the installation site and suffer injuries.
(13)
Caution
When the unit is installed on a rooftop or in a high place, set permanent ladders or handrails along the
route to the unit, and fences or handrails around the unit to prevent falls.
(14) Install the unit in a place where there will be no short circuit due to hot air from the radiator or the
accumulation of exhaust gases. When the unit is installed inside a building, use the specified duct to
route the hot exhaust air from the radiator to the outside without air leakage and expel it with a
pressure fan.
(15) Install the unit so that the hot air from the radiator or the exhaust gas has no direct effect on other
equipment.
(16) Install the unit in a place where there will be no adhesion of foreign substances to the radiator and no
materials (exhaust outlet, exhaust flue, etc.) that could cause significant deterioration of the exterior of
the unit.
(17) Install the unit in a place where noise or vibration will not cause problems around or below the
installation site. (Particularly in residential areas, care is required regarding the periods of operation.)
(18) Install the unit in a place where there are no walls near the unit that could reflect or resonate with the
operation noise.
(19) It must be possible to carry in, carry out, disassemble, and maintain the equipment. Depending on the
work processes, other equipment may be installed along the route or in the entrance after the unit is
carried in. Care is required as this could make it difficult to carry out the unit at a later date.
(20) Refer to Section 3 when installing two or more units in parallel.
(21) Avoid places with a large amount of dust or litter.
(22) Avoid sloping areas.
66
3) Installation Space Requirements

Caution
Secure the specified space for inspection and maintenance work. If the space is insufficient, it could
cause injuries due to a fall from the installation site.
Single unit installation
Multiple units installation
600 or more
600 (300)
or more*2
2000 or more
3790 or more
2000 or more
2000 or more
4040 or more
2270 or more
3790 or more
(300 or more)*2
800 or more
200 (600)
or more
800 or more
600 (300)
or more*2
2200 or more
800 or more
2200 or more
200 (600)
or more
600 or more
Secure 600 mm in either side of left or right for maintenance
600 or more
Secure 600 mm in either side of left or right for maintenance
Unit: mm
029013-00E
Notes
1: When surrounding the unit with soundproof walls, attach openings (louvers or the like) to the
bottom of the soundproof walls. (To prevent the short cycle of radiating air.)
2: Decide installation space after consideration of the piping space.
3: If the distance of retention is specified by local-government fire prevention ordinances and
enforcement regulations, secure the installation space according to these regulations.
4: Give consideration not to cause problems for neighboring houses due to operating noise,
radiating air, or hot ventilation air.
5: Depending on the situation, the site may be filled with radiating air and this has an effect on
performance. Prevent a short cycle with the optional wind direction boards, etc.
67
4) Installation of Cogeneration Package

Warning
Fix the cogeneration main unit with anchor bolts to prevent falls and to make the base firm and
horizontal. If the base or the anchorage is not fixed sufficiently, it could cause gas leaks or injuries due to
a unit falling from its installation site.
(1) Dimensional drawing of base (for reference)

Direct mount
Anti-vibration mount
4-100 hole
For use of box-out L-type/
LA-type bolt
F.L.
1900
150
90
200
Reinforcing bar 10
150
90
200
Reinforcing bar 10
F.L.
310
310
310
150
150
F.L.
310
(280)
(200)
Embedded depth A (mm)

Type of anchor
Size
bolt
Direct mount Anti-vibration mount
Male screw
mechanical
Resin
M12
300
300
300
300
300
(200)
029014-00E
When the unit is installed indoors, a syphon(option)

should be installed(see Section 8.)
If the back pressure of the extension of the exhaust-piping
exceeds 800Pa, use a long-syphon and make the height
of the base from F.L. to 250mm or more.
L-type/LA-type
350
840
1800
(280)
1300
1250
F.L.
850
4-14.5 hole
For use of resin
anchor bolt or
mechanical anchor bolt
350
350
4-14.5 hole
For use of resin
anchor bolt or
mechanical anchor bolt
350
860
1300
350
350
4-100 hole
For use of box-out L-type/
LA-type bolt
60 or more
70 or more
60 or more
70 or more
30 or more
40 or more
Notes
1. For use of box-out L-type/LA-type bolt
When laying the concrete for the base, provide a box-out for fixing
the anchor bolts, fix the anchor bolts, and then secure them in the
concrete.
2. It is sometimes necessary to change the thickness of the base
depending on the foundation strength, so carry out the work after
consulting construction engineers.
3. Earthquake-resistance strength: Horizontal seismic coefficient of 0.6
(Numeric values with * show the dimensions in the case of a
horizontal seismic coefficient 1.0.)
4. When using a smaller base, join the base and the structure with
reinforcing bars.
(2) Points to note in constructing the base

Set the standard compounding ratio, cement 1:
sand 2: aggregate 4, and insert reinforcing bars
of 10 (interval: approx. 300 mm) into the base.
Finish the surface with mortar so that it is flat.
Chamfer the edges of the concrete.
When setting the base on a concrete floor,
rubble is not necessary, but make the concrete
surface of such parts uneven.
Build the waterway around the base, and pay
attention to the drainage around the machine.
When installing the unit on a rooftop, be careful
about the surface strength, and be sure to
make the area waterproof.
68
In places where the soil has a low weight-bearing

capacity (clay layer, sand area, loam layer), be
sure to carry out foundation improvement work.
Fix the cogeneration main unit with anchor
bolts to prevent falls and to make the base firm
and horizontal.
When installing the unit in places such as on a
roof, rooftop, or balcony where noise or
vibration may become an issue, use antivibration mounts.
Observe any relevant local laws and
regulations related to the installation of the unit.
5) Carrying-in
Warning
Lift the unit in the specified places in the specified way. If it is lifted in other places or in other ways,
there is a possibility of damage or dropping.
Keep out from under the lifted unit.
The carrying-in and installation processes involve risk. It is important to carry in and install the unit properly in
the specified place, while paying attention to safety.
Carry out the loading and unloading work
Lifting belt (Nylon sling)
to and from vehicles calmly with due
For 1.5 t (Width of belt: 50 mm or more)
consideration to the center of gravity.
Never load or unload the units on their
sides and pile up.
At the time of lifting, use the lifting belts
(nylon slings), and be careful not to cause
Insert a blanket cloth so as
damage to the unit.
not to damage the unit.
(Local procurement)
Depending on the situation, decide the
work method, personnel, and mechanical
handling equipment. In addition, when
using mechanical handling equipment,
have qualified personnel handle it.
Mass (Including lubricating oil and cooling water): 790 kg
Caution
When lifting the unit with a crane, lift
the unit with the nylon slings as shown
in the figure. Use two nylon slings with
a lifting load of more than 1.5 t and a
width of more than 50 mm.
Lifting position plate
69
029015-00E
6) Hot Water Piping

(1) Make sure to fasten the screws, bolts, and nuts of the hot water pipes. Be careful not to damage them
by over-fastening.
(2) Fix 48.2 L/min (max. of +5%: 50.6 L/min) as the rated flow rate for the hot water piping.
(3) Use steel or stainless steel pipes for the hot water piping.
(4) Use the pipe of 1 (O.D.33.4mm) or more for the hot water piping and 2.0 m/sec or less for the flow
speed.
(5) Set the pressure of the hot water inlet to 8 bars or less. Incorporate of a hydraulic safety group and/or a
pressure relief valve in accordance with the local regulations.
(6) Perform the heat insulation work for the hot water pipes.
(7) Fix the hot water piping with supports.
(8) Install the hot water piping so that it does not become an obstacle to maintenance.
(9) When the unit is installed on an anti-vibration mount, be sure to use flexible pipes and adequately deal
with any potential vibration.
(10) Before connecting the piping to the unit, clean inside the hot water pipes to remove any dust or dirt.
(11) Install the hot water piping so that air bleeding can be performed. The air bleeding must be performed
with high reliability.
(12) Link the operation of the hot water circulation pump to the operation of the cogeneration main unit.
(13) Attach a thermometer and manometer to the hot water pipes to confirm operation after performing the
piping work.
Customers arrangement
Rear Side
Flexible pipe
Thermometer
Cock
Front Side
Front Side
Rear Side
Hot water inlet (R1)
70
Hot water outlet (R1)
029016-00E
7) Fuel Gas Piping

Installation must be according local and national standards or legislation.
(1)
Caution
Confirm that the fuel gas supplied is the same as the type specified on the unit.
Use of a fuel gas other than the specified type could cause incomplete combustion,
leading to carbon monoxide poisoning
(2)
Caution
Use reinforced gas hoses approved for gas or low-pressure gas hoses with a joint fixture for liquefied
petroleum gas hoses between the gas cocks of the fuel gas piping and the unit. If a gas hose other than
the specified ones is used and it is damaged by vibration, it may cause a fire, etc. due to a fuel gas leak.
(3)
Caution
After the completion of the fuel gas fitting work, check that there is no gas leak along the fuel gas piping
route. If there is any fuel gas leak, it may cause a fire, etc.
(4) Before connecting the piping to the unit, clean inside the fuel gas pipes to remove any dust or dirt.
(5) When there is contamination in the fuel gas piping, attach a strainer between the reinforced gas hose
and the cock.
(6) If sealing tape is used on the thread of the screw, it eats the valve seat of the gas regulator and may
cause a gas leak. Use tight seals, etc.
(7) Be careful that the piping of the fuel gas inlet does not become an obstacle to maintenance work.
(8) Fix the piping of the fuel gas inlet with supports.
(9) When the cogeneration main unit is installed on an anti-vibration mount, be sure to take adequate
measures against any vibration.
(10) When the unit is installed inside a building, install a gas leakage alarm and an incomplete combustion
alarm (CO detector) in the vicinity of the unit. If leaked gas accumulates inside the building, it could
cause an explosion or fire. The signal lines of the alarms should be connected to the terminals for the
external stop signals of the unit.
Reinforced gas hose
Gas cock
25A or more (Gas inlet pipe)
Customers
arrangement
Rear Side
Front Side
Fuel gas inlet (R1)

029017-00E
71
8) Exhaust Drain Piping

(1)
Caution
Use the supplied hose for an exhaust drain. After checking the local regulations of the jurisdictional area,
extend it to the appropriate place for the drainage of the discharge and secure the tip. When installing
multiple units, install the piping of each unit separately. When installing multiple units as a group, install
the specified exhaust drain piping as indicated in the diagram below.
(2)
Caution
When the cogeneration main unit is installed above a room, extend the exhaust drain piping to an outlet
that is appropriate for the discharge of water. If drainage is discharged directly onto floor surfaces, it may
cause staining of waterproof sheeting or damage to concrete surfaces.
(3)
Caution
Install the drain hose so that it has a definite slope

and there will no pooling of water or clogging. If
the drain water freezes in the hose in winter, the
engine may not be able to run.
(4)
Inner syphon
(neutralizer)
Exhaust drain piping
Drain outlet
Caution
When the unit is installed indoors, a syphon must

be installed correctly.
Extending the length of the drain piping causes the
volume of drainage to increase. An additional
neutralizer must be installed.
The siphon outlet may not be connected directly to
the drain of the building (no fixed connection),
drainage must be with an open connection into a
siphon of the building.
When the unit is installed indoor
Indoor
Exhaust drain hose

Air release
Exhaust drain hose

14/19 x L1500 attachment
029021-01E
Exhaust
ventilation according national or local requirements
Install the syphon correctly and there will no pooling

of water or clogging.
CP10WE There are two kinds of syphon (short one and long
one).
Use along syphon if the back pressure of the
extension of the exhaust piping exceeds 800Pa.
In that case, make the height of the base to 250mm
or more to have a definite slope.
Drain piping
After the first installation and the maintenance,

fill this syphon with the water before running the unit.
The syphon
Extend it to the appropriate place

for the drainage Fuel pressure
(Pa)
The Base
The syphon and neutralizer must be
ordered as an optional kit.
Neutralizer
Syphon select
Short syphon applicable

0~800
800~1500 Long syphon applicable
The siphon outlet may not be connected directly to the drain

of the building (no fixed connection), drainage must be with
an open connection into a siphon of the building.
029020-01E
72
9) Ventilation Amount of Generator Room

The ventilation airflow rate that is required for the building or room that houses the microgeneration unit is
determined by radiator exhaust rate, airflow rate required for gas engine combustion, airflow rate
required for controlling room temperature increase and the considerations of staff responsible for site
safety.
Exhaust pipe
Generator room
Radiator exhaust rate:

5,500 m3/h
Airflow rate required for
controlling room
temperature increase
Airflow rate required for
gas engine combustion:
60 m3/h
Package
Reference
Ventilation airflow
rate inside package:
850 m3/h
Engine room
Generator
room
Decide the airflow rate for

generator room so that the room
temperature during operation
does not exceed 40C.
Guide the exhaust air from
radiator to outdoors via a duct
and use a positive pressure fan.
Required ventilation airflow rate Q
Eng
030992-00E
Required ventilation airflow rate for generator room, Q: Ensure that Q is greater than the result of
the calculations , and below.
For electricity-oriented operation: Q > + +
For heat-oriented operation:
Q>+
Calculation example 1
Calculation example 2
Conditions
- Temperature of ventilation air to generator room: 30C
When controlling generator room temperature to 40C max.
(Room temperature increase: 10C max. (: Q2 = 850 m3/h)
- Natural gas G20 (calorific value: 35.9 MJ/m3N)
Conditions
- Temperature of ventilation air to generator room: 35C
When controlling generator room temperature to 40C max.
(Room temperature increase: 5C max. (: Q2 = 1,700 m3/h)
- Natural gas G20 (calorific value: 35.9 MJ/m3N)
For electricity-oriented operation

Q = + + = 5,500 + 60 + 850 = 6,410 m3/h min.
For heat-oriented operation
Q = + = 60 + 850 = 910 m3/h
For electricity-oriented operation

Q = + + = 5,500 + 60 + 1,700 = 7,260 m3/h min.
For heat-oriented operation
Q = + = 60 + 1,700 = 1,760 m3/h
Detailed calculations
(1) Radiator exhaust rate*: 5,500 m3/h min ......................................................
(2) Required airflow rate for gas engine combustion: Q1 (m3/h)
* Guide the exhaust air from radiator to outdoors via a duct and use a positive pressure fan.
<Formula> Q1 = B 3.6 9.524 0//35.9 ..........................................
where, B
: fuel gas consumption (32.34 kW)
3.6
: 1 kW = 3.6 MJ
9.524 : theoretical air requirement (for natural gas) (m3N/m3N)
: excess air factor (1.51)
: air density at 0C and 1 atm. pressure (1.29 kg/m3N)

0
: intake air density (1.128 kg/m3 at 40C)
35.9 : calorific value of G20 natural gas (MJ/m3N)

<Calculation example> CP10WE and G20 natural gas (calorific value being 35.9 MJ/m3N)
Q1 = 32.34 3.6 9.524 1.51 1.29/1.128/35.9 = 53.3 60 (60 m3/h min.)
For other calorific values of gas, calculate similarly, using the values shown above.
73
(3) Required airflow rate for controlling room temperature increase Q2 (m3/h)
<Formula> Q2 = B 3.6 0.08/T//Cp ........................................................
where, B
: fuel gas consumption (32.34 kW)
3.6
: 1 kW = 3.6 MJ
0.08 : ratio of heat radiation from engine and generator
T
: permissible room temperature increase (C)
: intake air density (1.128 kg/m3 at 40C)
Cp
: specific heat of air at constant pressure (9.75 10-4 MJ/kgC at 40C)
Design generator room so that the room temperature will not exceed 40C.
<Calculation example 1> Required airflow rate for controlling room temperature to 40C max.
when temperature of ventilation air to generator room is 30C (temperature increase T = 10C max.)
Q2 = 32.34 3.6 0.08/10/1.128/0.000975 = 847 850 (850 m3/h min.)
<Calculation example 2> Required airflow rate for controlling room temperature to 40C max.
when temperature of ventilation air to generator room is 35C (temperature increase T = 5C max.)
Q2 = 32.34 3.6 0.08/5/1.128/0.000975 = 1,694 1,700 (1,700 m3/h min.)
To control room temperature to 40C at maximum when temperature of ventilation

air to generator room is 35C (temperature increase T = 5C max.), the required
airflow rate is twice that required in the case of calculation example 1 (T = 10C).
Decide the required ventilation airflow rate for generator room according to the permissible temperature
increase.
If operators enter the room while the system is in operation, add 30 m3/h per person ............
74
10. Flue system

Installation must be according to local and national standards or legislations.
Warning
Construct the piping of the exhaust extension alone without the confluence of other piping.
Connect each piping by the welding or the flange connection. Confirm there is no leakage from all
joints in the test run.
Locate the outlet port of the exhaust gas to the position in which the exhaust gas doesn't hazardously
affect surroundings. Note that the exhaust gas doesn't enter indoor again.
Warning
When the unit is installed on an anti-vibration mount, be sure to use flexible pipes and adequately deal
with any potential vibration. Construct the flexible pipes vertically so that the condensed water is not
collected in the piping.
Construct the total extension of the exhaust-piping so that the back pressure is 1.5 kPa or less. If the
back pressure exceeds 200 Pa, use the stainless flue system completely welded and verify that the
system is sound (no leakage).
Construct the exhaust piping applying the inclination (2 degree or more) so that the condensed water
is not collected in the piping.
Adjust the direction of flue exit or install the cover so that the falling object don't enter from the
flue exit.
Construct the exhaust piping so that there is not obstacles around the flue exit.
Refer to the table below. The table is the result of the calculation of the diameter/maximum-length of a
straight-tube as 200 Pa.
Use the pipe of 1 1/2 (O.D. 48mm) or more.
Use the adapted pipe to AlSl 316L, 316 Tl or 304L, or the same quality pipe.
Joint
(The joint is supplied as option.)
Install stainless wire

mesh or louver.
Top cover
Mist separator
The inclination of pipe
When the unit is installed

on the anti-vibration mount,
use the flexible pipes
Install it vertically.
(The flexible pipe is
supplied as option.)
Joint
Customers
arrangement
Please fix the pipe at this position.
The Top of the Unit
CP10WE
029019-01E
75
11) How to install Inverter KP40G

(1) Mounting Dimensions
430
198
19
150
150
120
280
399
92
150
030994-00X
(2) Safety Precautions

Do not install the Unit on ocean-going vessels or in places near the seacoast that are subject to
saltwater spray.
When installing outdoors, be sure to provide an awning or eave of some kind to prevent direct sunlight or
rain from striking the Unit.
Leave space of 200 mm minimum between the Unit and the ceiling or eave, 600 mm minimum between
the Unit and the floor or ground, and 500 mm minimum between the Unit and right or left wall.
200mm min.
500mm min
500mm min
600mm min.
030995-01X
When installing multiple Inverters, leave a space of 500 mm minimum to the side of the Inverter. Do not
install multiple Inverters vertically.
Incorrect
500 mm min
030996-00E
76
Mount the Inverter in the specified direction.

Correct
Incorrect
Correct
Incorrect
60min.
Mount Inverter straight or tilted to back
Never mount tilted to front
030997-00E
(3) Mounting Precautions

Mount the enclosed caps on any MC connectors or communications plugs that are not used. (It is 6
pieces attached to CP10WE.)
030998-00X
Mount the mounting base plate to the wall using the enclosed mounting screws. Install the product in a
location that will be able to support its weight (24 kg). The installation location must be able to withstand
the force of 80 Nm of torque at each mounting screw. Refer to P18 for the mounting dimensions.
*Be sure to mount it using all six screws.
030999-00X
Hang the KP40G main body on the two support ridges of the mounting base plate.
031000-00X
Use the M5 body mounting screw included with the enclosed screw set to secure the KP40G main body
to the mounting base plate. Tighten the screw with 2.5 to 3.0 Nm of torque.
031003-00X
77
12) Points to Be Checked after Completion of Work

(1) Operation Check after Exhaust Gas Piping Work
Perform operation check after completion of the exhaust gas piping work.
Is not there any gas or daring leakage from the connection areas of the exhaust gas piping during operation?
Does not the vibration from unit convey to the exhaust gas pipes?
Does the discharged gas from the exhaust gas outlet release into the open air without negative effect
on the surrounding area?
< Sound generated from the exhaust gas pipes >
If a long pipe is connected after the gentle-sloped pipe, water-stirring like sounds may happen to be
generated from inside the exhaust pipes. This is no problem because the exhaust drain stays inside the
exhaust gas pipe and generates the sound in combination with the exhaust gas.
In order not to prevent the generation of sound, make the slop of the piping steep not to keep the exhaust
drain inside the pipe.
(2) Recheck: Recheck the following items.
Check Items
In Case of Defects
Is the unit installed securely?
Falls, vibration, noise

Not possible to perform maintenance
Has the required maintenance space been secured?

Is the hot water piping secure?
Water leakage
Has flexible piping been used for the hot water inlet/outlet of the unit?
Damage to piping, water leakage
Are the water volume, water speed, piping size, and pressure of the hot water piping appropriate?
Damage to piping, water leakage
Are the supports for the hot water piping secure?
Vibration
Has the heat insulation for the hot water piping been completed?
Heat release, burns, freezing
Has the hot water piping been flushed?
Contamination of hot water, clogging
Is there any obstacle to maintenance due to the hot water piping?
Is the fuel gas piping secure?
Gas leakage
Is there any gas leakage along the path of the fuel gas piping?
Fire
Has the specified gas hose been used?
Gas leakage, fire
Are the supports for the fuel gas piping secure?
Vibration, gas leakage

Is there any obstacle to maintenance due to the fuel gas piping?

Has the main cock for the fuel gas been installed?
Has an independent exhaust gas pipe been routed to outside the room?
Increase in exhaust resistance,

backflow of exhaust
Is there any gas leakage from the connection areas of the exhaust gas piping?
Gas poisoning
Is there any gas leakage from the flange area of the exhaust gas piping?
Gas poisoning
Is the discharge point for the exhaust gas located so that the gas is released into the open air and
there is no negative effect on the surrounding area?
Gas poisoning, staining
Have adequate measures been taken to prevent the exhaust gas entering the room?
Gas poisoning
Has the specified type of stainless steel pipe been used for the exhaust gas piping?
Gas leakage due to rusting (poisoning)
Has flexible piping been used if a anti-vibration mount is installed?
Damage to exhaust piping
Has the exhaust piping been installed with an upward slope so that drainage does not back-up?
Discharge of drainage
Has the exhaust piping been fully wound with heat insulation?
Burns, fire, increase in room temperature
Is the resistance of the exhaust flue piping 150 mm Aq or less?
Increase in exhaust resistance,

backflow of exhaust
Is there any lifting of the exhaust drain hose?
Pooling of drain water
Has the exhaust drain been routed to an outdoor water discharge outlet?
When the unit is installed indoors, have the additional drain filter and the syphon been installed
correctly?
Staining of floor surfaces

Flue gas leakage
When the unit is installed indoors, does the ventilation fan run during operation of the unit, and is
the required ventilation level maintained?
Increase in room temperature,

deterioration of work environment
When the unit is installed indoors, is the exhaust airflow from the radiator routed to outside the
room using a dedicated duct and expelled using a pressure fan?
Increase in room temperature,

deterioration of work environment
When the unit is installed indoors, are both a gas leakage alarm and an incomplete combustion
alarm (CO detector) installed in the vicinity of the unit?
Gas poisoning
When the unit is installed indoors, are the signal lines for the alarm devices connected to the
external stop signal terminals of the unit?
Gas poisoning
78
Check
Column
Wiring M an u al
CP10WE
This Wiring Manual describes how to perform the wiring for the YANMAR Cogeneration
Package CP10WE, and includes work procedures and points to note during the wiring
process.
1) Introduction
This Wiring Manual employs the following symbols to ensure the wiring is performed safely for the
product. As these instructions are very important, ensure they are observed.
Warning
Denotes a case in which operating errors may cause dangerous conditions

leading to serious injury or death.
Caution
Denotes a case in which operating errors may cause dangerous conditions leading
to light or moderate injury and conditions where only equipment damage may occur.
Caution markings can also indicate conditions that can have serious
consequences.
(1)
Warning
Do not perform installation yourself. Ask your dealer or a qualified technician to install the system. If the unit is not installed
correctly, this could lead to issues such as poisoning if exhaust gas enters buildings, water leakage, electric shock, or fire.
(2)
Warning
Carefully follow the instructions in this manual when performing installation. If the unit is not installed correctly, this
could lead to issues such as poisoning if exhaust gas enters buildings, water leakage, electric shock, or fire.
(3)
Warning
The wiring must be performed by a qualified wiring technician according to the relevant laws and regulations.
Incorrect work could cause electric shock, fire, etc.
79
2) Wiring Connections with Individual Units

(1)
Warning
Use the specified cables and connect the wiring securely. The wiring must be fixed securely so that external force
from the cables is not transmitted to the terminal connections. If the wiring is not properly connected or secured, it
could cause the generation of heat or fire.
(2)
Caution
Be sure to carry out the grounding work. If the grounding work is not carried out, it may cause electric shock.
(3)
Caution
When the unit is installed on an anti-vibration mount, carry out the work so that the wiring is not affected by vibration. If excessive
force is applied to the wiring by vibration, it could cause the breakage of wires, electric shock due to short circuiting, fire, etc.
(4) Intake Position of Wiring, Accessories

Detail of part A
Terminal block
part A
Accessories
Cable gland 8 pieces
8-29.0 hole
Bind and fix wiring to this ring.
80
029042-01E
Allocation of Terminal block
WH1 WH2 861
862
841
Hot water
storage unit Unit Failure
malfunction signal
signal
LC1
(+)
LC1
(-)
Remote monitor
communication
wiring
DC1 DC1
(+)
(-)
RDA RDB
842
843
844
Operation
signal
RS485 RS485
(+)
(-)
881
882
External start
signal
DC3 DC3
(+)
(-)
H1
H2
main
External stop External stop Hot
operation
signal 1
signal 2
signal
UK
System controller Inverter

communication
communication
wiring
wiring
DC2 DC2
(+)
(-)
GS1 GS2 GS3 GS4
UL
VK
VL
WK
WL
Reverse Power Reverse Power Reverse Power

input signal
input signal
input signal
L1
DC380V OUTPUT 1 DC380V OUTPUT 2 DC380V OUTPUT 3
L2
L3
AC230V INPUT
032818-00E
For connection to this unit, install the wiring in a plastic-coated 2nd-type flexible conduit.
The wiring should not interfere with the maintenance of the unit. Vibration should not cause damage to
the wiring.
Secure the wiring using fixing bands so that excessive force is not applied to the wiring.
Use the crimp terminal for the terminal to be connected.
81
For connection to this unit, use the cable gland of the attachment.
Cable gland (Development chart)

COVER
032806-00E
(5) Precautions for Wiring

Perform the wiring accurately in accordance with the diagram for the wiring connection with individual
equipment and the following precautions.
For wire connection to the terminal block, use crimp style terminals fitted to the size of the following
terminals, and do not use multi-conductor wire for locations where 2-core wire is specified.
If the wiring is performed incorrectly, it could cause malfunction, damage to the equipment, and fire.
Terminal block
CP10WE For output
CP10WE For control
System Controller LKC10B3
Remote Monitoring Adapter CLCW2B1
Power
Multi-conductor
source line wire
Size of terminal
For M4 (Width of terminal: 10 mm or less)
For M4 (Width of terminal: 10 mm or less)
For M3 (Width of terminal: 7.3 mm or less)
For M3 (Width of terminal: 5.5 mm or less)
Duct (or flexible conduit)
Duct (or flexible conduit)
NG
N
G N
NG
G O
OK
K
Communication/
Signal line
Communication/
Signal line
Power source
line
82
Communication/
Signal line
Power source
line
025411-01E
(6) Inter-unit Connection Wiring Diagram (Wiring Specifications)

Below diagram is one example for wiring connection.
Wiring work must be conducted not to flow current exceeding to the rated current of the panel board.
For communication cables, use shielded cables and install in a dedicated duct (flexible conduit).
The emergency stop signal and power source lines cannot share the same duct.
In the case of multiple units installed, perform the wiring according to Multiple units wiring diagram.
Grid
Earth
Cogeneration
Package
UK
UL
*4 CVV 1.25sq or more (2core) phase:L1

Reverse power detection signal
VK
VL

WK
WL

L2
L3
K
L
K
L
K
L
Terminating resistance
(It is attached to Remote monitor)
TB3
LC1 (+)
LC1 (-)
E
L1
CVV-S (Shield cable) 0.5sq or more (2core)

Communication
1+
1Shield
Shield
earth
Shield
earth
B+
B+
-
Connect the Power meter,etc

ELB
Connect the Heat meter,etc
TB1
TB5
Load
+
FG
DC24V power supply

Load
*3 Rmote monitor
Load
DC1 (+)
DC1 (-)
E
RS485 (+)
RS485 (-)
E
Shield
earth
CV-S (Shield cable) 3.5sq or more (2core)
DC Power DC380V
DC (+)
DC (-)
Shield
earth
Shield
earth
Load
*1
ELB
Inverter KP40G
Pin4 (RS485+)
Pin3 (RS485-) COM1
CVV-S (Shield cable) 0.3~0.7sq or more (2core)

*8 Communication
Shield
earth
Pin4 (RS485+)
Pin3 (RS485-) COM2
same as *8
DC2 (+)
DC2 (-)
E
No.1
AC
CV 4sq (3core)
AC power AC230V
Shield earth
Shield
earth
DC Power DC380V
No.2
DC (+)
DC (-)
Shield
earth
ELB
L
N
FG
Pin4 (RS485+)
Pin3 (RS485-) COM1
Pin4 (RS485+)
Pin3 (RS485-) COM2
*1
Inverter KP40G
same as *8
DC3 (+)
DC3 (-)
E
Shield
earth
DC Power DC380V
AC
CV 4sq (3core)
AC power AC230V
Shield
earth
No.3
DC (+)
DC (-)
Shield
earth
ELB
L
N
FG
Pin4 (RS485+)
Pin3 (RS485-)
COM1
Pin10 (RS485END)
Pin6 (RS485END)
*1
Inverter KP40G
AC
ELB
L
N
FG
CV 4sq (3core)
AC power AC230V
(It is attached to System controller)
ELB
RDA
RDB
E
RDA
RDB
CVV-S (Shield cable) 1.25sq or more (2core)

Communication
Shield
earth
Shield
earth
*2
System controller
X
Y
E2
E1
CVV1.25sq or more (2core)

AC230V power supply
ELB
L1
L2
L3
N
E
Conact rating
125V AC,1A
CV 2sq or more (3core L1,N,E)

CHP Power Iuput AC230V
*4 CV 2sq or more (5core L1,L2,L3,N,E)
CHP Power Iuput AC400V
Conact rating
125V AC,1A
*7 Customers
control panel
Unit failure signal CVV1.25sq or more (2core)

No-voltage A contact output (FailureON)
861
862
GS1
GS2
*5 External emergency stop signal CVV1.25 or more (2core)

*6 No-voltage B contact input (OFFAbnormal stop)
881
882
External start signal CVV1.25 or more (2core)

No-voltage A contact input (ONStart,OFFStop)
841
844
Operation signal CVV1.25sq or more (2core)

No-voltage A contact output (In operationON)
*5 Heat main operation signal CVV1.25 or more (2core)
No-voltage A contact input (ONWith heat demand)
H1
H2
GS3
GS4
842
843
WH1
WH2
Conact rating
24V DC,2A or more
Conact rating
24V DC,2A or more
Conact rating
24V DC,2A or more
*5 *6
Same as
GS1,GS2
*7 Hot-water
strage unit
Unused
Hot-water strage unit mulfunction signal CVV1.25 or more (2core)
No-voltage A contact input (ONHot-water strage unit mulfunctionON)
Conact rating
24V DC,2A or more
*1.
*2.
*3.
*4.
Perform the Inverter wiring according to the term of For inverter wiring.
Perform the system controller wiring according to the term of For system controller wiring, and Install manual of system controller.
Perform the Remote monitor wiring according to the Install manual of Remote monitor.
When customer prevents the reverse power, CT need to be connected.
And select the CT accoring to the term of Installation and wiring of CT.
Perform the transducer installation into the CHP according to the install manual of TRC10W (Option).
*5. These are short-circuited at the time of shipping.
Disconnect the short circuit line for use.
*6. Used to enable emergency stops initiated from outside by,for example, gas-leak alarms or fire alarms.
(When installing the unit indoors, be sure to connect a gas-leak alarm.)
*7. Customers Arrangement
83
032819-00E
Multiple units wiring diagram

In the case of multiple units installed, perform the wiring according to below diagram.
Connect the signal lines except following lines with each CHP in parallel.
The shield lines must be used for the communication cables (RDA/RDB, LC1+/LC1-) and do not
connect the terminals in reverse.
[Wiring of System controller and Remote monitor]
(It is attached to System controller)
Rmote monitor
1+
1E
CVV-S (Shield cable)

0.5sq or more (2core)
Shield
Shield
earth
earth
Shield
earth
Shield
earth
CP10WE No.2
CP10WE No.3
Shield
earth
Shield
earth
84
LC1(+)
LC1(-)
E
CP10WE No.1
LC1(+)
LC1(-)
E
RDA
RDB
E
Shield
earth
Shield
earth
RDA
RDB
E
Shield
earth
Shield
earth
LC1(+)
LC1(-)
E
RDA
RDB
E1
RDA
RDB
E
System controller
Shield
earth
Shield
earth
(It is attached to Remote monitor)
031013-00E
(7) For inverter wiring

Perform the DC side wiring as shown in the diagram below. The connector (DC and Communication) for
the KP40G inverter should be obtained locally. (AC connector attachment)
E L1 L2 L3 N
AC breaker
(25A)
AC breaker
(25A)
Communication wiring
AC breaker
(25A)
DC3 (+)
DC3 ()
E
DC2 (+)
DC2 ()
E
DC1 (+)
DC1 ()
E
Harness (3.5 sq)
* Dotted lines show the shield ground lines.
Install the piping in a duct (or a flexible conduit).

Protect the end of the duct so that it is not
damaged by the harness.
029035-02E
Connector specifications
Maker
Contact
DC(+)
Multi-Contact USA
PV-BP3/4
DC(-)
Multi-Contact USA
P-SP3/4
Communication HIROSE ELECTRIC CO.,LTD JRC-PC2-112
85
Cover
PV-T3II/B
PV-T3II/S
JR16WP-10PC(72)
As required
3
3
5
DC wiring
Perform the DC side wiring as shown in the diagram below. The connector for the KP40G inverter
should be obtained locally. Use a wire with 3.5 to 5.5 mm2 and shielded wire. Use shielded wires, and
connect both ends of the shielding part to the earth of the inverter side and the unit side.
Be sure to attach the MC caps (standard accessory) to the unused holes of DC.
AC wiring
Perform the AC side wiring according to the Technical Manual (section titled Wiring/Processing the AC
Plug) supplied with the inverter.
[Processing the AC Plug]
Use the following procedure to wire to the AC connector and AC connector cover.
AC connector
AC connector cover
Tightening cap
031040-00E
Fig, 1 Structure of the AC plug
Strip the electric wire insulation.

Strip the insulation for wires connecting to L, N, and FG according to the recommended values in the
table below.
The maximum insulation diameter (A) for wires to be connected to the AC connector is 4.1 mm. The
cross-sectional area for electric wires is 4 mm2.
Wire insulation outer diameter (A)
Stripping length (B)
3.4 mm max.
9 to 9.5 mm
3.4 to 4.1 mm
12.5 to 13 mm
B
4 mm2
Insulation
Conductor
031041-00E
Fig, 2 Electric wire insulation stripping
Loosen the tightening cap.

Loosen the tightening cap of the AC connector cover as shown in Fig, 3.
031042-00X
Fig, 3 Loosen the tightening cap
86
Passing the cable through.

Insert the cables from the loosened tightening cap into the AC connector cover.
The diameter of cables that can be inserted into the AC connector cover is 11 to 16 mm.
11 to 16 mm
031043-00X
Fig, 4 The diameter of cable
Connect wires to the AC connector.
Connect the wires to the AC connector as shown in Fig, 5.

The use of the single wire is recommended in consideration of the easiness of wiring.
Use the recommended screwdriver in the table below, or an equivalent one, for wiring. (See Table
1 and Fig, 6)
Using a screwdriver other than the recommended one may break or deform the AC connector
housing or spring.
After wiring, be sure to pull each wire gently to make sure that it cannot be pulled out.
When wiring the AC connector, do not put two or more wires into one wire insertion opening.
Confirm pin arrangement and polarity before wiring connectors to ensure correct wiring.
Wire
Screwdriver
031044-00E
Fig, 5 Connecting wires to the AC connector

Table 1 Recommended screwdriver
Manufacturer
WAGO
Model
210-119
210-619
0.4 -0.2
10
2.5 -0.2
031045-00X
Fig, 6 Recommended screwdriver (mm)
87
Connect the AC connector.

Insert the wired AC connector into the main unit connector as shown in Fig, 7.
When inserting the AC connector into the main unit connector, be sure to insert it until the connectors
make contact with each other.
031046-00X
Fig, 7 Connecting the AC connector
Mount the AC connector cover.

Tighten the 4 screws (tightening torque: 1.3-1.6 Nm) to mount the AC connector cover to the Unit.
Tighten the tightening cap.
Tighten the tightening cap to the dimension A listed in Table 2.
Table 2 Tightening torque for tightening cap
Cable diameter
11 mm
12 mm
13 mm
14 mm
15 mm
16 mm
Recommended dimension of A
0.0 mm
0.9 mm
1.5 mm
1.8 mm
3.2 mm
4.0 mm
031048-00X
Fig, 8 Tighten the tightening cap
88
Communication wiring
Perform the communication wiring according to the Technical Manual (section titled Wiring/Processing
the Communications Plug) supplied with the inverter. Please see the following drawing.
Use shielded wires, and connect both ends of the shielding part to the earth of the inverter side and the
unit side.
About RS485, connect the RS485 (-) of the unit and the "3" of the plug, connect the RS485 (+) of the
unit and the "4" of the plug, and short the "6" and "10" of the plug of the inverter 3. Do not use the "1",
"2", "5", "7", "8", and "9" of the plug for the unit.
Inverter 1
Communications plug (1)

Pin 3 RS-485_DA ()
Pin 4 RS-485_DB (+)
Pin 3 RS-485_DA ()
Pin 4 RS-485_DB (+)
Inverter 2

Pin 3 RS-485_DA ()
Pin 4 RS-485_DB (+)
Pin 3 RS-485_DA ()
Pin 4 RS-485_DB (+)
Inverter 3

Pin 3 RS-485_DA ()
Pin 4 RS-485_DB (+)
Pin 6 RS-485 END
Pin 10 RS-485 END
E
RS485 ()
RS485 (+)
E L1 L2 L3 N
Short
* For termination, short pins 6 and 10,

and be sure to connect them to the
communications plug.
* The ground of the shield wire should be
on the both side as indicated.
* Dotted lines show the shield ground lines.
Cap
029040-02E
89
[Processing the Communications Plug]
3 2 1
7
4
10 9 8
031049-00X
Fig, 9 Communication plug pin numbers (seen from the wiring side)
Terminal
Coupling
Cord tube
C
Clamp
Gasket
Washer
P shell unit
Clamp piece
Spanner fitting part

Set screw
0.3 to 0.7mm
AWG20~24
Cord tightening screws
Conductor Insulator
Cable sheath
B
Size
031050-00E
A
B
C
3.5 to 4.0 mm Approx.19 mm 39 mm or less
D
7.5 to 8.5 mm
Fig, 10 Exploded view of the communications plug
[Disassembly of connector]
To remove the plug, remove the set screw, fit a communication plug to fix, and remove the cord tube.
To remove the cord clamp, remove the cord tightening screws.
[Connection]
Use a wire with 0.3 to 0.7 mm2 (AWG20~24) is allowed for the communications plug, and a cable with
diameter of 7.5 to 8.5 mm for the communications plug.
After the terminal treatment of the cable size given in Fig, 10, thread on the cable the clamp, washer,
gasket, cord tube and coupling in this order and direction as shown in Fig, 10. When strip the covering
from the connection cable, use the applicable tool to securely crimp it.
After crimping the crimp terminals to the conductor with the following applicable tool, insert the crimp
terminals into terminal holes of the P shell unit. After inserting, adjust to meet the C size. Keep the size
until assembling is completed. Insert the communications cable to the pin number corresponding to the
contact as given below. Carefully confirm the pin number of the plug connector prior to inserting the
contact pin. (Refer to Fig, 9 for the pin numbers.)
After connecting, be sure to confirm that it cannot be pulled out by pulling.
90
[Assembly of connector]
Fit the connected P shell unit to the receptacle fixed with a vice or the like. Tighten the cord tube to the
specified torque (3 to 3.5 Nm).
Fit the gasket, washer, and clamp. Tighten the clamp to the specified torque (3 to 3.5 Nm) while
preventing the cable from being rotated.
Torque the set screw to 0.2 to 0.25 Nm.
Torque the cord tightening screws (two positions) to 0.3 to 0.35 Nm.
(8) Inverter Setting

Perform the Inverter setting as shown in the diagram below.
Switch (1)
RotarySW: 0
Switch(2)
(Don't Change) RotarySW: Refer to Table 1
78
901
23
456
12345678
23
ON
78
901
456
DipSW1: ON
DipSW2-8: OFF
Country setting switch (moving a lever up means ON value)

029287-00E
Table 1
Unit number
Inverter 1
Inverter 2
Inverter 3
91
Setting
(RotarySW)
0
1
2
(9) For system controller wiring

Use a 2-core shielded wire for the communication wire, and install the wiring in a specialized metal duct
(or a flexible conduit). Ground the duct (or a flexible conduit).
Install the wiring for the power source line in a duct (or a flexible conduit). It should be separated from
the communication wire.
The length of the communication wire should be less than 200 m.
The shield lines must be used for the communication cables (RDA/RDB) and do not connect the
terminals in reverse.
The ground of the shielded wire should be on the both side as indicated.
The system controller side of shielded wire should be connected on "E1" terminal, and both E1,
E2 terminal should be connected to the grid earth.

[Correct connection method]
Cogeneration
package
RDA RDB E
L1 L2 L3 N E
Shield
earth
E2
E1
System controller
92
Shielded
communication line
ELB (1A or more)
Shield earth
Y RDA RDB
032816-00E
(10) Installation and wiring of CT

For installation of the CT, check the direction of installation and the phase of the power source line.
Use the specialized metal duct (or the flexible conduit) for the signal wire. (The signal wires of the CT
can share the same duct.)
The length of the signal wire should be less than 200 m.
Select CT(Current Trans)
Select the CT according to the primaly side power of transducer.
[Recommended table of CT]
Max Grid power
[kW]
CT spec
Primaly [A]
Transducer Primaly
side Power [kW]
Secondary [A]
< 10kW
50
10
10kW < 20kW
100
20
20kW < 40kW
200
40
* The setting for the primaly side power to exceed 40kW cannot be done.
(11) Other wirings

Use 2-core cable for each signal wire and do not use multi-conductor wire.
The length of each signal wire should be less than 200 m.
If each signal wire runs parallel to the power source line, another power line, or electric light line, install
the wiring in the specialized metal duct (or a flexible conduit).
When connecting the ground wire, ground it at the point nearest to the grounding electrode.
Correct connection example
CP10WE
Other
device
CP10WE
Other
device
CP10WE
Note: Do not install grounding jumper wiring for units unless they are of the same type.
93
CP10WE
CP4WE
or other
cogeneration
unit
Other
device
029041-00E
(12) Connection of Cogeneration Package at Grid-Connected Point

If the earth leakage breaker (ELB) for the unit is connected just behind the system switch, there is a
possibility of overrated current flowing to the distribution board. To prevent this, perform the connection
work with reference to the figures below.
The ELBs in the figures must be interactive.
Connection example 1
INV
Load
INV
Distribution
board
INV
(ELB25A)
System
side
CP10WE
ELB
40A
ELB
Load
Load
029043-01E
Connection example 2
Load
Distribution
board
System
side
ELB
(If necessary)
ELB
ELB
40A
Load
Load
INV
INV
INV
(ELB25A)
CP10WE
029044-01E
Cautions for wiring

When performing the wiring, check the installation direction of the CT for reverse power detection. If it is
installed in the reverse direction, the inverter will not operate normally.
Install the wiring in a specialized duct (flexible conduit) to prevent induced noise being generated on the
CT signal wire.
94
3) DNO approval
Be sure to take corrective actions properly in accordance with E.R.G83/1.
The following provides the major content on Engineering Recommendation G83/1 (E.R.G83/1).
(1) Compliance with DNO requirements will include
Dual supply labeling should be provided at the service termination, meter position and all points
of isolation to indicate the presence of on-site generation and indicating the position of the main
a.c. switch disconnector (for suitable label see ER G83/1 or see the sample reproduced in
Example Signs and on the back cover of this guide).
At the point of interconnection, the following information is to be displayed
(typically all displayed on the circuit diagram).
Circuit diagram showing the relationship between the inverter equipment and supply.
A summary of the protection settings incorporated within the equipment.
A contact telephone number for the supplier/installer/maintainer of the equipment.
(2) Labeling
Requirements for labeling are contained within the relevant sections of this guide. Example labels
can be seen below.
All labels must be clear, easily visible, constructed and affixed to last and remain legible for the
lifetime of the system.
WARNING
dual supply
Do not work on this equipment until it is

isolated from both mains and on-site
generation supplies
Isolate on-site generator at

Isolate mains supply at
031006-00E
95
4) Points to Be Checked after Completion of Work

Check Items
In Case of Defects
Is the specified cable used for

the wiring?
Malfunction, heat
generation, fire
Check
Column
Check Items
In Case of Defects
Is there any incorrect wiring?
Not possible to
output, failure
Is the cable fixed so that

external force is not applied to Heat generation, fire
the terminal connection area?
Is the unit grounded?
Electrostatically
charged, noise
Does the wiring become an

obstacle to the maintenance
of the unit?
Is the system controller

installed properly?
Is the installation direction of

the CT for performing power
detection correct?
Not possible to
output
Is a shielded wire used as a

communication line for the
system controller and is it
grounded?
Malfunction,
incorrect indication
Is a specified duct used for

the CT signal line?
96
Ungainly, unstable
Malfunction
Check
Column
Te st Run M an u al
CP10WE
This Test Run Manual describes how to perform the test run for the YANMAR Cogeneration
Package CP10WE, and includes work procedures and points to note when conducting the test
run.
1) Introduction
This Test Run Manual employs the following symbols to ensure the test run is performed safely for
the product. As these instructions are very important, ensure they are observed.
Warning
Caution
conditions leading to serious injury or death.
conditions leading to light or moderate injury and conditions where

only equipment damage may occur.

serious consequences.
(1)
Caution markings can also indicate conditions that can have
Warning
Do not perform installation yourself. Ask your dealer or a qualified technician to install the system. If the unit is not installed
correctly this could lead to issues such as poisoning if exhaust gas enters buildings, water leakage, electric shock, or fire.
(2)
Warning
Carefully follow the instructions in this manual when performing installation. If the unit is not installed correctly this
could lead to issues such as poisoning if exhaust gas enters buildings, water leakage, electric shock, or fire.
2) Test Run of Cogeneration Package

(1) Confirmation of Installation and Construction Conditions for Cogeneration Package
97
Caution
Confirm whether adequate space for safe maintenance is secured.
Caution
Confirm whether the unit is properly isolated from flammable materials.
Warning
Confirm whether the base is firm and horizontal.
Warning
Confirm whether the unit is fixed firmly with anchor bolts.
Warning
Confirm whether the piping and wiring are installed as designed.
Handle with Care

Confirm whether the cooling water level reaches the specified level. (Visual check from the inspection window.)
Handle with Care

Confirm with the gauge whether the engine oil level reaches the specified level.
Caution
Confirm with the tester whether the input power supply voltage to the unit is single-phase 230 V.
Power on
Caution
Confirm whether the unit is grounded.
Warning
Check the connection of the exhaust drain piping of the unit.
Warning
Check the isolation of the exhaust gas outlet (installed outdoors) and the connection of exhaust gas ducts (installed indoors).
Warning
Check the inlet and outlet of the unit (clogging, isolation from the windows, etc.).
Warning
Check whether there is a fuel gas leak.
The gas cock is open.
Warning
Confirm the proper performance of installation work to enable correct ventilation and discharge of exhaust gas
when the unit is installed inside a building.
Warning
Confirm the installation of alarms and proper connection of the signal lines to the unit when the unit is installed
inside a building.
98
(2) Switch & MCB location

Display board
Display
DSW1
DIP SW
SW2
UP
SW6
Operation SW
SW1
ON
Normal
1 2 3 4 5 6 7 8
SW13
1 2 3 4 1 2 3 4
Gas category Option
DSW3
SW4
DOWN
DSW2
Set value
ON
1 2 3 4 5 6 7 8
1 2 3 4 5 1 2 3
Remote setting System
NEXT
SW5
Menu
ENTER
SW3
BACK
Set
ON
1 2 3 4
Normal
1 2 3 4
System
Check
SW1
Normal
SW13
Set
Normal
Stop
Start
Power
transmission
Unit side Manual
Normal
Normal
Stop
Emergency
stop
Interrupt
SW11
SW10
SW11
Interrupt
SW9
SW12
Emergency
stop
Power
transmission
SW10
SW8
SW7
SW12
Unit side Manual
Normal
Start
SW7
SW9
Remote Automatic
Remote Automatic
Check
SW8
Operation button
Normal
025412-00E
Control board
CN3
CN10
DSW2
CN11
CN1
ON
1 2
Terminal1 Terminal2
DIP SW
CN2
DSW2
CN12
ON
1 2
CPU2
CPU2
SW3
Normal
CN15
CN4
Normal SW1
CPU Select
CN13
Terminal1 Terminal2
CN5
RY1
CN18
Control Unit
CN16
CPU2
Normal
SW2
CPU Writing
CN8
CN7
RY3
RY2
RY4
CN19
CN14
CN6
CPU1
CN17
028200-00E
MCB
MCB2
031005-00X
99
(3) Setting before Test Run

Setting of the DIP Switch
Check that the control power source breaker (MCB2) is OFF.
If it is not, turn it OFF.
Set DIP switches 1 to 3 on the display board.
(Refer to the following table for the setting items.)
Name
SW No.
Setting item
DIP SW1
ON
Setting details
4
Status at
shipment
Setting
required on
site
All OFF
Setting is
required
during remote
monitoring.
All OFF
Setting is
required
when
installing
multiple
units.
Address No.
OFF OFF OFF OFF OFF Not valid (Address has not been set.)
1 2 3 4 5 6 7 8
Remote monitoring address
15
ON OFF OFF OFF OFF
Remote monitoring address = 1
OFF ON OFF OFF OFF
ON
ON OFF OFF OFF
OFF OFF ON OFF OFF
ON OFF ON OFF OFF
OFF ON ON OFF OFF
ON
ON ON OFF OFF
OFF OFF OFF ON OFF
ON OFF OFF ON OFF
OFF ON OFF ON OFF Remote monitoring address = 10

ON
ON OFF ON OFF Remote monitoring address = 11
OFF OFF ON ON OFF Remote monitoring address = 12

ON OFF ON ON OFF Remote monitoring address = 13
OFF ON ON ON OFF Remote monitoring address = 14
ON
68
DIP SW2
ON
1 2 3 4 5 6 7 8
14
ON ON ON OFF Remote monitoring address = 15
OFF OFF OFF OFF ON
Address No.
System address
Gas fuel
category
OFF OFF OFF
Unit No. 1
ON OFF OFF
Unit No. 2
OFF ON OFF
Unit No. 3
OFF OFF OFF OFF
Gas category
2H
Based on the
specifications at
shipment.
Check
58
Unused
14
Unused
DIP SW3
ON
1 2 3 4
100
Set DIP SW2 on the control board.

When connecting multiple units using a system controller, make the settings shown in the
illustrations below. (All switches are set to ON at the time of shipment.)
Unit No.
DIP SW No.
2-1
2-2
2-1
2-2
2-1
2-2
For one unit
OFF
ON
For two unit
OFF
OFF
OFF
ON
For three unit
OFF
OFF
OFF
OFF
OFF
ON
[For one unit]

Unit No. 1
Control board
DIP SW2
12
ON
OFF
System controller
032817-00E
[For two units]

Unit No. 1
Unit No. 2 (End unit)
Control board
Control board
DIP SW2
DIP SW2
12
ON
12
OFF
ON
OFF
System controller
025415-00E
[For three units]

Unit No. 1
Unit No. 2
Unit No. 3 (End unit)
Control board
Control board
Control board
DIP SW2
DIP SW2
DIP SW2
12
ON
OFF
12
ON
OFF
System controller
12
ON
OFF
025414-00E
101
Setting of Memory Switches

On the display board, switch operation SW7 to Unit Side , SW8 to Manual , and SW9 to
Stop .
Turn the earth leakage circuit breaker on the grid-connection side ON. (Ask the person in
charge of the site.)
Turn the grid-connection power output breaker and the control power source breaker
(MCB2) ON.
Switch operation SW1 to Set .
Set the memory switch using the operation button.
(Refer to the following table for the setting items.)
[Setting procedures for the memory switch using the operation button]
1) Press [UP] or [DOWN], set the high-order digit of the menu, and press [NEXT].
2) Press [UP] or [DOWN], set the low-order digit of the menu, and press [NEXT].
3) Press [UP] or [DOWN], switch over to the set value, and press [ENTER].
*When setting the items continuously, repeat the procedure from 1) to 3)
After the completion of setting, switch operation SW1 back to Normal .
Menu
Name
Unit
Range
0 (Without remote controller)
-1 (Unused)
-2 (With system controller)
0 Remote controller setting

1 Catalyst specification
ON/OFF
Setting required
on site
Check
OFF (Standard) ON (With catalyst)
ON
Check
1 to 6
Set when required
ON/OFF
OFF (Without stop) ON (With stop)
OFF
Set when required
1 to 6
Set when required
9 Water heater failure setting
ON/OFF
OFF (Normal open) ON (Normal close)
OFF
Set when required
b Cold district specification setting
ON/OFF
OFF (Standard) ON (Cold district)
OFF
Check
1(step)
-20 to 0 to 20
Not required
ON/OFF
OFF (Normal) ON (No air-fuel ratio control)
ON
Not required
1(sec)
5 30 60 120 180 300 600
Set when required
ON/OFF
OFF (Not valid) ON (Valid)
OFF
Set when required
4 Unit failure output alarm level

5 Maintenance alarm mode
6 Remote sounding alarm level
1.
Setting at
shipment
C GVM level corrected on site

d
Cancellation setting of air-fuel

ratio control
Timer setting of condition

F assessment for heat-oriented
operation signal OFF
P
Continuous operation setting

during U4*1
*1. When installing multiple units, this setting is for the function that continues operation or stop of unit based on the set values
of power source for operation start and stop before generation of U4 keeping these set values when judging communication
error [U4] by each unit with system controller.
Setting of Connected Number of Units

Set the number of units connected to the system controller. Make the setting based on the
Operation Manual supplied with the controller.
Even if only one unit is connected, make sure to specify "1".
102
(4) Checks prior to test run

Actuator check
On the display board, switch operation SW7 to Unit Side , SW8 to Manual , and SW9 to
Stop .
Turn the earth leakage circuit breaker on the grid-connection side ON. (Ask the person in
charge of the site.)
Turn the grid-connection power output breaker and the control power source breaker
(MCB2) ON.
Switch operation SW1 to Check .
Use the operation button to check that each actuator operates.
(Refer to the table blow for actuator items.)
[Actuator check procedures by the operation button]
1) Press [UP] or [DOWN], set the high-order digit of the menu, and press [NEXT].
2) Press [UP] or [DOWN]. set the low-order digit of the menu, and press [ENTER] to
operate the actuator and the display changes from [OFF] to [ON].
3) Press [ENTER] again to stop the actuator and the display changes from [ON] to [OFF].
*Press [BACK] to return to the previous display.
*The display of the instruction condition is displayed by [ON/OFF], [H/L], or number.
Menu
1.
Name
Remarks
ON/OFF Turned ON for maximum 10 seconds. Disabled for 15 seconds after turned ON
1 Starter transformer
ON/OFF
2 Gas Valve 1
ON/OFF
3 Gas Valve 2
ON/OFF
4 Coolant water pump
ON/OFF
5 Throttle valve
6 GVM
2.
Unit
0 Starter motor
H/L
H/L
0 Oil pump
ON/OFF Turned ON for maximum 90 seconds. Disabled for 20 seconds after turned ON
1 Radiator fan
ON/OFF
2 Ventilation fan 1
ON/OFF
4 Coolant water motor valve
600/0
6 Engine room heater
ON/OFF Cold weather version only
7 Engine block heater
ON/OFF Cold weather version only
9 Unit failure signal
ON/OFF
A Operation signal
ON/OFF
(5) Cautions during Operation

Warning
During operation or immediately after a stop, be careful not to touch the exhaust
manifold, exhaust duct, and engine, etc. As the whole engine is very hot, there is a
possibility of burns.
During operation, do not touch or even go near the rotating parts. There is a possibility
of being caught in the radiator fan or ventilation fan, etc.
During operation, do not touch the terminal parts and high-voltage cord of the spark
plug. There is a possibility of electric shock. When inspecting the system, turn off the
power.
When operating the system controller, pay close attention and prevent people from
going near the unit. The engine may start suddenly and there is a possibility of injury.
103
(6) Procedure for Non-Load Operation (Test Mode)

Check that SW7 on the display board is set to Unit Side .
On the display board, switch SW1 to Normal and SW8 to Manual .
On the display board, change SW9 to Start and check that the engine starts. (Non-load)
Is there any start-up delay?
Frequency check: Check that the frequency indication of the display board is the same as
the commercial frequency.
Check that LED4 on the display board is lit.
Check the operation data of the unit.
Voltage check: Check that the voltage indication of the display board is the same as the
voltage of the commercial power supply.
Check the start-up and stop of the exhaust heat recovery pump.
Confirm that the pump works with the main unit. If it does not, contact the dealer where
you purchased the unit, and confirm that the relevant work has been carried out properly.
(7) Procedure for Grid-Connected Load Operation (Test Mode)
On the display board, change SW7 to Unit Side , SW1 to Normal , SW8 to Manual , SW9 to
Start
, and SW10 to Power transmission . Then start the engine and check that electricity
is transmitted.
Check that LED4 and LED5 on the display board are lit.
Check the power output on the display board.
Check the engine data for the unit.
On the display board, switch SW10 to Interrupt and SW9 to Stop , and then stop the unit.
Preparation for automatic operation
On the display board, change SW7 to Remote .
On the display board, change SW1 to Normal , SW8 to Automatic , SW9 to
Stop
, and
SW10 to Interrupt .
(8) Procedure for Grid-Connected Operation Using System Controller (Automatic Mode)
Manual operation
Start up the unit in the manual mode and check the operation from the start-up to when the
electricity transmission turns ON.
Stop the manual operation and check the process from electricity transmission OFF to
operation stop.
Check the activation of the stop operation if the unit is shut down using an emergency stop.
(Check the buzzer.)
* Refer to the Operation Manual supplied with the system controller regarding the operation procedure for the controller.
Check the activation of an emergency stop. (Do not forget to reset the alarm after checking the
activation of the emergency stop.)
Turn the grid-connection breaker OFF and check the operation stop. Then, turn the breaker ON
again and check that the system reboots automatically after three minutes.
Scheduled operation
Set the present time using the system controller.
Set the operation date and operation time on the schedule screen, and then perform the test
operation. (Ensure that the operation date is not set to a holiday. Set the operation time to start
a few minutes after the present time and to stop after 15 minutes.)
* Refer to the Operation Manual supplied with the system controller regarding the operation procedure for the controller.
104
(9) Points to Check during Operation of Unit

Power generation check: Check that the generated power is 10.0 kW using the system controller
or display board.
Current leakage check: Check that current leakage is less than 50 mA using a clamp meter. If the
leakage exceeds 50 mA, please contact the dealer where you purchased the unit to arrange for
an inspection to determine the cause of the leakage.
Engine speed governing check:
Operate the unit in the test run mode, and change SW10 on the board to Power transmission .
Stop the power supply by changing SW10 on the display board to Interrupt during rated power
generation and check this on the display board. Then, check that there are no problems related
to over-speed.
After the test run checks, on the display board, change SW7 to Remote , SW8 to
Automatic , SW9 to Stop , and SW10 to Interrupt .
[Adjusting the O2 concentration]
Check the density value of O2 during rated power generation.
Adjust the main adjusting screw(MAS) of the mixer of the engine in order to set the density value
of O2 to the density standard value(7.1%~8.1%) during rated power generation.
Loosen the fixing nut of the main adjusting screw (MAS).
Using a slotted screwdriver, turn the main adjusting screw (MAS) clockwise or counterclockwise
little by little.
* The main adjusting screw should be gradually turned till the O2 concentration satisfies the
requirement. (Standard value: 7.60.5%)
Once the O2 concentration meets the requirement, tighten the fixing nut of the main adjusting
screw (MAS).
* Take care to keep the main adjusting screw at the adjusted point.
Main Adjusting Screw (MAS)

(Adjusting the mixer)
105
027907-00E
(10) Final System Check

Conduct the following checks after the completion of the test run.
Check the setting of the dates and time of the system controller.
Set the regular holidays and other holidays.
Set the timer of the system controller.
Set the power of both the electricity transmission start and stop.
Check the operating hours of the test run of the system controller.
When the system is to be used: Change the execution switch on the schedule screen of the
system controller to ON.
When the system is not to be used: Check that the main fuel gas cock is fully closed and the
scheduled operation switch of the system controller is paused.
Check the unit installation site and the unit serial number. (unit, inverter, or system controller)
Check the operation pattern mode. (Heat or electricity main operations)
Check the number of annual operating hours. (Expected number of hours based on the operation
mode in (8).)
106
(11) Table of Alarm Codes
Alarm Code
A1
A2
A9
AA
AF
C0
C1
C5
CE
CF
E0
E1
E2
E3
E4
E7
EA
EC
EH
F0
F3
F4
F5
F7
FA
FC
FE
FJ
H0
HA
HC
HE
HF
HH
HJ
J3
J4
J6
J7
J8
JA
JC
JH
JJ
L1
L7
L8
LA
LE
P0
P6
P8
U2
U3
U4
U5
U6
Description
Alarm level
Inverter malfunction 1B
Inverter malfunction 1C
Inverter malfunction D
Grid malfunction A
Grid malfunction B
Grid malfunction C
Engine start malfunction
Over speed of engine
Engine stall
Low hydraulic pressure
Cooling water temperature malfunction
Low cooling water
EEPROM malfunction
Engine room temperature malfunction
Software incompatibility
Starter system malfunction
Malfunction of hydraulic pressure switch
Disconnection/short-circuit of cooling water temperature sensor
Lubricant supply function Malfunction
Transformer temperature malfunction
Emergency stop1
External emergency stop1
Emergency stop2(communication)
External emergency stop2
Detection of engine misfire
Fail-safe device malfunction
Control box temperature malfunction
Gas valve malfunction
Low gas pressure
Difference between dual CPUs
Disconnection/short-circuit of Transducers
Disconnection/short-circuit of outside air temperature sensor
Disconnection/short-circuit of Heat Exchanger inlet temperature sensor
Disconnection/short-circuit of Heat Exchanger outlet temperature sensor
Disconnection/short-circuit of generator temperature sensor
Disconnection of exhaust temperature sensor
Disconnection/short-circuit of lubricant temperature sensor
Disconnection/short-circuit of engine room temperature sensor
Disconnection/short-circuit of hydraulic pressure sensor
Disconnection/short-circuit of transformer temperature sensor
Abnormal exhaust temperature
Continuation of no/low-load operation
200 hours or less until next periodic inspection (no malfunction)
Malfunction of engine pulse sensor
Malfunction of starter relay
Over current of generator
Generator temperature malfunction
Generator malfunction
Transmission malfunction between CPUs
Transmission malfunction between Control board and Ignition board
Transmission malfunction between CHP system and System controller
Transmission malfunction between Control board and Display board
Transmission malfunction between CHP system and Inverter
5
6
5
6
5
4
4
4
5
6
4
5
4
5
5/8
4
1/3
8
3/5
4
5
4
1/2
9
7
7
7
7
8
8
8
8
8
8
2
4
1
4
4
4
1
4
4
4
5
2
2/4
8
9
5
5
5
3
3
2/3
1/3
4
*1. Alarm codes are shown on the hour-meter display area of the unit. The operating time is also usually displayed.
*2. The buzzer sounds, the display changes to the alarm screen, and the alarm code is displayed.
107
Display of alarms
Cogeneration
System
package*1
controller*2
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
y
3) DNO approval
Be sure to take corrective actions properly in accordance with E.R.G83/1.
The following provides the major content on Engineering Recommendation G83/1 (E.R.G83/1).
(1) Compliance with DNO requirements will include
Dual supply labeling should be provided at the service termination, meter position and all points
of isolation to indicate the presence of on-site generation and indicating the position of the main
a.c. switch disconnector (for suitable label see ER G83/1 or see the sample reproduced in
Example Signs and on the back cover of this guide).
At the point of interconnection, the following information is to be displayed
(typically all displayed on the circuit diagram).
Circuit diagram showing the relationship between the inverter equipment and supply.
A summary of the protection settings incorporated within the equipment.
A contact telephone number for the supplier/installer/maintainer of the equipment.
(2) Labeling
Requirements for labeling are contained within the relevant sections of this guide. Example labels
can be seen below.
All labels must be clear, easily visible, constructed and affixed to last and remain legible for the
lifetime of the system.
WARNING
dual supply
Do not work on this equipment until it is

isolated from both mains and on-site
generation supplies
Isolate on-site generator at

Isolate mains supply at
031006-00E
108
(3) APPENDIX
APPENDIX 1
CONNECTION PROCEDURE FLOW CHART
Note: The processes shown here only refer to the interface between the Installer and the DNO, it
may also be necessary for the Installer / User to inform the relevant Meter Operator and
Supplier that a SSEG has been installed.
Stage 1 Process
(Single installation)
Stage 2 Process
(Planned / Multiple installation)
Single SSEG within a

single customers
installation.
Planned installation of
multiple SSEGs in the
same geographic area.
Installer submits Application

pro-forma to local DNO
(Appendix 2).
DNO assesses impact of

connection, and where
necessary carries out network
design.
DNO confirms connection

requirements with the Installer.
SSEG Installed and

Commissioned in accordance
with ER G83/1, DNO notified
as required under ESQCR.
SSEG Installed and

Commissioned in accordance
with ER G83/1, DNO notified
as required under ESQCR.
Installer submits
Commissioning pro-forma
(Appendix 3) to local DNO
within 30 days of
commissioning.
Installer submits
Commissioning pro-forma for
each SSEG (Appendix 3)
to the local DNO within 30 days
of commissioning.
031007-00E
109
APPENDIX 2
APPLICATION FOR CONNECTION
Application for the connection of multiple SSEG units in parallel with the public distribution
Network - in accordance with Stage 2 of Engineering Recommendation G83/1. It is only necessary
to submit one Application Pro-forma per multiple installation project.
This information is to be provided to the DNO prior to the installation of a SSEG unit(s) in order
that a DNO can assess the potential impact that the connection will have on the Network.
Project Details
Site/project address (inc. post code)
Telephone number
Customer supply number(s) (MPAN)
use separate sheet if necessary
Distribution Network Operator (DNO)
Installer Details
Installer
Accreditation/Qualification:
Address (incl post code)
Contact person
Telephone Number
Fax Number
E-mail address
SSEG Details
SSEG owner
SSEG location within the installation
Total number of SSEG units to be installed
under this project, to include SSEG Unit
capacity in kVA and location.
110
Other Information to be Enclosed

SSEG type verification test certificate, to include the following information:
Manufacturer and model type
SSEG rating (A) and power factor
Single or Multi phase
Maximum peak short circuit current (A)
Type of prime mover and fuel source
Contact details - telephone numbers, web address etc.
Copy of system circuit diagram within the installation.
Earthing arrangements.
Site layout plan showing location of SSEGs - if applicable.
Declaration - to be completed by applicant
Comments (use separate sheet if necessary)
I declare that this installation has been designed to comply with the requirements of ER G83/1
Name and signature:
Date:
DNO comments - to be completed by DNO representative following application

A representative of the DNO will wish to witness the commissioning
yes / no
As a representative of the DNO, I give, in principle, permission for the connection of these SSEG units. If "no",
see comments below
yes / no
Comments
DNO:
Contact:
111
Date:
APPENDIX 3
SSEG INSTALLATION COMMISSIONING CONFIRMATION
Confirmation of commissioning of a SSEG unit connected in parallel with the public distribution
Network - in accordance with Engineering Recommendation G83/1. One Commissioning Proforma per installation is to be submitted to the DNO.
Site Details
Property address (inc. post code)
Telephone number
Customer supply number (MPAN)
Distribution Network Operator (DNO)
Contact Details
SSEG owner
Contact person
Contact telephone number
SSEG Details
Manufacturer and model type
Serial number of SSEG
Serial number / version numbers of software
(where appropriate)
SSEG rating (A) and power factor
(under normal running conditions)
Maximum peak short circuit current (A)
Type of prime mover and fuel source
Location of SSEG within the installation
Location of multi pole isolator
112
Installer Details
Installer
Address (incl post code)
Contact person
Telephone Number
Fax Number
E-mail address
Information to be Enclosed
Final copy of circuit diagram
SSEG Test Report or web address if appropriate (not necessary if already provided
e.g. under a Stage 2 connection)
Computer print out (where possible) or other schedule of protection settings
Electricity meter(s) make and model:
Declaration - to be completed by Installer

The SSEG installation complies with the relevant sections of Engineering
Recommendation G83/1.
Protection settings have been set to comply with Engineering Recommendation
G83/1.
The protection settings are protected from alteration except by prior written
agreement between the DNO and the Customer or his agent.
Safety labels have been fitted in accordance with section 6.2 of Engineering
Recommendation G83/1.
The SSEG installation complies with the relevant sections of BS7671 and an
installation test certificate is attached.
Comments (continue on separate sheet if necessary)
Name:
Signature:
Date:
113
Title
Type of Business:
Person in Charge (signature):
Completion date:
Completion date:
Not present / Present
Witness of Test Run
Witness (signature):
Starting Date of Guarantee (or Delivery Date)
Tel:
Company Name:
Completion date:
<Information on Test Run>
Tel:
Company Name:
<Person in Charge of Construction Company - Installation Work>
Tel:
Company Name:
<Person in Charge of Construction Company - Wiring>
Tel:
Company Name:
<Person in Charge of Sales (Responsible person of test run)>
Department
Person in Charge at Destination:
Address:
Tel:
Customers Name:
( New / Additional / Replacement )
Test Run Check Sheet
Annual Operation Hour:
hr
Special Notes
Timer setting (Described in Appendixes 4 to 6)

Switch-on of the timer SW, Switch-off of the
manual SW (Not done/Done)
Far SW of the unit (Not done/Done)
5) Final Check of the System
Measurement
Defects are described
in the Special Notes.
Supplement
Fastening
None
Repair
Adjustment
Good
Check the inverter setting value.

Check the inverter output.
Check the speed control condition of the engine/generator.
Check the density value of O2 during rated power generation.
4) Cogeneration Package: Check of the Operation Continuation

(Described in Appendixes 2, 3)
Check the manual start and stop. (Check the operation, the lamps of the system
controller, or the switch-over.)
Check the start and the stop of the timer.
Check the emergency stop. (Check using a buzzer.)
3) Cogeneration Package: Operation by System Controller

(Automatic Mode)
Check the engine start.

Check the startup and the stop of the exhaust heat recovery pump.
(Check the interlocking with the unit.)
2) Cogeneration Package: Operation (Test Mode)
Is the cogeneration unit installed outdoors? If it is installed indoors, has the installation
work, including that for the discharge of exhaust gas, been performed correctly?
Is the space for safe maintenance secured?
Is the isolation distance from flammable substances secured?
Is the base firm and horizontal?
Is the unit fixed firmly with anchor bolts?
Are the piping and wiring installed as designed?
Check the cooling water level.
Check the engine oil level.
Confirm whether there is a power earth leakage breaker to the unit
or not. Check the capacity. (40 A or more)
Check the supply voltage of the unit. (Single-phase 230 V)
Check the grounding work.
Exhaust drain piping of the unit
Check the isolation of the exhaust gas outlet.
Check the air inlet and outlet of the unit (clogging, isolation from the windows).
Check the presence of fuel gas leaks.
1) Cogeneration Package: Check of Installation and Construction
(Cogeneration Package)
Points to Check on Site
Installation Site:
Operation Pattern: Electric main / Heat main
Serial Number:
hr
Hour-Meter
Number of Operation Units: 1 / 2 / 3
Model:
Cogeneration Package
Entry Method
Upstream of the
grid connected point /
Installation site of CT for reverse

power flow detection
CT capacity for reverse power
flow detection
Secondary side wiring size of CT for
reverse power flow detection
(Hz)
(Hz)
OFR (Over-frequency Relay)

UFR (Under-frequency Relay)
Items
(A)
(C)
Timer Value
Stop
(MPa)
(C)
(C)
(min-1)
(%)
(C)
(V)
(Hz)
(A)
(mA)
(sec.)
(sec.)
(sec.)
(sec.)
mm2
Junction
box
mA
kW
mm2
(Appendix 7)
Transmission start power
Transmission stop power
From
(%)
(%)
to
(Appendix 5) Setting of Holidays

Day of the week
Sunday Monday Tuesday Wednesday Thursday Friday Saturday
Setting of Holidays
* Enter O in the column if it is a holiday.
(Appendix 6) Timer Setting of System Controller
Start
Outlet:
N phase
(Appendix 4) Timer Setting of System Controller

Operation Time
Day of
the week
Start
Stop
Start
Stop
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Transmission voltage check

L-N phase
Frequency check
Transmission current value
L phase
Leakage current
Temperature at inlet/outlet on
the heat-exchanger engine side Inlet:
Lubricating oil pressure
Lubricating oil temperature
Cooling water temperature
Engine rotations
Density value of O2
Contents
(V)
UVR (Under-voltage Relay)
(Appendix 3) Check on Operation
(V)
Setting Value
OVR (Over-voltage Relay)
Setting Items
Others (
Inside of the distribution board (New

installation/Diversion from the existing one)
AT /
Via a junction
box
mm2 / DC side
(Appendix 2) Check on Inverter Setting Value (PC checker)
AF /
Directly to the
distribution board
AC side
Breaker at grid connected point
Demand power
Connection to commercial power
Size of incoming wire
(Appendix 1) Installation Condition

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CP 10WE

Yanmar Cogeneration Package

Installation Work Manual

Denotes a case in which operating errors may cause dangerous

Denotes a case in which operating errors may cause dangerous

conditions leading to serious injury or death.

conditions leading to light or moderate injury and conditions where

Note that there are cases where

Caution markings can also indicate conditions that can have

2) Selection of Installation Locations

3) Installation Space Requirements

Single unit installation

Multiple units installation

Secure 600 mm in either side of left or right for maintenance

Secure 600 mm in either side of left or right for maintenance

4) Installation of Cogeneration Package

(1) Dimensional drawing of base (for reference)

Embedded depth A (mm)

When the unit is installed indoors, a syphon(option)

(2) Points to note in constructing the base

In places where the soil has a low weight-bearing

Lifting position plate

6) Hot Water Piping

Hot water inlet (R1)

Hot water outlet (R1)

7) Fuel Gas Piping

Fuel gas inlet (R1)

8) Exhaust Drain Piping

Install the drain hose so that it has a definite slope

When the unit is installed indoors, a syphon must

Exhaust drain hose

Exhaust drain hose

Install the syphon correctly and there will no pooling

After the first installation and the maintenance,

Extend it to the appropriate place

Short syphon applicable

The siphon outlet may not be connected directly to the drain

9) Ventilation Amount of Generator Room

Radiator exhaust rate:

Decide the airflow rate for

Required ventilation airflow rate Q

For electricity-oriented operation

For electricity-oriented operation

: air density at 0C and 1 atm. pressure (1.29 kg/m3N)

35.9 : calorific value of G20 natural gas (MJ/m3N)

To control room temperature to 40C at maximum when temperature of ventilation

10. Flue system

Install stainless wire

When the unit is installed

Please fix the pipe at this position.

The Top of the Unit

11) How to install Inverter KP40G

(2) Safety Precautions

Mount the Inverter in the specified direction.

Never mount tilted to front

(3) Mounting Precautions

12) Points to Be Checked after Completion of Work

Is the unit installed securely?

Falls, vibration, noise

Has the required maintenance space been secured?

Damage to piping, water leakage

Damage to piping, water leakage

Are the supports for the hot water piping secure?

Radiator exhaust rate: