C:\Users\msawisch\Documents\Generac Manuals\QT070 Manual.xps

Owner's Manual
Stationary Emergency Generator
NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT
APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST
FUMES! OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
QT
6.8L
70kW Models
EPA Certified
with Optional Catalyst
Table of Contents
SECTION
PAGE
OPERATION ..........................................................................9-1
INTRODUCTION ....................................................................1-1
Stationary Emergency Generator Control and Operation .........9-1
Operating Unit with Manual Transfer Switch...........................9-1
SAFETY RULES ....................................................................1-2
Operating Unit with Automatic Transfer Switch ...................... 9-1
IDENTIFICATION RECORD ....................................................2-1
MAINTENANCE ...................................................................10-1
Maintenance Performed by Authorized Service Dealers .......10-1
EQUIPMENT DESCRIPTION ..................................................3-1
Cooling System...................................................................10-1
Equipment Description ..........................................................3-1
Checking Fluid Levels..........................................................10-1
Engine Oil Recommendations ................................................3-1
Maintenance Owner/Operator Can Perform ..........................10-2
Coolant Recommendations ...................................................3-1
Miscellaneous Maintenance ................................................10-3
ENGINE PROTECTIVE DEVICES ............................................4-1
SERVICE SCHEDULE ..........................................................11-1
Engine Protective Devices .....................................................4-1
TROUBLESHOOTING ..........................................................12-1
FUEL SYSTEMS ...................................................................5-1
Troubleshooting Guide.........................................................12-1
SPECIFICATIONS ..................................................................6-1
EMISSIONS WARRANTY ....................................................13-1
GENERAL INFORMATION .....................................................7-1
NOTES
Alternator AC Lead Connections ............................................7-1
Alternator Power Winding Connections ..................................7-1
EXPLODED VIEWS & PARTS LISTS
CONTROL PANEL .................................................................8-1
Control Panel Interface ..........................................................8-1
Activate the Generator ...........................................................8-1
Display Interface Menus........................................................8-1
Setting the Exercise Timer .....................................................8-3
User Adjustable Settings .......................................................8-3
Fuel Conversion ....................................................................8-3
Operation ..............................................................................8-3
Auto Start .............................................................................8-4
Manual Start .........................................................................8-4
Alarm and Warning Messages...............................................8-4
Common Alarm Relay ...........................................................8-6
Maintenance Alerts ...............................................................8-6
Menu System........................................................................8-7
WIRING DIAGRAMS & SCHEMATICS
Safety Instructions
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential
hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this
equipment.
This symbol points out potential fire hazard.
Thank you for purchasing this model of the stationary emergency
generator product line.
This symbol points out potential electrical shock hazard.
Every effort was expended to make sure that the information and
instructions in this manual were both accurate and current at the
time the manual was written. However, the manufacturer reserves
the right to change, alter or otherwise improve this product(s) at
any time without prior notice.
The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that the operator
read this Owner's Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and operate
the unit. This prepares them if they need to operate the equipment
in an emergency.
If any portion of this manual is not understood, contact the nearest
Service Dealer for starting, operating and servicing procedures.
For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards and
regulations. The operator also must comply with all such codes,
standards and regulations.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are
as follows:
It is the operator's responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is performed
promptly, and to have the equipment checked periodically by a
Service Dealer. Normal maintenance service and replacement of
parts are the responsibility of the owner/operator and, as such,
are not considered defects in materials or workmanship within the
terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Proper maintenance and care of the generator ensure a minimum
number of problems and keep operating expenses at a minimum.
See a Service Dealer for service aids and accessories.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Operating instructions presented in this manual assume that the
generator electric system has been installed by a Service Dealer or
other competent, qualified contractor. Installation of this equipment
is not a “do-it-yourself” project.
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to preventing accidents.
When the generator requires servicing or repairs, simply contact
a Service Dealer for assistance. Service technicians are factorytrained and are capable of handling all service needs.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
When contacting a dealer about parts and service, always supply
the complete Model Number, Serial Number and Type Code (where
applicable) from the DATA LABEL that is affixed to the unit.
This symbol points out important safety information that,
if not followed, could endanger personal safety and/or
property of others.
This symbol points out potential explosion hazard.
1-1
Safety Instructions
• The engine exhaust fumes contain carbon monoxide gas, which
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. For
that reason, adequate ventilation must be provided. This should
be considered prior to installing the generator. The unit should
be positioned to direct exhaust gasses safely away from any
building where people, animals, etc., will not be harmed. Any
exhaust stacks that ship loose with the unit must be installed
properly per the manufacturer's instruction, and in strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical in any room or building housing the generator to prevent
buildup of explosive gases and to ensure correct generator
operation. Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect
safe operation of the generator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or replace
all worn, damaged or defective parts using only factoryapproved parts.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner’s
Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If a procedure, work method or operating technique is used that
the manufacturer does not specifically recommend, ensure that it
is safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
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GENERAL HAZARDS
• For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service
Dealer or other competent, qualified electrician or installation
technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with all such
codes, standards and regulations.
• Installation, operation, servicing and repair of this (and related)
equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply with regulations
the Occupational Safety and Health Administration (OSHA) has
established. Also, ensure that the generator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
ELECTRICAL HAZARDS
• All stationary emergency generators covered by this manual
produce dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the generator.
Avoid contact with bare wires, terminals, connections, etc.,
on the generator as well as the transfer switch, if applicable.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
1-2
Safety Instructions
FIRE HAZARDS
• If personnel must stand on metal or concrete while installing,
operating, servicing, adjusting or repairing this equipment,
place insulative mats over a dry wooden platform. Work on the
equipment only while standing on such insulative mats.
• The National Electrical Code (NEC) requires the frame and
external electrically conductive parts of the generator to be connected to an approved earth ground. This grounding will help
prevent dangerous electrical shock that might be caused by a
ground fault condition in the generator or by static electricity.
Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets must
be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make
sure that all power voltage supplies are positively turned off at
their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied
by an electric utility shall be by means of a transfer switch so as
to isolate the generator electric system from the electric utility
distribution system when the generator is operating. Failure to
isolate the two electric system power sources from each other
by such means will result in damage to the generator and may
also result in injury or death to utility power workers due to
backfeed of electrical energy.
• Stationary emergency generators installed with an automatic
transfer switch will crank and start automatically when normal
(utility) source voltage is removed or is below an acceptable
preset level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit.
Then, place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
• In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a dry rope or board, to free the victim from
the live conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
• Keep a fire extinguisher near the generator at all times. Do NOT
use any carbon tetra-chloride type extinguisher. Its fumes are
toxic, and the liquid can deteriorate wiring insulation. Keep the
extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult
the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surrounding the
generator clean and free from debris.
• These generators may operate using one of several types
of fuels. All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care. Comply with all
laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak
tested according to applicable fuel-gas codes before placing
this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids such
as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier
than air; install leak detectors accordingly.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
1-3
General Information
NOTE:
For actual information related to this particular model, please
refer to the Manual Drawing Listing located at the end of this
manual, or to the data label affixed to the unit.
Every generator set has a DATA LABEL that contains important
information pertinent to the generator. The data label, which can be
found attached to the generator’s lower connection box, lists the
unit’s serial number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, production date, etc.
This number is the key to numerous engineering and manufacturing details pertaining to your unit. Always supply this number
when requesting service, ordering parts or seeking information.
Data Label
2-1
Equipment Description
This equipment is a revolving field, alternating current Stationary
Emergency Generator set. It is powered by a gaseous fueled
engine operating at 1800 rpm for 4-pole direct drive units, 3600
rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet
drive gear units. See the Specifications section for exact numbers.
The unit comes complete with a sound attenuated enclosure, internally mounted muffler, control console, mainline circuit breaker,
battery charger, and protective alarms as explained in the following
paragraph.
Use a mixture of half low silicate ethylene glycol base anti-freeze
and deionized water. Cooling system capacity is listed in the
specifications. Use only deionized water and only low silicate
anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the
recommended 50-50 mixture.
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All AC connections, including the power leads from the alternator, 120 volt battery charger input and control connections to the
transfer switch are available in the main connection box.
The Stationary Emergency Generator incorporates the following
generator features:
• Rotor and Stator insulation is Class H rated as defined by NEMA
MG1-32.6, MG1-1.66. The generator is self ventilated and dripproof constructed.
• The voltage waveform deviation, total harmonic content of the
AC waveform and telephone influence factor have been evaluated and are acceptable according to NEMA MG1-32.
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The unit has been filled with 5W-20 engine oil at the factory. Use
a high-quality detergent oil classified “For Service SJ or SH.”
Detergent oils keep the engine cleaner and reduce carbon deposits.
When changing the engine oil, be sure to use 5W-30 engine oil
(synthetic oil is recommended).
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NOTE:
For temperatures below 32° F, it is strongly recommended to
use the optional Cold Weather Start Kit. The oil grade for temperatures below 32° F is 5W-30 synthetic oil.
3-1
Engine Protective Devices
The Stationary Emergency Generator may be required to operate
for long periods of time without an operator on hand to monitor
such engine conditions as coolant temperature, oil pressure or
rpm. For that reason, the engine has several devices designed to
protect it against potentially damaging conditions by automatically
shutting down the unit when the oil pressure is too low, the coolant
temperature is too high, the coolant level is too low, or the engine
is running too fast.
After a prespecified duration of cranking, this function ends the
cranking if the engine has failed to start. The overcrank message
will turn ON. Turn OFF the AUTO/OFF/MANUAL switch, then turn
switch back to AUTO to reset the generator control board.
NOTE:
If the fault is not corrected, the overcrank feature will continue
to activate.
NOTE:
Engine protective switches and sensors are mentioned here for
the reader’s convenience. Also refer to the applicable control
panel manual for additional automatic engine shutdown information.
•
•
•
•
•
•
An analog coolant temperture sender, located in the engine's
cooling system will cause an engine shutdown if the temperature
should exceed approximately 125° C (257° F). The generator will
automatically restart once the temperature has returned to a safe
operating level.
15 seconds ON
7 seconds OFF
7 seconds ON
7 seconds OFF
Repeat for 45 seconds
Approximately 90 seconds total.
A speed circuit controls engine cranking, start-up, operation and
shutdown. Engine speed signals are delivered to the circuit board
whenever the unit is running. Should the engine overspeed above
a safe, preset value, the circuit board initiates an automatic engine
shutdown. Contact the nearest Authorized Dealer if this failure
occurs.
To prevent overheating, the engine has a low coolant level sensor.
If the level of engine coolant drops below the level of the low coolant level sensor, the engine automatically shuts down.
If the speed signal to the control panel is lost, engine shutdown
will occur.
This switch has normally closed contacts that are held open by
engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the
engine shuts down. The unit should not be restarted until oil is
added, and the AUTO/OFF/MANUAL switch must be turned to OFF
and then back to AUTO.
A fuse (7.5 amp) is located on the control panel. It protects the
panel components from damaging overload. Always remove this
fuse before commencing work on the generator. The unit will not
start or crank if the fuse is blown.
A fuse (25 amp) is located in the engine wire harness adjacent
to the DC alternator. It is used to prevent circuit failure due to DC
alternator falure. It will also protect the system in the event of a
wiring short-dircuit. If this fuse is blown, the generator will not
operate. Replace these fuses with the same size, type, and rating.
4-1
Fuel System
Natural gas is supplied in its vapor state. In most cases, the gas
distribution company provides piping from the main gas distribution line to the standby generator site. The following information
applies to natural gas fuel systems.
The Stationary Emergency Generator may be equipped with one of
the following fuel systems:
• Gas pressure in a building is usually regulated by national, state
and local codes.
• To reduce gas pressure to a safe level before the gas enters a
building, a primary regulator is needed. The natural gas supplier
may or may not supply such a regulator.
• It is the responsibility of the gas supplier to make sure sufficient
gas pressure is available to operate the primary regulator.
• Gas pressure at the inlet to the fuel shutoff solenoid must never
exceed approximately 14 inches water column (0.5 psi).
• Natural gas fuel system
• Propane vapor (LPV) fuel system
Recommended fuels should have a Btu content of at least 1,000
Btu's per cubic foot for natural gas; or at least 2,520 Btu's per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
NOTE:
The fuel consumption requirements are identified in the
Specifications section of the Owner's Manual. Refer to the
Installation Manual if assistance is required for the sizing of
the pipe diameter for the generator. Any piping used to connect
the generator to the fuel supply should be of adequate size to
achieve the 100% load fuel consumption requirements identified in the Specifications section regardless of actual load.
This type of system utilizes the vapors formed above the liquid
fuel in the supply tank. Approximately 10 to 20 percent of the tank
capacity is needed for fuel expansion from the liquid to the vapor
state. The vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer should be aware
of the following:
NOTE:
The recommended fuel pressure is identified in the Specifications
section this manual.
• When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function
efficiently.
• Ambient temperatures around the supply tank must be high
enough to sustain adequate vaporization, or the system will not
deliver the needed fuel volume.
• In addition to the cooling effects of ambient air, the vaporization
process itself provides an additional cooling effect.
NOTE:
It is the responsibility of the installer to make sure that only
the correct recommended fuel is supplied to the generator fuel
system. Thereafter, the owner/operator must make certain that
only the proper fuel is supplied.
5-1
Specifications
Type......................................................................Synchronous
Rotor Insulation.............................................................Class H
Stator Insulation ............................................................Class H
Total Harmonic Distortion..............................................< 3.5%
Telephone Interference Factor (TIF) .................................. < 50
Alternator Output Leads 1-phase ..................................... 4-wire
Alternator Output Leads 3-phase ..................................... 6-wire
Bearings .................................................................. Sealed Ball
Coupling ................................................................Flexible Disc
Load Capacity (Standby Rating) .....................................70kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE
J1349, ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate
with natural gas.
Excitation System ............................................................Direct
Engine Lubrication System
Type of Oil Pump ...............................................................Gear
Oil Filter .......................................................Full Flow, Cartridge
Crankcase Oil Capacity ............................................ 5 U.S. qts.
Type............................................................................... Closed
Water Pump ............................................................. Belt Driven
Fan Speed.........................................................................2030
Fan Diameter..............................................................22 inches
Fan Mode....................................................................... Pusher
Air Flow (inlet air including alternator and
combustion air) .................................................5200 ft3/min.
Coolant Capacity ................................................. (4.5 U.S. gal.)
Heat Rejection to Coolant ....................................287,000 Btu/h
Maximum Operating Air Temp. on Radiator ......... 60° C (150° F)
Maximum Ambient Temperature ......................... 50° C (140° F)
Circuit Breaker Size (Amps)
Voltage
LP kW
CB
Amps NG kW
CB
Amps
120/240V - 1ø
67
300
279
64
300
267
120/208V - 3ø
70
300
120/240V - 3ø
70
250
243
67
300
232
210
67
250
201
277/480V - 3ø
70
125
105
67
125
101
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase............................................................. 145 KVA
480V, 3-phase .......................................................... 160 KVA
208V, 3-phase .......................................................... 145 KVA
Make ........................................................................... Generac
Model ............................................................................. V-type
Cylinders and Arrangement ...................................................10
Displacement ............................................................... 6.8 Liter
Bore.............................................................................. 3.55 in.
Stroke ........................................................................... 4.17 in.
Compression Ratio.......................................................... 9-to-1
Air Intake System ......................................... Naturally Aspirated
Valve Seats ................................................................ Hardened
Lifter Type.................................................................. Hydraulic
Engine Parameters
Rated Synchronous RPM .......................................60 Hz, 1800
Exhaust System
Exhaust Flow at Rated Output 60 Hz .............................557 cfm
Exhaust Temperature at Rated Output ..............................890° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz ...........................................205 cfm
Governor
Type...........................................................................Electronic
Frequency Regulation .............................................Isochronous
Steady State Regulation ............................................ ± 0.25 %
Type of Fuel ........................................ Propane or Natural Gas*
Carburetor............................................................... Down Draft
Secondary Fuel Regulator............................................ Standard
Fuel Shut-off Solenoid ................................................. Standard
Operating Fuel Pressure ............... 11 in. - 14 in. Water Column
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise
25%
50%
75%
100%
Cycle
Load
Load
Load
Load
110/44
260/104
500/200 696/280 1020/411
* Engine is not field convertible between natural gas and propane. Jet size and ignition timing
are factory set for the specific fuel.
Battery Charge Alternator ......................................12V, 30 Amp
Smart Charger ........................................................12V, 2 Amp
Recommended Battery .......................................... 24F 525CCA
System Voltage ............................................................ 12 Volts
Voltage Regulator
Type...........................................................................Electronic
Regulation........................................................................± 1%
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C ..............................................25
1.65% for every 10° above °F .............................................77
Altitude Deration
1% for every 100 m above m............................................183
3% for every 1000 ft. above ft. .........................................600
Controller ................................................................. Nexus
Specifications
To keep the generator running at its peak, the following kits are
offered:
• Cold Weather Kit
~ Recommended for climates with temperatures below 32° F.
• Scheduled Maintenance Kit
~ Kit includes the recommended parts to maintain the generator. Refer to the Service Schedule for regular maintenance
intervals.
For additional information, or to order any of these kits, please
contact an Authorized Service Dealer or Customer Service
Representative.
6-2
General Information
The electrical wires in the unit’s AC connection (lower) panel
should be installed according to the number of leads and the
voltage/phase required for the application. The voltage and phase
are described on the generator data label. The number of lead
wires can be identified using the Specifications section and the
power output rating on the generator data label. For example, if
the generator produces 130kW, 277/480 Volt, 3-phase power, the
generator has 12 alternator output leads. Figure 7.3 describes the
stator power winding connection for the generator.
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Y” configuration as shown in
Figures 7.2 through 7.6.
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 480V, 208V or 600V depending on the model.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 277V, 120V, or 346V depending on the model.
Four-lead alternators (see Figure 7.1) are designed to supply electrical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical
power is produced in the stator power windings. These windings
were connected at the factory to the main circuit breaker as shown
in Figure 7.1.
Figure 7.2 — Stator Power Winding
Connections - 3-phase, 277/480V (6 Lead)
The rated voltage between each circuit breaker terminal is 240V.
The rated voltage between each circuit breaker terminal and the
neutral point 00 is 120V.
)
-28)62%0
'322)'8-327
7
Figure 7.1 — Four-lead, Single-phase Stator
00
7
7
2)986%0
7
7
7
)
)
02
Figure 7.3 — Stator Power Winding
Connections - 3-phase, 277/480V (12 Lead)
)
7
7
7
00
7
7
7
7
7
7
7
7
7
)
7-1
02
)
General Information
Figure 7.4 — Stator Power Winding
Connections - 3-phase, 120/208V (6 Lead)
-28)62%0'322)'8-327
The Stationary Emergency Generator is designed to supply
3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory
to the main circuit breaker with a “Delta” configuration as shown
in Figures 7.7 and 7.8.
)
7
7
The rated voltage between circuit breaker terminals E1-E2, E1-E3
and E2-E3 is 240V.
7
7
)
7
The rated voltage between E1 or E3 and the neutral point 00 is
120V.
00
7
7
2)986%0
Figure 7.7 — Stator Power Winding
Connections - 3-phase, 120/240V (6 Lead)
7
7 7
7
)
)
7
7
7
02
-28)62%0
'322)'8-327
Figure 7.5 — Stator Power Winding
Connections - 3-phase, 120/208V (12 Lead)
00
)
7
7
7
7
7
7
)
) 7
00
7
7
7
)
02
7
2)986%0
7
7 7
7
7
Figure 7.8 — Stator Power Winding
Connections - 3-phase, 120/240V (12 Lead)
)
02
)
7
Figure 7.6 — Stator Power Winding
Connections - 3-phase, 346/600V (6 Lead)
)
-28)62%0
'322)'8-327
7
7
7
7
00
7
00
7
7
7
7
7
) 7
2)986%0
7
7 )
02
2)986%0
7
7
)
02
)
7-2
Control Panel
1.
2.
3.
Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting occurs when utility
power source voltage drops below a preset
level or during the normal exercise cycle. To
prevent possible injury that might be caused
by such sudden starts, always set the switch
to OFF and remove the fuse before working on or around the generator or transfer
switch. Then, place a “DO NOT OPERATE”
tag on the generator panel and on the transfer switch.
“AUTO” Position – Selecting this switch activates fully automatic system operation. It also allows the unit to automatically start and exercise the engine every seven days with the
setting of the exercise timer (see the Setting the Exercise
Timer section).
“OFF” Position – This switch position shuts down the engine.
This position also prevents automatic operation.
“MANUAL” Position – Set the switch to MANUAL to crank
and start the engine. Transfer to standby power will not occur
unless there is a utility failure.
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
NOTE:
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
This test will be performed each time the controller is powered
up.
Next, the user must enter the minimum settings to operate. These
settings are current date and time and exercise day and time. The
maintenance intervals will be initialized (i.e. started) the first time
the clock is set. If the clock is never set at power up, the maintenance intervals will be reset every time power is applied.
If a subsequent power loss (loss of battery power) occurs the
Installation assistant will operate upon power restoration. The self
test routine will be run and then the customer will be required to
re-enter the time and date, as this is not retained during a power
loss. The unit will not require re-activation.
When battery power is applied to the generator during the installation process, the controller will turn ON and the LCD screen will
illuminate. However, the generator still needs to be activated before
it will automatically run in the event of a power outage.
The LCD display is organized as detailed below:
• The “Home” page, this page is the default page which will be
displayed if no keys are pressed for 30 seconds. This page
normally shows the current Status message and the current
date and time. The highest priority active Alarm and/or Warning
will be automatically posted on this page as well as flashing
the backlight when such an event is detected. In the case of
multiple Alarms or Warnings, only the first message will be
displayed. To clear an Alarm or Warning, see the Protection
Systems section - Clear Alarm.
• The display backlight is normally off. If the user presses any
key, the backlight will come on automatically and remain on for
30 seconds after the last key was pressed.
• The “Main Menu” page will allow the user to navigate to all other
pages or sub-menus by using the Left/Right and Enter keys.
This page can be accessed at any time with several presses of
the dedicated Escape key. Each press of the Escape key takes
you back to the previous menu until the main menu is reached.
This page displays the following options: HISTORY; STATUS;
EDIT; AND DEBUG. (See the Appendix - "Menu System".)
Activating the generator is a simple one time process that is guided
by the controller screen prompts. Once the product is activated,
the controller screen will not prompt you again, even if you disconnect the generator battery.
To obtain the activation code, record the generator serial number
and log onto www.activategen.com or call 1-888-9ACTIVATE and
follow the steps to retrieve the activation code.
After obtaining your activation code, please complete the following
steps at the generator’s control panel in the Activation Chart on the
following page.
NOTE:
The generator will only run in manual until the passcode has
been entered.
8-1
Control Panel
CHOOSE LANGUAGE
TROUBLESHOOTING
Display Reads:
Escape
If the wrong language is chosen, it can be
changed later using the “edit” menu.
Press ENTER to begin the activation process.
If ESCAPE is pressed instead of ENTER,
your generator will only run in manual mode
(for test purposes) and NOT ACTIVATED will
be displayed. You will need to remove the
generator control panel fuse AND disconnect
the T1, N1 and N2 connector in the external
connection box (if equipped); or disconnect
utility input (main breaker) to the transfer
switch for 3-5 seconds and reconnect, then
begin with Step 1.
Enter
Display Reads:
Escape
Use ARROW keys to scroll to desired language. Press ENTER to select.
Enter
Display Reads:
If you do not have your activation code,
go to www.activategen.com or call
1-888-9ACTIVATE (922-8482).
If you already have your activation code,
wait 3-5 seconds for the next display.
Escape
Enter
ENTER ACTIVATION CODE (Passcode)
Display Reads:
TROUBLESHOOTING
Use ARROW keys to scroll and find the first
number of your Activation Code.
Press ENTER to select.
Repeat this step until all digits have been
entered.
Escape
Enter
Display Reads:
Escape
Use ESCAPE to correct previous digits.
Activation is complete when all digits are
entered above and your screen shows this
display.
Enter
Follow the controller prompts to continue
setting the time function. Refer to your
Owner’s Manual with questions.
8-2
What happens if “Wrong Passcode Try
Again” appears?
Re-enter the activation code. If a second
attempt is unsuccessful, check the number
against the code given on activategen.com.
If it is correct and the generator will not
accept it, contact 1-888-9ACTIVATE (9228482).
Control Panel
• If utility is still lost after the “line interrupt period”, run the engine
up to normal RPM and transfer the load. At this time the controller will exit the exercise routine and assume full automatic
operation.
Interconnect System Self Test Feature (follow the on-screen
prompts).
Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
Setting
Factory
Default
Minimum
Setting
Maximum
Setting
Increment
Exercise
time
2 pm
00:00 (12 am)
23:59
(11:59 pm)
1 min
Exercise
day
Wed
Sun
Sat
1 day
Current
Time
12 am
00:00 (12 am)
23:59
(11:59 pm)
1 min
Current
Day
Sun
Sun
Sat
1 day
Current
Month
Jan
Jan
Dec
1 month
Current
Year
2008
2008
2100
1 year
Language
English
French
Spanish
N/A
Contrast
80%
0%
100%
1%
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
NOTE:
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
This test will be performed each time the controller is powered
up.
Upon first power up of the generator, the display interface will
begin an installation assistant. The assistant will prompt the user
to set the minimum settings to operate. These settings are simply:
Current Date/Time and Exercise Day/Time. The maintenance intervals will be initialized when the exercise time is entered.
The exercise settings can be changed at any time via the "EDIT"
menu (see Appendix, "Menu System").
For fuel conversion steps, refer to the GenSpec section,
RECONFIGURING THE FUEL SYSTEM.
If the 12 volt battery is disconnected or the fuse removed, the
Installation Assistant will operate upon power restoration. The
only difference is the display will only prompt the customer for the
current Time and Date.
IF THE INSTALLER TESTS THE GENERATOR PRIOR TO
INSTALLATION, PRESS THE “ENTER” KEY TO AVOID SETTING
UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN
THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE
PROMPTED TO ENTER AN EXERCISE TIME.
This system is intended to supply standby power in the event of a
utility failure. The control system will monitor the utility voltage to
determine if stand-by power is required. Should the utility voltage
fail, the generator will start and run normally, detaching from the
utility and supplying the customer load from the generator. When
utility power returns, the controller will re-transfer the customer
load back to utility and shut down the generator.
This generator is equipped with an exercise timer. Once it is set,
the generator will start and exercise every seven days, on the day
of the week and at the time of day specified. During this exercise
period, the unit runs for approximately 12 minutes and then shuts
down. Transfer of loads to the generator output does not occur
during the exercise cycle unless utility power is lost.
To select automatic operation, do the following:
1.
Make sure the transfer switch main contacts are set to their
UTILITY position, i.e., loads connected to the utility power
source.
2. Be sure that normal UTILITY power source voltage is available to transfer switch terminal lugs N1 and N2 (Refer to the
Electrical Data section).
3. Set the generator’s AUTO/OFF/MANUAL switch to AUTO.
4. Set the generator’s main circuit breaker to its ON (or CLOSED)
position.
With the preceding steps complete, the generator will start automatically when utility source voltage drops below a preset level.
After the unit starts, loads are transferred to the standby power
source. Refer to the Sequence of Automatic Operation section.
The standard start sequence will be initiated.
• All 1800 rpm units will exercise at 1400 RPM
• All 3600 rpm units will exercise at 1800 RPM
If utility is lost during exercise the controller will do the following:
• Wait for the “line interrupt period” for utility to return. If utility
returns within the “line interrupt period”, continue to exercise
at low RPM.
8-3
Control Panel
Initial Conditions: Generator in Auto ready to run, load being supplied by the Utility Source through the transfer switch.
1.
2.
3.
4.
Allows the user to start and run the generator manually.
Transfer of the load to the generator will occur if utility is lost while
the unit is running in the manual mode (only if activated).
When the utility voltage fails (falls below 60% of nominal), a
10-30 second (programmable) “line interrupt” delay timer is
started. The factory set time delay is 10 seconds. If at the
end of the line interrupt time the utility voltage is above 60%
the engine will not crank. If the utility voltage is still below
the 60% of nominal at the end of the line interrupt time, the
unit will crank and start. If the unit cranks for more than 10
seconds and the utility voltage rises above 80% of nominal
(programmed pickup voltage) and the unit has not started, the
crank cycle will abort.
As soon as the unit starts a 5 second “warm-up” timer is initiated. When the warm-up timer expires the control will transfer
the load to the generator (through the RTS switch) if the utility
voltage is less than 80% of nominal. If the utility voltage is
greater than the 80% of nominal at the end of the warm-up
time the load will not be transferred to the generator and a one
minute low-speed cool down period will start. At the end of
the one minute cool down period the generator will stop.
Once the unit is running and the switch has transferred the
load to the generator the unit will monitor utility voltage.
When utility voltage returns (above the programmable pickup
voltage, normally 80% of nominal), a 15 second “Return to
Utility” timer will start. At the end of the return to utility time,
if the utility voltage is still above the pickup voltage, the unit
will transfer the load back to the utility source and run the unit
through a one minute cool down period. When the cool down
period is over the unit will shut down and be ready for the next
outage.
If during the cool down period utility voltage should fall below
60% of nominal the 5 second warm-up timer is initiated and
the unit will transfer the load back to the generator and continue to monitor the utility.
Alarms are defined as “Latching” which means they must be
cleared before the alarm message on the screen will clear. They
can be of type “Shutdown” or not and are logged in the alarm log.
Alarms are all annunciated on the display).
Warnings are “Non Latching” meaning the message automatically clears when the warning condition goes away. Warnings can
not be of type “Shutdown” but they are logged in the alarm log.
Warnings are all annunciated on the display.
There is a 10 second delay before oil pressure is monitored.
There is a 10 second delay before engine temperature is monitored.
Once running there is a 1/4 second delay before shut down. The
limit is set at 125° C or 257° F.
Occurs if the engine has not started within the specified crank
cycle.
Warning indicator is measured and calculated by the microprocessor. Overspeed is defined as +20% of nominal engine speed for 3
seconds, or +25% immediate.
If the unit fails to start during a cranking period it will display the
Overcrank Shutdown Alarm. The system will control the cranking
cycles as follows:
Nominal engine speed = 60.0 Hz
The first crank cycle is a 16 second crank time followed by a 7
second rest. The next 5 cycles will be 7 seconds of cranking time
each followed by a 7 second rest time.
During cranking: If the board does not see a valid RPM signal
within four (4) seconds of cranking it will shut down and lock out
on RPM sensor loss.
If the unit fails to start by the end of the 6 crank/rest cycles
the Overcrank Shutdown Alarm will display and the unit will not
attempt to crank until the alarm is reset.
During running: If the RPM signal is lost for one full second the
board will shut the engine down, wait 15 seconds, then re-crank
the engine if in AUTO, it will not re-crank in MANUAL.
If no RPM signal is detected within the first four (4) seconds of
cranking, the control board will shut the engine down and latch out
on RPM sensor loss.
This unit is designed to automatically start in the event of a utility failure or brown out condition. Brown out is defined as utility
voltage less than 60% nominal, while utility is considered good
when it is restored to at least the pickup value, 80% of nominal.
These levels are fixed. The “Line Interrupt period” is an adjustable
parameter by the dealer. If 2-wire start mode is activated, the unit
will start when 2-wire start is active.
If the RPM signal is detected the engine will start and run normally.
If the RPM signal is subsequently lost the control board will try
two more re-cranks before latching out and flashing the RPM
Sensor Failure message (if it is in AUTO).
8-4
Control Panel
Figure 1 – Generator Control Panel
The control system has detected an emissions related fault. This
fault cannot be cleared using the control panel interface. The unit
will continue to operate in automatic mode. Contact your local
servicing dealer.
This is a shutdown alarm. The alarm will activate after five (5)
seconds of continuously missing cam pulses.
This is a shutdown alarm. The alarm will activate after 12 consecutive revs where crank pulses are missing.
After starting, if the generator stays under frequency for more than
30 seconds, it will shutdown.
Fuel pressure is monitored by a digital sensor with a fixed setpoint
of below five (5) inches water column.
While running, if the average battery voltage falls below 11.9 volts
for one (1) minute, the low battery alarm will be displayed.
The governor position is monitored by an analog feedback signal. If
the throttle position is seen outside of the normal operating range,
a shutdown alarm is displayed. If the throttle is commanded to
move, and no movement is seen, a shutdown alarm is displayed.
The microprocessor will continually monitor the battery voltage
and display the Low Battery Voltage message if the battery voltage
falls below 12.2 Volts for one (1) minute.
No other action is taken on a low battery warning condition. The
warning will automatically clear if the battery voltage rises above
12.2 volts.
When power is first apllied to the contoller, the software will perform a check on the wiring of the transfer output, and ensure it
does not have high voltage on the wire. If this is the case, it will
signal a miswire alarm and will not run. The test can be skipped
by use of the escape key.
NOTE:
The battery sentinel is a separate feature that monitors battery
condition.
If the generator voltage falls below 60% for >5 seconds, an alarm
will be issued.
This is a shutdown alarm. The sensor will be continuously monitored. If an error condition is seen for five (5) consecutive seconds, the alarm will be displayed.
8-5
Control Panel
If the generator voltage rises above 110% for >3 seconds, an
alarm will be issued.
When the generator is shut down due to a latching alarm, the Auto
/Off/ Manual switch must be set to the off position and the ENTER
key pressed to unlatch any active fault and clear the corresponding
fault alarm message.
If the generator voltage rises above 130% for >0.2 seconds, an
alarm will be issued.
Any internal failure that can be detected such as corrupted
firmware will cause this shutdown alarm. This alarm cannot be
cleared.
The common alarm relay will be activated if there is a shutdown
alarm. It will not activate on warnings or indicate that the Auto/Off/
Manual switch is in the OFF position. The OFF position will clear
the alarms and the relay. The relay will not be used to indicate a
generator is not activated.
Where applicable, if the Canbus communications link fails to communicate, a “Canbus Alarm” will be generated. This only applies
to systems with external ignition modules. The alarm may be
generated if:
The common alarm connections are wired to a set of potentialfree (dry) contacts on the Nexus controller board. These Normally
Open (N.O.) contacts close when an alarm condition occurs and
are used to activate a remote signaling device. The circuit is rated
for a maximum of 130mA at 24 VDC. The connections are a short
set of free hanging wires that exit the engine harness loom directly
behind the Nexus Control Panel and are labeled numbers 209 and
210.
1.
2.
3.
4.
5.
6.
The physical link is broken.
The Ignition Module fails or resets.
The Nexus Controller fails or resets.
Having the Battery Chargers 120 VAC connected without a
battery installed.
A blown 10 amp Ignition Module fuse (approximately 12
inches away from the starter).
A blown 25 amp system fuse (located approximately 12
inches away from the DC alternator).
NOTE:
Maintenance alerts will be provided for these conditions.
The “Canbus Alarm” will not clear on its own. To clear the
alarm, press the “enter” key to acknowledge the alarm. The
alarm will clear and if the fault is still present, the alarm will
reoccur.
When an ignition alarm occurs, a generic message “Ignition Fault”
will be displayed as the fault code.
Inspect Accessory Drive Alert
1yr / 100hrs*
Coolant Change & Flush
1yr / 100hrs
Inspect Spark Plugs Alert
1yr / 100hrs
Change Oil & Filter Alert
1yr / 100hrs*
Inspect Battery Alert
1yr / 100hrs
Change / Inspect Air Filter Alert
1yr / 100hrs
Clean/Inspect Air Inlet & Exhaust
6mo / 50hrs*
* Items require a 3 month / 30 hour break-in change or check.
When a maintenance period expires, a warning message will be
posted. The warning can be reset by hitting the Enter key. Resetting
will clear the warning and reset the maintenance counters for the
condition annunciated. The history log will reflect the maintenance
warning.
Change / Inspect spark plugs alert
8-6
2yr/ 250hr
Control Panel
8-7
Operation
Refer to the appropriate control panel operator’s manual for this
unit.
•
•
•
If the Stationary Emergency Generator was installed in conjunction
with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is
one that will not provide automatic start-up and does not include
an intelligence circuit.
•
(SRSXGVEROXLIIRKMRIGSRXMRYSYWP]JSVPSR
KIVXLERWIGSRHWSVXLILIEXQE]
HEQEKIXLIWXEVXIVQSXSV
Let engine stabilize and warm up.
Check all applicable instrument and gauge readings. When
certain that all readings are correct, move the transfer switch
manual handle to the STANDBY (or EMERGENCY STANDBY)
position, i.e., load circuits supplied by the generator.
Set the generator’s main line circuit breaker to its ON (or
CLOSED) position.
Load circuits are now powered by the generator.
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
For additional information, refer to the applicable control panel
manual for this unit, as well as any literature pertaining to the
specific transfer switch.
To transfer the load back to the utility power source and shut down
the generator, follow these directions:
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Manually move the transfer switch handle to its UTILITY
(NORMAL) position, i.e., load circuits connected to the utility.
• Turn ON the utility power supply to the transfer switch, using
the means provided (such as the utility power source main line
circuit breaker).
• Let the generator run at no-load for a few minutes to stabilize
internal temperatures.
• Shut down the generator.
8LI1EMRXIRERGI(MWGSRRIGX7[MXGLERHXLI
%9833**1%29%0W[MXGLIWMJWSIUYMTTIH
QYWXFIWIXTVSTIVP]SVXLIKIRIVEXSV[MPP
GVEROERHWXEVXEWWSSREWXLIYXMPMX]TS[IVXS
XLIXVERWJIVW[MXGLMWXYVRIHSJJ6IJIVXSETTPM
GEFPIGSRXVSPTERIPERHXVERWJIVW[MXGLQERYEPW
JSVQSVIMRJSVQEXMSR
(SRSXTVSGIIHYRXMPGIVXEMRXLEXYXMPMX]WSYVGI
ZSPXEKIMWEZEMPEFPIXSXLIXVERWJIVW[MXGLERH
XLIXVERWJIVW[MXGLQEMRGSRXEGXWEVIWIXXS
98-0-8=
(SRSXEXXIQTXQERYEPSTIVEXMSRYRXMPEPP
TS[IVWYTTPMIWXSXLIXVERWJIVW[MXGLLEZIFIIR
TSWMXMZIP]XYVRIHSJJSVI\XVIQIP]HERKIVSYW
TSWWMFP]PIXLEPIPIGXVMGEPWLSGO[MPPVIWYPX
If the Stationary Emergency Generator has been installed with an
automatic transfer switch, the engine may be started and stopped
automatically or manually.
8VERWJIVW[MXGLIRGPSWYVIHSSVWWLSYPHFIOITX
GPSWIHERHPSGOIH3RP]EYXLSVM^IHTIVWSRRIP
WLSYPHFIEPPS[IHEGGIWWXSXLIXVERWJIVW[MXGL
MRXIVMSV)\XVIQIP]LMKLERHHERKIVSYWZSPXEKIW
EVITVIWIRXMRXLIXVERWJIVW[MXGL
In order to transfer load from the utility source to the generator,
follow these directions:
Refer to the applicable manual for your transfer switch and to
“Transfer Switch Start Signal Connections”. In addition, please
note the dangers under “Engine Start-up and Transfer.”
NOTE:
• Turn OFF or disconnect the utility power circuit to the transfer
switch, using the means provided (such as the utility source
main line circuit breaker).
• Set the transfer handle to its UTILITY (NORMAL) position with
load circuits connected to the utility power supply.
• Set the generator’s main line circuit breaker to its OFF (or OPEN)
position.
• Start the generator.
9-1
Maintenance
Refer to the Service Schedule for engine oil and filter change frequencies.
•
•
•
•
Drain the oil while the engine is still warm from running. This
means warm up the engine, shut it down and drain immediately
as follows:
Before working on the Stationary Emergency
Generator, ensure the following:
The AUTO/OFF/MANUAL switch is in the OFF position.
The control panel fuse has been removed from the control
box.
The 120VAC supply to the battery charger is switched OFF.
The negative battery cable has been removed.
1.
2.
3.
4.
Check engine crankcase oil level (Figure 10.1) according to the
Service Schedule and SIB10-10-L24G.
•
•
•
•
5.
Remove oil dipstick and wipe dry with a clean, lint-free cloth.
Install oil dipstick, then remove again.
Oil should be between FULL and ADD marks.
If oil level is below the dipstick ADD mark, remove oil fill cap.
Add the recommended oil to bring oil level up to the FULL
mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil
Recommendations” for recommended oils.
6.
Figure 10.1 - Oil Dipstick and Oil Fill Cap
3MP*MPP
7.
8.
3MP
(MTWXMGO
9.
Remove the drain hose from its retaining clip or cut the zip-tie
securing the oil drain hose.
Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
When all oil has drained, install and tighten OIL DRAIN HOSE
CAP and secure drain hose with a new zip-tie, or place the
hose in its retaining clip.
Turn OIL FILTER (Figure 10.1) counterclockwise and remove.
Properly dispose of old filter.
Apply light coating of new engine oil to seal of new oil filter. Install FILTER and tighten by hand only. DO NOT OVER
TIGHTEN.
Remove OIL FILL CAP and add recommended oil. Crankcase
oil capacity is listed in the "Specifications" section.
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK
“ADD” MARK.
Start engine and check for oil leaks.
Shut OFF engine and wait 10 minutes for the oil to settle down
into the oil pan. Recheck oil level on dipstick. DO NOT fill
above the dipstick "FULL" mark.
Dispose of used oil at a proper collection center.
Air intake and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. This
includes such obstructions as high grass, weeds, brush, leaves
and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the
installation diagram.)
3MP*MPXIV
The exhaust system parts from this product
get extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc.
must remain clear of the exhaust. Such materials may ignite and burn from the heat of the
exhaust system.
Hot oil may cause burns. Allow engine to
cool before draining oil. Avoid prolonged
or repeated skin exposure with used oil.
Thoroughly wash exposed areas with soap.
• Inspect engine cooling system. See the Service Schedule.
• Check hoses for damage, deterioration, leaks, etc. Correct any
discrepancies found.
• Check hose clamps for tightness.
10-1
Maintenance
Check coolant level in coolant recovery bottle. See the Specifications
and Service Schedule sections.
• Inspect fan belts every year. Replace any damaged, deteriorated, worn or otherwise defective belt.
• Check fan belt tension. Thumb pressure, exerted midway
between pulleys, should deflect about 3/8 to 5/8 of an inch.
Adjust belt tension as required.
• Check fan belt alignment (see Figure 10.2).
• Add recommended coolant mixture as necessary.
• Periodically remove radiator pressure cap (only when engine
has cooled down) to make sure the coolant recovery system
is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have pressure cap
tested, contact a Service Facility. Inspect cooling system and
coolant recovery system for leaks.
Figure 10.2 – Fan Belt
Every year, have a service facility drain, flush and refill the cooling
system. See the Specifications and Service Schedule for cooling
system recommendations.
Engine cranking, start up and running are controlled by a solid
state Engine Controller circuit board. Battery voltage is delivered
to that circuit board via the control panel fuse. This overcurrent
protection device will open if the circuit is overloaded.
If a circuit breaker opens or a fuse element
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
Visually inspect electronic governor.
Do not attempt to adjust the governor. Only
qualified service facilities should adjust
the governor. Excessively high operating
speeds are dangerous and increase the
risk of personal injury. Low speeds impose
a heavy load on the engine when adequate
engine power is not available and may
shorten engine life. Correct rated frequency
and voltage are supplied only at the proper
governed speed. Some connected electrical
load devices may be damaged by incorrect
frequency and/or voltage. Only qualified service technicians should adjust the governed
speed.
Starts the Stationary Emergency Generator engine once every
seven days and lets it run for 12 minutes.
Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded
nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
Inspect the exhaust system at least once every year. Check all
exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage.
To replace the engine air filter, remove the air filter cover and
replace the air filter making sure it is positioned properly before
reattaching the cover (Figure 10.3).
See the Service Schedule for air filter maintenance.
10-2
Maintenance
Figure 10.3 – Engine Air Filter
Battery electrolyte fluid is an extremely corrosive sulfuric acid solution that can cause
severe burns. Do not permit fluid to contact
eyes, skin, clothing, painted surfaces, etc.
Wear protective goggles, protective clothing
and gloves when handling a battery. If fluid
is spilled, flush the affected area immediately with clear water.
%MV*MPXIV
Do not use any jumper cables or booster
battery to crank and start the generator
engine. If the battery has completely discharged, remove it from the generator for
recharging.
Be sure the AUTO/OFF/MANUAL switch is
set to the OFF position, before connecting
the battery cables. If the switch is set to
AUTO or MANUAL, the generator can crank
and start as soon as the battery cables are
connected.
Be sure the 120VAC power supply to the battery is turned OFF, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
Reset the spark plug gap or replace the spark plugs as necessary.
1.
2.
3.
Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plugs to clean.
Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
“Service Schedule” section for recommended inspection.
Check the spark plug gap using a wire feeler gauge. See the
Specifications section for the required spark plug gap.
NOTE:
Unit DOES NOT include battery.
When supplying or replacing the battery, the recommended number and type of battery is listed in the Specifications Section.
NOTE:
The BCI number should be located directly on the battery.
The battery should be inspected per the Service Schedule section.
The following procedure should be followed for inspection:
1.
2.
3.
Check battery electrolyte fluid based on the Service Schedule.
Fluid should cover separators in all battery cells. If fluid level is
low, add distilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if
necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERIES.
Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
Keep the generator as clean and as dry as possible. Dirt and
moisture that accumulates on internal generator windings have an
adverse effect on insulation resistance.
Periodically clean generator exterior surfaces. A soft brush may be
used to loosen caked on dirt. Use a vacuum system or dry, low
pressure air to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the
gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a
storage battery must be properly ventilated.
Do not allow smoking, open flame, sparks or
any spark producing tools or equipment near
the battery.
Once each year have the generator cleaned and inspected by a
Service Dealer. That dealer will use dry, low pressure air to clean
internal windings.
Finally, have the insulation resistance of stator and rotor windings
checked. If insulation resistances are excessively low, the generator may require drying.
10-3
Service Schedule
System / Component
Frequency
Procedure
Weekly - W
Monthly - M
Yearly - Y
Inspect
M
X
Oil Level
M
X*
Oil
Y
X**
Oil Filter
Y
X**
Change
Clean
Fuel
Fuel Lines & Connections
Lubrication
Cooling
Engine Coolant Lines & Connections
M
X
Engine Coolant Level
M
X
Engine Coolant
Y
Enclosure Louvers
W
X
Air Cleaner
Y
X
X***
Spark Plugs
Y
X
X***
Remove Corrosion, Ensure Dryness
M
X
X
Clean & Tighten Battery Terminals
M
X
X
Check Charge State
M
X
X***
Check Electrolyte Level
M
X
X***
M
X
X
X
Engine
Battery
General Condition
Vibration, Noise, Leakage, Temperature
Generator System
Complete Tune-up and System Inspection
Y
To be completed by an Authorized Service Dealer.
Footnotes
* Inspect the oil level monthly or every 12 hours during continuous operation.
** Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter, whichever occurs first.
Change sooner when operating under heavy load or in a dusty or dirty environment or in high ambient temperatures.
*** Replace as necessary.
11-1
Troubleshooting
Engine won’t crank.
1. Control panel 7.5 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
1. Replace fuse.*
2. Tighten, clean or replace
battery cables as necessary.*
3. Replace contactor.*
4. Replace starter motor.*
5. Remove, change or replace battery.*
Engine cranks but won't start.
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Spark plugs defective.
1. Replenish fuel/turn on fuel valve.
2. Replace solenoid.*
3. Clean, regap or replace plugs.
Engine starts hard, runs rough.
1. Air cleaner plugged or damaged.
2. Defective spark plugs.
3. Fuel pressure incorrect.
1. Clean or replace as needed.
2. Clean, regap or replace plugs.
3. Confirm fuel pressure to regulator is as
recommended in SPECIFICATIONS.*
4. Confirm fuel pressure to regualtor is as
recommended in SPECIFICATIONS.*
5. Reconfigure the fuel system. (See
RECONFIGURING THE FUEL SYSTEM in
manual.*
4. Insufficient fuel supply.
5. Fuel system set to wrong fuel type.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
Engine oil level is low.
Engine is overheated.
Defective Low Oil Pressure Switch
Defective Coolant Temperature Switch
Defective Control Module circuit board.
Coolant Level is Low.
Defective Low Coolant Level Switch
1.
2.
3.
4.
5.
6.
7.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.*
Replace switch.*
Replace board.*
Repair leak - Add coolant.
Replace Switch.*
AUTO/OFF/MANUAL Switch at OFF,
engine continues to run.
1. Defective AUTO/OFF/MANUAL switch
2. Defective Control Module circuit board
1. Replace board.*
2. Replace board.*
No AC output from generator.
1. Main line circuit breaker is tripped/open.
2. Generator internal failure.
3. Thermal circuit breaker open.
1. Reset to ON/CLOSED.
2. *
3. Auto-reset - Wait 5 min. and attempt restart.
*Contact the nearest Dealer for assistance.
12-1
Warranty
United States Environmental Protection Agency Warranty Statement
(Stationary Emergency Spark-Ignited Generators)
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the
Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system
or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system
may include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below.
Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse,
neglect, unapproved modification or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years
from the date of sale to the ultimate purchaser. For engines greater than or equal to 130 HP the warranty period is three years from the
date of the engine being placed into service.
Purchaser's/Owner's Warranty Responsibilities
As the engine purchaser/owner you are responsible for the following. 1.) The engine must be installed and configured in accordance
to the Generac's installation specifications. 2.) The completion of all maintenance requirements listed in your Owner’s Manual. 3.) Any
engine setting adjustment must be done in accordance and consistent with the instructions in the Owner’s Manual. 4.) Any emission control system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control
system to minimize emissions at all times.
Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system
or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use
of counterfeit and/or 'gray market' parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting
either your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/
owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the
inspection or repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine
is being transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control
System Warranty related information, Generac Power Systems, Inc. P.O. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.
generac.com.
Important Note
This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by
Generac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential or indirect damages caused by
defects in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other
warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
Emission Related Parts Include the Following (if so equipped)
3)
1) Fuel Metering System
1.1) Gasoline Carburetor Assembly And Internal
Components A) Fuel Filter, B) Carburetor, C) Fuel
Pump
1.2) Carburetion Assembly And Its Components
A) Fuel Controller, B) Carburetor And Its Gaskets, C)
Mixer And It Gaskets, D) Primary Gas Regulator E)
Liquid Vaporizer
1.3) Fuel Regulator
2) Air Induction System Including
A) Intake Pipe/Manifold,
B) Air Cleaner
4)
5)
6)
7)
13-1
Ignition System Including
A) Spark Plug, B) Ignition Module,
C) Ignition Coil, D) Spark Plug Wires
Exhaust System
A) Catalyst Assembly, B) Exhaust Manifold,
C) Muffler, D) Exhaust Pipe, E) Muffler Gasket
Crankcase Breather Assembly Including
A) Breather Connection Tube, B) Pcv Valve
Oxygen Sensor
Diagnostic Emission-Control System
Warranty
United States Environmental Protection Agency Compliance Requirements
(Stationary Emergency Spark-Ignited Generators)
Purchaser's/Owner's Recordkeeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your recordkeeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines
as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains their
certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this
Owner's Manual, you are required to meet the following notification and recordkeeping requirements to demonstrate compliance. 1.) Maintain
documentation that the engine is certified to meet emission standards. 2.) Recordkeeping of maintenance conducted. 3.) Recordkeeping of
the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely during emergency operations provided the engine is not certified to operate on propane. 4.) Meet all compliance notifications submitted to the
purchaser/owner and maintain all supporting documentation. 5.) Recordkeeping of hours of operation, including what classified the operation
as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130 HP, recordkeeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, recordkeeping of hours of operation begins
January 1, 2009; Engines are equipped with non-resettable hour meters to facilitate recordkeeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.
Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air
Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,
provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emergency
stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be used for
maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal, State, or local
standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may operate up to 50
hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for maintenance and
testing.
The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to
an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,
any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year, as
permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance
to the specifications and guidelines in this Owner’s Manual EPA will not require engine performance testing. If not, your engine will be considered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Ignition
Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
Emission-Related Installation Instructions
Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of nonroad equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.
13-2
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