Attachment 9 Generac Owners Manual for Generators.pdf

SAVE THIS MANUAL FOR FUTURE REFERENCE

Owner’s Manual For

Stationary Industrial Generators Gas or Diesel

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

Engine: D4.5F.2 Type: SD80 S.O.: 4183828 10 ii Owner’s Manual for Stationary Industrial Generators

(000394)

WARNING

Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to www.P65Warnings.ca.gov/diesel.

Owner’s Manual for Stationary Industrial Generators iii

Table of Contents Section 1: Introduction and Safety

Introduction Read This Manual Thoroughly

Installation, Operation, and Maintenance How to Obtain Service Safety Rules General Hazards Electrical Hazards Fire and Explosion Hazards Battery Hazards Standards Index

Section 2: General Information Unit Identification

Data Label Model Identification Code Voltage Code Fuel Type Engine RPM Controller Type

Equipment Description Standard Generator Features Generator and Load Compatibility Single-Phase “A” or “M” Code Units Three-Phase Load Imbalance Limits Ambient Condition Derate

Engine and Generator Protective Devices (If Equipped)

Coolant Temperature Sensor Low Coolant Level Sensor Oil Pressure Sensor Oil Temperature Sensor (If Equipped) Overspeed Shutdown Overcrank Shutdown RPM Sensor Loss Shutdown Low Fuel Pressure Warning

DC Fuses Fuel System

Diesel Fuel System Natural Gas Fuel System

Bi-fuel Fuel System LP Fuel System LP Vapor Withdrawal Fuel System LP Liquid Withdrawal Fuel System Dual Fuel: NG/LP Fuel System

Specifications Generator Engine Oil Recommendations Coolant Gearbox Lubrication (If Equipped)

Starting Aids (If Equipped) Engine Coolant Heater Engine Oil Sump Heater Battery Warmer Glow Plugs / Intake Air Heater

Section 3: Operation Generator Control and Operation

Grounding the Generator Generator AC Neutral Connections Initial Startup

Control Panel Interface Emergency Stop Button Common Alarm Horn Key Switch Fuse Block

Additional Components Main Line Circuit Breaker (MLCB) Automatic Transfer Switch Automatic Battery Charger

Alarm Response Procedures Warnings Non-Shutdown Alarms Shutdown Alarms Alarm Display Window General Fault Response Procedure

Operating the Unit with an Automatic Transfer Switch Operating the Unit with a Manual Transfer Switch

Manual Engine Startup and Transfer Re-Transfer and Shutdown Shutting Generator Down While Under Load 18 iv Owner’s Manual for Stationary Industrial Generators

Section 4: Maintenance Maintenance

Service Maintenance Intervals Maintenance Schedule Notes and Maintenance Item Explanations ..20

Disabling a Generator for Maintenance

To Disable the Generator From Starting Shutdown and Restart an Operating Generator

Maintenance Tasks Visually Inspect Unit Check Engine Fluids

Check Engine Oil Level Check Coolant Level Check/Change Gearbox Oil (If Equipped)

Battery Inspection Battery Installation and Replacement

Preliminary Instructions 12 VDC System 24 VDC System Final Instructions

Other Maintenance Checks Maintenance and Repair Parts Extended Run-Time Maintenance Checks Maintenance Level 1A Maintenance Level 1 - Monthly or Every 24 Hours Maintenance Level 2 - Semi-Annual or Every 125 Hours Maintenance Level 3 - Annual or Every 250 Hours Maintenance Level 4 - Bi-Annual or Every 500 Hours

Section 5: Warranty Information For Stationary Emergency Spark-Ignited Generators For Stationary Emergency Compression-Ignition Generators

Owner’s Manual for Stationary Industrial Generators 1

Introduction and Safety

Section 1: Introduction and Safety Introduction Thank you for purchasing a Generac Power Systems, Inc. product. This unit has been designed to provide high-performance, efficient operation, and years of use when maintained properly.

The information in this manual is accurate based on products produced at the time of publication. The manu-facturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

Read This Manual Thoroughly

If any section of the manual is not understood, contact your nearest Independent Authorized Service Dealer (IASD), or contact Generac Customer Service at 1-888- GENERAC (1-888-436-3722), or www.generac.com with any questions or concerns. The owner is responsible for proper maintenance and safe use of the equipment.

Save these instructions for future reference. This manual contains important instructions for the generator that should be followed during installation, operation and maintenance of the generator and batteries. Always supply this manual to any individual that will use this machine.

Installation, Operation, and Maintenance Installation and initial startup of this equipment is not a “do-it-yourself” project. This generator set must be installed by an IASD or other competent, qualified contractor. The initial startup must be performed and documented by an IASD. An IASD can also provide the necessary training for authorized operators. 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 an IASD.

Access to the generator shall be through the use of a special tool, or lock and key, or other means of security and shall be controlled by the authority responsible for the location.

Normal maintenance service and replacement of parts are the responsibility of the owner 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.

Proper maintenance and care of the generator will ensure a minimum number of problems and keep operating expenses at a minimum. See an IASD for service aids and accessories.

How to Obtain Service NOTE: Use this page to record important information about the generator set. This label is typically located on the side of the control panel.

Each generator set has a data label containing important information about the unit.

When contacting an IASD about parts or service, always supply the complete model number and serial number of the unit as given on the data label. For quick and easy reference, copy the information printed on the data label located on the generator onto the sample label printed here. See Figure 1-1.

Figure 1-1. Data Label (Sample)

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

GENERATOR UNIT

GEN MODEL:

MODEL:

SERIAL:

ALTERNATE

PROD DATE:

COUNTRY OF ORIGIN:

GENERATOR DATA

KW KVA HZ PF

UPSIZE ALT KW KVA

VOLT / AMP

ENG RPM ALT RPM

BREAKER KW AMP

X’D X”D

ROTOR STATOR CLASS

WINDINGS @ AMBIENT TEMP

MANUF.

LOC

003564

2 Owner’s Manual for Stationary Industrial Generators

Safety Rules 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 using a procedure, work method or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

NOTE: Notes contain additional information important to a procedure and will be found within the regular text 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 action or service are essential to preventing accidents.

General Hazards

(000001)

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

(000190)

DANGER

Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000115)

Moving Parts. Do not wear jewelry when starting or operating this product. Wearing jewelry while starting or operating this product could result in death or serious injury.

WARNING

(000194)

WARNING

Sudden start-up. Always set the safety disconnect switch to MANUAL before working on equipment.

Failure to do so could result in death or serious injury.

(000142a)

WARNING

Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.

Vision Loss. Eye goggles are required to be worn when using this machine. Failure to wear eye goggles could result in permanent vision loss. (000101)

WARNING

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application.

Failure to adhere to this warning could result in death or serious injury.

Owner’s Manual for Stationary Industrial Generators 3

Electrical Hazards

(000107)

Hearing Loss. Hearing protection is recommended when using this machine.

Failure to wear hearing protection could result in permanant hearing loss.

WARNING

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

CAUTION

(000229)

Equipment or property damage. Do not block air intake or restrict proper air flow. Doing so could result in unsafe operation or damage to unit.

(000145)

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000144)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000152)

DANGER

Electrocution. Verify electrical system is properly grounded before applying power.

Failure to do so will result in death or serious injury.

(000123)

DANGER

Electrocution. Turn utility supply OFF before working on utility connections of the transfer switch. Failure to do so will result in death or serious injury.

(000150)

Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury.

DANGER

4 Owner’s Manual for Stationary Industrial Generators

Fire and Explosion Hazards Battery Hazards

Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org.

(000105)

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

DANGER

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000147)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000137a)

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000238)

Explosion. Batteries emit explosive gases.

Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

WARNING

(000162)

Explosion. Do not dispose of batteries in a fire.

Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

(000163a)

Risk of burn. Do not open or mutilate batteries.

Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

WARNING

(000228)

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

http://batterycouncil.org

Owner’s Manual for Stationary Industrial Generators 5

Standards Index The generator owner must strictly comply with all applicable national, state, or local laws, codes, and regulations pertaining to the installation of engine-generator power systems. Always use the current acceptable version or edition of the applicable code or standard which applies to the local jurisdiction. In the absence of pertinent local laws and standards, the following published booklets may be used as a guide:

National Fire Protection Association (NFPA) 70: The National Electric Code (NEC)*

1. NFPA10: Standard for Portable Fire Extinguishers*

2. NFPA 30: Flammable and Combustible Liquids

Code*

3. NFPA 37: Standard for Stationary Combustion

Engines and Gas Turbines*

4. NFPA 54: National Fuel Gas Code*

5. NFPA 58: Standard for Storage and Handling of

Liquefied Petroleum Gases*

6. NFPA 68: Standard on Explosion Protection by

Deflagration Venting*

7. NFPA 70E: Standard for Electrical Safety in the

Workplace*

8. NFPA 99: Health Care Facilities Code*

9. NFPA 101: Life Safety Code*

10. NFPA 110: Standard for non-emergency and

Standby Power Systems*

11. NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances*

12. NFPA 220: Standard on Types of Building Con-struction*

13. NFPA 5000: Building Code*

14. International Building Code**

15. Agricultural Wiring Handbook***

16. ASAE EP-364.2 Installation and Maintenance of

Farm Standby Electric Power**** This list is not all inclusive. Check with the Authority Having Local Jurisdiction (AHJ) for any local codes or standards which may be applicable to the jurisdiction where the generator is installed. The above listed standards are available from the following Internet sources:

* www.nfpa.org

** www.iccsafe.org

*** www.rerc.org Rural Electricity Resource Council; P.O. Box 309; Wilmington, OH 45177-

**** www.asabe.org American Society of Agricultural & Biological Engineers; 2950 Niles Road; St.

Joseph, MI 49085

6 Owner’s Manual for Stationary Industrial Generators

This page intentionally left blank.

Owner’s Manual for Stationary Industrial Generators 7

General Information

Section 2: General Information Unit Identification

Data Label Each generator set has a data label containing important information about the generator. The data label lists the unit serial number, rated voltage, amps, wattage capacity, etc.

NOTE: The figure below is a generic representation only.

For actual information on your particular model, refer to the data label(s) affixed to your unit.

Model Identification Code The model identification code gives important information about the generator set. For example, if the code is:

SG 0100 A G03 6.8 N 23 H B Y Y 3

Then the generator would have the attributes shown in bold below:

S Standby M Modular (MPS) P Prime W Prime Modular (MPS) C Continuous Z Protector Series

G Gaseous engine D Diesel engine B Bi-Fuel.

0100 kW rating (100kW) A Voltage code (see Voltage Code)

G03 Engine designation (for internal use)

6.8 Engine size (6.8 = 6.8L, 14.2 = 14.2L)

N Fuel type (see Fuel Type) 23 Engine RPM (see Engine RPM) H Control Panel (see Controller Type) B Brushless excitation

P Permanent magnet (external) excitation D Direct excitation

Y Standard enclosure (weather protective) N No enclosure, standard — suitable for indoor installation S Level 1 sound attenuated L Level 2 sound attenuated E Level 3 sound attenuated C Containerized

Y Exhaust muffler mounted N Exhaust muffler not provided L Exhaust muffler shipped loose with unit

3 Emission designation (for internal use)

SG0100AG036.8N23HBYY3

Sample

8 Owner’s Manual for Stationary Industrial Generators

Voltage Code

Fuel Type

Engine RPM

NOTE: Engines operating above 1,500 or 1,800 RPM use a gearbox to reduce the engine RPM to the desired alternator rotor RPM of 1,500 RPM (50 Hz operation) or 1,800 RPM (60 Hz operation).

Controller Type

Voltages Code Description

60 Hz

A 120/240 VAC, single-phase, three-lead

D 120/240 VAC, single- or three-phase, 12-lead (Full capacity single- or three-phase; cannot be reconnected for 277/480 VAC)

G 120/208 VAC, three-phase, 12-lead H 231/400 VAC, three-phase, 12-lead (Adjustable from 380 VAC to 416 VAC) J 120/240 VAC, three-phase, 12-lead K 277/480 VAC, three-phase, 12-lead L 346/600 VAC, three-phase, three-lead

50 Hz

M 110/220 VAC, single-phase, three-lead (Adjustable to 120/240 VAC) N 115/200 VAC, single-phase, 12-lead P 100/200 VAC, three-phase, 12-lead (Adjustable to 240 VAC) R 231/400 VAC, three-phase, 12-lead (Adjustable from 380 VAC to 416 VAC) S 480 VAC, three-phase, three-lead

Code Description B Bi-Fuel Diesel and Natural Gas D Diesel G Gasoline N Natural Gas (11-14” WC) S Natural Gas Low Pressure (7-11” WC) V Liquid Propane Vapor Withdraw (LPV) L Liquid Propane Withdraw (LPL) P Dual Fuel NG (Normal) / LPL Secondary R Dual Fuel NG (Normal) / LPV Secondary Q Dual Fuel NG (Low Pressure) / LPL Secondary T Dual Fuel NG (Low Pressure) / LPV Secondary

Example Description

15 1500 RPM

18 1800 RPM

23 2300 RPM

30 3000 RPM

36 3600 RPM

Code Description A ComAp D Power Zone 410 G G-Panel H H-Panel P Power Zone Pro Sync S Power Zone Pro

Owner’s Manual for Stationary Industrial Generators 9

Equipment Description This equipment is a revolving field, alternating current type generator set. The generator is designed to supply electrical power for the operation of compatible electrical loads when the utility power supply is not available or has dropped to an unacceptable level.

The generator’s revolving field is directly connected to and driven by an engine by means of flexible discs or a gearbox. Generators with a four-pole rotor are driven at a rated speed of 1,800 RPM to supply a frequency of 60 Hertz. Four-pole rotors operating at 50 Hertz are driven at 1,500 RPM.

Refer to the data label affixed to the unit for rated AC voltage, wattage, amperage, number of phases, etc. See Model Identification Code for an explanation of how to identify the unit’s features.

Standard Generator Features The generator incorporates the following features:

• The rotor insulation system is Class “H” rated, and the stator insulation is Class “H” rated as defined by NEMA MG1-22.4 and NEMA MG1-1.65.

• The generator is self-ventilated and drip-proof 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 MG1-22.

• All prototype tested models have passed three-phase symmetrical short circuit test to ensure system protection and reliability.

Generator and Load Compatibility The generator must be fully compatible with the rated voltage, phase, and frequency of the connected electrical loads. The generator, connected electrical devices, or both, can be damaged if voltage, phase, and frequency are not compatible.

NOTE: This manual assumes that the generator set has been properly selected, installed and interconnected by a competent, qualified electrician or installation contractor.

Once the installation is complete, do nothing that may result in non-compatibility between the generator and connected electrical loads.

Single-Phase “A” or “M” Code Units The following statement applies to single-phase units with an “A” or “M” code alternator:

The generator is suitable for supplying typical residential loads, such as induction motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), electronic components (TV, computer, monitor, etc.), lighting loads, and microwaves.

Three-Phase Load Imbalance Limits For three-phase units the maximum load imbalance between phases can not exceed 25% of rated load (current).

Ambient Condition Derate The maximum ambient temperature for the generator is indicated on the unit data label. Derate values for ambient temperature in excess of that indicated on the data label, as well as altitude, may apply depending on the engine and kW rating of the unit. Contact an IASD for any derate values applicable to this specific generator at its installed location.

Engine and Generator Protective Devices (If Equipped) The generator set may be required to operate for long periods of time without an operator to monitor conditions such as coolant temperature, oil pressure, voltage, frequency, etc. For this reason, the generator set has numerous sensors to provide the control panel with the information it needs to protect both the engine and generator. The control panel is designed to shut down the engine if potentially damaging conditions occur. These conditions can include low oil pressure, high coolant temperature, low coolant level, engine overspeed, over or under voltage, over or under frequency, etc. These settings are configured at the factory and can be adjusted by an IASD if required.

NOTE: Engine and generator protective devices are only mentioned here for the owner’s general information. For details, consult the applicable control panel technical manual. The list below is not all inclusive.

Coolant Temperature Sensor The control panel automatically shuts down the engine if the engine coolant temperature rises above a safe level.

10 Owner’s Manual for Stationary Industrial Generators

Low Coolant Level Sensor Should the engine coolant level drop below the level of the low coolant temperature sensor, it is possible for the engine to overheat without automatic shutdown. To prevent such 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 control panel will shut the engine down.

Oil Pressure Sensor This sensor monitors engine oil pressure. If oil pressure drops below a safe level, the control system automatically shuts down the engine.

Oil Temperature Sensor (If Equipped) The control panel automatically shuts down the engine if the oil temperature rises above a safe level.

Overspeed Shutdown A speed circuit controls engine cranking, startup, operation, and shutdown. Engine speed signals are delivered to the control panel whenever the unit is running. Should the engine overspeed above a safe, preset value, the control panel initiates an automatic engine shutdown.

Overcrank Shutdown After a pre-specified duration of cranking, this function ends the cranking if the engine has failed to start. The default settings are:

• The unit will attempt to start (crank) three times.

• Each crank cycle lasts either 10 or 15 seconds, followed by a five second rest (to cool the starter).

• After three starting attempts the unit will shutdown.

RPM Sensor Loss Shutdown If the speed signal to the control panel is lost, engine shutdown will occur.

Low Fuel Pressure Warning

• Some gaseous units are equipped with a low fuel pressure warning switch which will trigger a Warning alarm if the fuel pressure drops below a minimum setting.

• Diesel units with fuel tanks are equipped with High and Low fuel level warning alarms, as well as a low fuel level shutdown alarm.

DC Fuses Located inside the front panel, the fuses protect the control panel wiring and components from damaging overload. For fuse location and identification, see the corresponding control panel manual.

Fuel System This generator set is equipped with one of the following fuel systems:

• Diesel fuel system

• Natural Gas (NG) fuel system

• Bi-Fuel Diesel and Natural Gas

• LP gas vapor withdrawal fuel system (LPV)

• LP liquid withdrawal fuel system (LPL)

• Dual fuel system: Natural Gas (primary fuel source), LP gas vapor (secondary fuel source)

• Dual fuel system: Natural Gas (primary fuel source, LP liquid (secondary fuel source)

Diesel Fuel System The manufacturer recommends the use of No. 2 diesel fuel when temperatures are above freezing, and No. 1 diesel fuel when temperatures drop below freezing.

Diesel fuel must meet the following requirements:

Beginning October 1, 2010, owners and operators that use diesel fuel must use diesel fuel that meets:

• Sulfur content of 15 parts per million (ppm) maximum.

• Cetane index or aromatic content as follows: A minimum cetane index of 40, or a maximum aromatic content of 35 volume percent.

Natural Gas Fuel System Natural gas is supplied by a local utility in its vapor state through in ground piping.

Bi-fuel Fuel System Combines diesel fuel and natural gas fuel systems.

LP Fuel System LP is supplied as a liquid in pressurized tanks. It is usually made up of propane, butane, or a mixture of both gases.

Owner’s Manual for Stationary Industrial Generators 11

LP Vapor Withdrawal Fuel 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.

LP Liquid Withdrawal Fuel System LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor. A vaporizer converter is used to accomplish this. In such a converter, heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state.

NOTE: Units with LP gas liquid withdrawal systems incorporate a block heater as standard equipment. The heater is powered by the utility power source during non-operating periods to provide heated coolant to aid in the fuel vaporization process.

Dual Fuel: NG/LP Fuel System Some applications consist of a dual-fuel system. This type of fuel system allows the generator to run on either natural gas (primary) or LP vapor or liquid (secondary). In the event that the primary source (utility supplied) becomes unavailable, the unit automatically switches to the secondary source. It can do so while in operation or while not operating.

NOTE: Engines using propane as an alternative fuel are limited to a maximum of 100 hours per year solely during emergency operations and must keep records of such use. Further operation requires a performance test to confirm compliance with the emissions standards of §60.4233.

Specifications

Generator Refer to the data plate on the generator for rated watts, amperes, frequency, voltage, phase, and other important information.

Engine Oil Recommendations The engine has been filled with factory engine oil of a grade recommended by the engine supplier. See the applicable engine service manual for engine oil recommendations.

The manufacturer recommends an initial oil and filter change after the first 50 hours (or first three months) of service operation. Use a high quality detergent oil with an appropriate classification and viscosity for the engine type and ambient temperature conditions. Contact your

IASD for oil recommendations. Synthetic oils meeting the same service category and viscosity requirements for the application may be used.

• Recommended API Service Category for gaseous engines: SJ, SL, SM, or SN.

• Recommended API Service Category for diesel engines: CH-4, CI-4, or CJ-4

Coolant

Use only deionized or distilled water and Ethylene glycol antifreeze (Propylene glycol can also be used but do not mix with Ethylene glycol). When adding coolant, always add the recommended 50-50 mixture.

Gearbox Lubrication (If Equipped) Use only SAE 90 gear oil with the correct proportion of Lucas Heavy Duty Oil Stabilizer. See the Maintenance section for more information.

(000149)

DANGER

Risk of poisoning. Do not use mouth to siphon coolant. Doing so will result in death or serious injury.

(000154)

WARNING

Risk of burns. Do not open coolant system until engine has completely cooled. Doing so could result in serious injury.

Risk of overheating. Do not use any chromate base rust inhibitor with propylene glycol base antifreeze, boosters, or additives. Doing so will cause overheating and possible equipment damage. (000165a)

CAUTION

12 Owner’s Manual for Stationary Industrial Generators

Starting Aids (If Equipped) One or more of the following starting aids may be provided to ensure quicker, easier starts under varying climactic conditions.

• Engine coolant heater

• Engine oil heater

• Battery warmer

• Glow Plugs

These aids are powered by a normal (utility) power source during non-operating periods.

Engine Coolant Heater Heats the engine coolant when the unit is not operating.

This action keeps the engine warm even in cold weather, helping to ensure quicker starts. Powered by a circuit normally fed by the utility power supply.

Engine Oil Sump Heater Keeps the oil in the sump heated to allow easier starting and faster engine warm-up. Powered by a circuit normally fed by the utility power supply.

Battery Warmer Keeps the battery warm so it can provide full cranking current when starting in cold conditions. Powered by a circuit normally fed by the utility power supply.

Glow Plugs / Intake Air Heater Internally heat the cylinders of a diesel engine. This assists in achieving a chamber temperature high enough for combustion. Powered by a circuit normally fed by battery power.

Owner’s Manual for Stationary Industrial Generators 13

Operation

Section 3: Operation Generator Control and Operation

The operation of this generator set should only be performed by an Authorized Operator, that is, someone who has been properly trained by an IASD. Contact your local IASD for assistance in training Authorized Operators.

The following instructions assume that the generator has been properly installed, serviced, tested, adjusted, and otherwise prepared for use by a competent, qualified installation contractor and IASD. Carefully read the Safety Rules and any other safety information before attempting to operate this (and related) equipment.

Grounding the Generator Ground the generator set in accordance with all codes and regulatory requirements.

Figure 3-1. Grounding Electrode Terminal (Typical)

Generator AC Neutral Connections Grounding is recommended only at one point in the system. Consult local building codes for proper neutral grounding requirements.

Initial Startup The initial startup of the generator set must be performed and documented by an IASD.

Control Panel Interface The Control Panel Interface mounted on the generator allows the operator to monitor, and if necessary, manually start the generator. See Table 3-1 for callout definitions for the figures that follow.

Figure 3-2. H-Panel

Figure 3-3. G-Panel

A Grounding Electrode Terminal

B Base Frame

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000211)

DANGER

Explosion and Fire. Do not connect ground wire to any pipe that carries a flammable or explosive substance. Doing so will result in death or serious injury.

A B

001064

D

E F

C

G

B

A

H

009612

F

C

G

B

A

H

D

009613

14 Owner’s Manual for Stationary Industrial Generators

Figure 3-4. Power Zone® Pro

Figure 3-5. Power Zone Pro Sync

Figure 3-6. Power Zone 410

NOTE: Refer to the accompanying control panel manual for more information.

D

A B C 009614

A

B

G

C

D

009615

Table 3-1. Control Panel Interface Definitions

A Emergency Stop Button

B Common Alarm

C Key Switch

D Display Window

E Arrow Key Pad

F Communication Port

G Panel Access

H Battery Charger

A

B

C

D

012441

Owner’s Manual for Stationary Industrial Generators 15

Emergency Stop Button Pressing the Emergency Stop button while the unit is running will immediately shut the generator down. To restart the unit, the Emergency Stop Button must be manually reset, the alarm acknowledged, the Key Switch turned to the OFF position, and then turned to either the AUTO or MAN position, depending on the desired mode of operation.

Common Alarm Horn The Common Alarm and corresponding output are activated whenever a fault condition is set for Alarm and if the fault is Active. The Common Alarm will not activate on Warnings or DTC fault conditions. Pressing the ENTER button on the key pad will acknowledge the alarm and silence the horn. The manufacturer recommends that the local IASD be notified of any alarm condition in order for qualified service personnel to assess and correct the situation.

Key Switch The Key Switch positions are:

• AUTO: The generator will automatically start when a properly connected automatic transfer switch senses a loss or reduction of available utility power.

• OFF: Immediately shuts down the generator and prevents it from starting automatically.

• MAN: Immediately starts the generator.

Fuse Block The fuse block is located inside the control panel at the back lower left corner, and provides electrical protection for the DC power, wiring and other electrical components.

Figure 3-7. Panel Fuse Block (Reference Only)

NOTE: Some units will NOT have a fuse in the F4 slot.

Additional Components

Main Line Circuit Breaker (MLCB) A MLCB is located in the High Voltage Customer Connections panel, typically located to the right of the Control Panel. The MLCB serves as protection for the AC wiring and alternator, while also providing a means of disconnecting the generator.

Automatic Transfer Switch

A typical automatic transfer switch monitors utility voltage and when that voltage falls outside of specific parameters, it will initiate the generator start command.

As long as the generator control is in the AUTO position, it responds to the automatic transfer switch start command.

For information about any connected automatic transfer switch, consult the applicable transfer switch owner’s manual.

Automatic Battery Charger One of the following types of battery chargers may be provided:

• 2.5-amp

• 10-amp

• 20-amp

CAUTION

(000246b)

Equipment Damage. The emergency stop switch is not to be used to power down the unit under normal operating circumstances. Doing so could result in equipment damage.

001066

Electrocution, equipment and property damage. Handle transfer switches carefully when installing. Never install a damaged transfer switch. Doing so could result in death or serious injury, equipment and property damage. (000195)

DANGER

16 Owner’s Manual for Stationary Industrial Generators

The 2.5-amp charger is 12 VDC only. The 10-amp charger is available either as a 12 VDC or 24 VDC. The 20-amp charger operates as both 12 VDC or 24 VDC.

The appropriate battery charger is installed per the engine’s battery system.

All chargers are fully automatic float types and are fully fuse protected (input and output). They have automatic current limiting to reduce risk of overcharging, and have automatic maintenance of charge voltage. Therefore, they can be connected to the batteries continuously.

The chargers require the connection of a charged battery in order to turn on. The battery provides boost voltage for the charger, so a completely dead battery will not allow the charger to operate. The boost required is approximately 9 to 11 volts for a 12 VDC system, and 18 to 22 volts for a 24 VDC system. Replace the battery if it is below the boost voltage.

Alarm Response Procedures The generator is protected by factory set alarms and warnings. The alarms and warnings alert the owner of a fault condition that requires attention and action to keep the generator operating in an efficient and safe running order.

When any alarm is triggered, the Common Alarm Horn sounds and the corresponding fault will be displaed.

NOTE: Not all faults can be corrected and cleared by the owner/operator. Some Warnings, and most Alarm conditions, must be safely cleared by a qualified dealer or trained technician.

Warnings Warnings are the lowest level alarm, and are generated to alert the operator that an operating condition has changed and may require action or inspection. Warnings clear once they are no longer active.

Non-Shutdown Alarms Non-shutdown alarms are more urgent than warnings, and indicate a system parameter which is approaching or has exceeded a safe operating limit. Non-shutdown alarms require some form of action, such as inspection, close monitoring, etc. These types of alarms clear when they are no longer active and have been acknowledged.

Shutdown Alarms Shutdown Alarms protect the generator from damage and indicate a system fault that, if continued without immediate inspection or correction, would result in damage to the unit. Shutdown Alarms are cleared only after the key switch has been placed in the OFF position and they are no longer active.

Alarm Display Window For information regarding alarm codes and troubleshooting procedures, see the applicable manual for your control panel.

General Fault Response Procedure NOTE: See corresponding control panel manual for detailed alarm descriptions and specific procedures.

1. Use the keypad or touch screen to navigate to the Alarm Display.

2. Carefully read each line of the Alarm Warning Page to determine what fault condition is present. If there is more than one fault, the most recent is listed first.

3. Depending on the fault condition, toggle to the corresponding area.

4. Observe the information displayed for the affected area.

5. Determine corrective action necessary.

6. When the fault condition is cleared, the Alarm Dis-play will turn off.

Operating the Unit with an Automatic Transfer Switch If the generator has been installed along with an automatic transfer switch, the engine may be started and stopped automatically or manually.

NOTE: Refer to the applicable manual for any transfer switch being used and note the dangers during operation.

Normal operation is the generator in AUTOMATIC working with an automatic transfer switch. When the transfer switch senses a utility failure or loss it will provide a start command to the generator, the generator will automatically start and the transfer switch will transfer power to the load from utility to generator (emergency). It is important that both the generator and any connected automatic transfer switch(es) be properly connected and in AUTOMATIC mode for normal operation.

Owner’s Manual for Stationary Industrial Generators 17

Operating the Unit with a Manual Transfer Switch If the generator was installed in conjunction with a transfer switch capable of manual operation only, or when an automatic transfer switch has failed and can only be transferred manually, the following procedure applies. A manually operated transfer switch is one that will not provide automatic startup.

Manual Engine Startup and Transfer Refer to the applicable documentation for the control panel. For additional and specific information about any transfer switch connected to the generator, refer to the applicable transfer switch manual as well.

In order to manually transfer load from the utility source to the generator (emergency source):

1. With the generator OFF, and the generator MLCB in the OFF (OPEN) position, turn OFF or disconnect the utility power circuit to the transfer switch, using the means provided (such as the utility source MLCB or other means of disconnect).

2. Manually set the automatic transfer switch (ATS) to its EMERGENCY (STANDBY/GENERATOR) position with load circuits connected to the emergency (generator) power supply.

3. Set the generator’s MLCB to its OFF (OPEN) position.

4. Start the generator.

5. Allow the engine to stabilize and warm up.

6. Check all applicable instrument and gauge readings. When certain that all readings are correct, set the emergency generator’s MLCB to its ON (CLOSED) position.

7. Load circuits are now powered by the stationary emergency generator.

(000132)

Electrocution. Do not manually transfer under load.

Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.

DANGER

(000213)

DANGER

Electrocution. Only authorized personnel should access transfer switch interior. Transfer switch doors should be kept closed and locked. Failure to do so will result in death or serious injury.

18 Owner’s Manual for Stationary Industrial Generators

Re-Transfer and Shutdown To manually transfer the load back to the utility power source and shut down the generator:

1. Set the stationary emergency generator’s MLCB to the OFF (OPEN) position.

2. Verify utility power to the transfer switch is OFF (open the utility disconnect).

3. Manually move the ATS to the UTILITY (NORMAL) position, i.e., load circuits connected to the utility.

4. Turn ON the utility power supply to the transfer switch using the means provided (such as the utility power source MLCB).

5. Allow the generator to run at no-load for five to ten minutes to stabilize internal temperatures.

6. Shut down the generator.

Shutting Generator Down While Under Load IMPORTANT NOTE: To turn the generator OFF during utility outages to perform maintenance, or conserve fuel, follow these steps:

To turn the generator OFF (while running in AUTO and ONLINE):

1. Turn the main utility disconnect OFF.

2. Turn the MLCB on the generator to OFF (OPEN).

3. Allow the generator to run for five minutes to cool down.

4. Turn the generator OFF.

To turn the generator back ON:

1. Put the generator back into AUTO and allow to start and warm-up for a few minutes.

2. Set the MLCB on the generator to ON.

The system will now be operating in AUTOMATIC mode.

The main utility disconnect can be turned ON (CLOSED).

To shut the unit OFF, this complete process must be repeated.

Owner’s Manual for Stationary Industrial Generators 19

Maintenance

Section 4: Maintenance Maintenance Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD.

See the emissions warranty.

Periodic inspection, service, and maintenance of this unit is critical in ensuring its reliable operation. The following is the manufacturer’s recommended maintenance schedule. The established intervals are the maximum required when the unit is used in typical standby service applications (approximately 250 hours per year). The maintenance items will need to be performed more frequently if the unit is used in severe applications (such as long duration outages, very high or very low ambient conditions, or extremely dirty or dusty environments).

Use calendar time or hours of operation, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval. Note that some checks are based only on hours of operation.

There may be times when the generator must operate continuously for long periods of time (for example, extended utility outages). During such extended operational periods some items will require more frequent checking (based on hours). Use the “Extended Run-Time Maintenance Checks” recommendation for such periods of operation.

Be sure to follow all applicable safety and caution statements found in the unit operating manual or engine service/maintenance manual before performing any maintenance checks or service.

Service Maintenance Intervals Extended Run-Time Maintenance Checks: Daily checks which must be performed when the unit is operated continuously for extended periods of time.

These checks and routine monthly checks can be performed by an Authorized Operator.

NOTE: For units equipped with a gearbox, the gearbox oil should be checked monthly or every 100 hours of operation.

1A. A one-time post installation, initial operation, service inspection of the generator set to ensure it is ready to operate, transfer to, and carry the load when required, and to identify any potential problem areas. Performed ONLY ONCE following the first three months or first 50 hours of operation after installation and startup of the unit.

The various service maintenance intervals are designated by interval numbers:

1. A frequent, periodic inspection of the generator set to ensure it is ready to operate when required and to identify any potential problem areas. Performed monthly, or every 24 hours (interrupted) of operation of the unit.

2. An operational service inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed semi-annually (6 months) or every 125 hours of operation of the unit.

3. A mid-level service inspection of the generator set to ensure it is ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually or every 250 hours of operation of the unit.

4. A comprehensive service inspection of the generator set to ensure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas.

Performed biannually (every 24 months or 500 hours).

NOTE: Maintenance levels 2, 3, and 4 require the use of the applicable engine service manual and must be performed by a qualified service technician.

Maintenance Schedule The following pages contain the maintenance schedule describing the checks/tasks which need to be accomplished at each designated maintenance interval.

Some maintenance level tasks are combined. For example, if the six month tasks are due, both the monthly and the six month task should be completed at the same time. Similarly, when the annual tasks are due, the monthly and semi-annual tasks should also be completed. There is space on the sheets for recording the date and signature of the person completing the task, as well as recording the engine hours and other pertinent information. At the bottom of each sheet, space is also provided to record any fluids added, parts replaced or corrective action taken. All of this recorded information provides a detailed maintenance history of the unit. This maintenance history may be required for warranty validation purposes, and is a good idea to maintain throughout the lifetime of the unit.

It is recommended by the manufacturer that service procedures beyond the normal monthly checks be performed by an IASD.

20 Owner’s Manual for Stationary Industrial Generators

Notes and Maintenance Item Explanations

NOTE: Certain applications may require more frequent maintenance checks and more frequent operation under load.

NOTE: This schedule does not reflect all of the possible requirements of an individual engine manufacturer service schedule, particularly if the unit is used in other than a standby power application.

NOTE: For more information about service schedules and support for your application, please contact your local IASD.

Disabling a Generator for Maintenance There are two conditions when maintenance checks may have to be performed on the unit:

1. When the unit is in standby mode (automatic) and NOT running. To disable the unit from starting in this condition, in order to perform maintenance checks or service, follow the steps in To Disable the Generator From Starting.

2. When the unit is running and providing power to the load. To shut down the unit safely, without damaging loads or the generator, follow the steps for shutting down a unit while in operation. See Shutdown and Restart an Operating Generator.

Before shutting down an operating unit for maintenance, always warn personnel that power will be shut down temporarily, so equipment that might be damaged can be properly turned OFF or placed in standby.

To Disable the Generator From Starting To prevent injury, BEFORE performing any maintenance, disable the generator set from starting and/or connecting to the load:

1. Set the control panel AUTO/OFF/MANUAL switch to the OFF position.

2. Remove the control panel fuse (see wiring diagram).

3. Turn OFF power to the battery charger (remove battery charger ATC style fuse or open the battery charger circuit breaker located in the load control panel).

4. Disconnect the negative battery cable.

NOTE: The battery charger must be turned OFF BEFORE disconnecting the battery cable to prevent an over-current…