Owner's Manual US C LISTED 10, 15 & 20kW Air-cooled, Automatic Standby Generators 1-855-GEN-INFO
Table of Contents Introduction ................................................. 1 Read This Manual Thoroughly ................................................1 Safety Rules................................................. 1 Contents ...............................................................................1 Operation and Maintenance....................................................1 How to Obtain Service ...........................................................1 Standards Index...................
Safety Rules INTRODUCTION Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather, aluminum enclosure and is intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
Safety Rules THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment. nSAVE Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit.
Safety Rules • The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system. • After installing this home standby electrical system, the generator may crank and start at any time without warning. When this occurs, load circuits are transferred to the STANDBY (generator) power source.
General Information 1.2 Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. n 1.1 UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage. • This standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure that is intended for outdoor installation only.
General Information Displacement < 66 cc 66 cc < 225 cc 225 cc Category Compliance Period 1.6 SPECIFICATIONS A 300 Hours 1.6.1 GENERATOR B 125 Hours C 50 Hours A 500 Hours B 250 Hours C 125 Hours A 1000 Hours B 500 Hours Rated AC Frequency 60 Hz C 250 Hours Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum Model 10kW Rated Voltage 41.6 62.5 83.3 45 Amp 65 Amp 100 Amp Phase 1 Number of Rotor Poles 2 Weight (unit only in lbs.) 1.5 Figure 1.
General Information 1.7 READY TO RUN The "Ready to Run" on the display is ready when all of the following conditions are true: 1. 2. 3. The AUTO/OFF/MANUAL switch is set to the AUTO position. The utility voltage being supplied to the unit is being sensed by the PCB. If the utility sense voltage is not connected to the unit or if it is below approximately 150-160 volts AC, then the system will display the message "No Utility Present".
General Information 1.10 RECONFIGURING THE FUEL SYSTEM To reconfigure the fuel system from NG to LP, follow these steps: NOTE: Figure 1.5 - 15 & 20kW, GT-990/GT-999 (Airbox Cover Removed) Fuel Selection Lever - "In" Position for Natural Gas Fuel The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to 0.43 psi) to the fuel inlet of the generator MUST BE SUPPLIED. 1. 2. Open the roof.
General Information Figure 1.7 – Generator Clearances • The generator must be mounted safely per applicable codes and the manufacturer's specifications. Do NOT alter or add to the exhaust system, or do anything that might render the exhaust system unsafe or in noncompliance with applicable codes and standards. 1.11.1 GENERATOR Install the generator set, in its protective enclosure, outdoors, where adequate cooling and ventilating air is always available (Figure 1.7).
General Information Figure 1.8 – Installation Guidelines No windows or openings in the wall permitted within 5 feet from any point of the generator. 60 inches 36 inches These guidelines are based upon fire testing of the generator enclosure and the manufacturer’s requirement for air flow for proper operation. Local codes may be different and more restrictive than what is described here.
General Information Figure 1.9 – Battery Cable Connections Based on this testing and the requirements of NFPA 37, Sec 4.1.4, the guidelines for installation of the generators listed above are changed to 18 inches (457mm) from the back side of the generator to a stationary wall or building. For adequate maintenance and airflow clearance, the area above the generator should be at least 4 feet with a minimum of 3 feet at the front and ends of the enclosure.
Post Installation Start-up and Adjustments • Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried. Lead-acid batteries present a risk of fire because they generate hydrogen gas.
Post Installation Start-up and Adjustments ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Language English Escape Use ARROW keys to scroll to desired language. Press ENTER to select. 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.
Post Installation Start-up and Adjustments 2.3 CHECK TRANSFER SWITCH OPERATION Refer to the "Manual Transfer Operation" section, of the owner’s manual for procedures. tion until all power voltage supplies to the Do not attempt manual transfer switch operatransfer switch have been positively turned off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock. 2.4 ELECTRICAL CHECKS Complete electrical checks as follows: 1. 2. 3. 4.
Operation 14. Let the engine run at no-load for a few minutes. 15. Set the AUTO/OFF/MANUAL switch to OFF. The engine should shut down. 2.6 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation, proceed as follows: 1. 2. 3. 4. 5. 6. 7. 8. Set generator’s main circuit breaker to its OFF (or OPEN) position. Check that the AUTO/OFF/MANUAL switch is set to OFF.
Operation INSTALLATION ASSISTANT Display Interface Menus Interconnect System Self Test Feature (follow the on-screen prompts) The LCD display is organized as detailed below: 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.
Operation 3.3.2 CRANKING The system will control the cyclic cranking as follows: 16 second crank, seven (7) second rest, 16 second crank, seven (7) second rest followed by three (3) additional cycles of seven (7) second cranks followed by seven (7) second rests. Choke Operation 1. 2. The 990/999cc engines have an electric choke in the air box that is automatically controlled by the electronic control board.
Operation 5. manually until all power voltage supplies to Do not attempt to activate the transfer switch 4. the switch have been positively turned off. Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock. Use the manual transfer handle inside the transfer switch to move the main contacts to their STANDBY position, i.e., loads connected to the standby power source (Figure 3.2). Figure 3.2 – Manual Transfer Switch Operation 6. 7.
Operation Figure 3.4 – Open Side Compartment 120V GFCI Outlet Figure 3.5 – Low Oil Pressure and High Temperature Switches 15 Amp Outlet Breaker Low Oil Switch High Temp Switch Loos en Oil Filter LED Indicator Lights Main Circuit Breaker 3.6 PROTECTION SYSTEMS 3.6.1 ALARMS Highest Priority (Latching) Displayed on the control panel and the external red LED. They must be cleared before the alarm message goes away. The alarm log records each occurrence (see Appendix - "Menu System").
Maintenance Overvoltage (Shutdown Alarm) If the generator voltage rises above 110% of rating for greater than three (3) seconds, an alarm will be issued and the unit will shut down. If the generator voltage rises above 130% of rating for greater than 0.2 seconds, an alarm will be issued and the unit will shut down. Clear Alarm Clear the alarm by setting the AUTO/OFF/MANUAL switch to the OFF position. Press the ENTER key to unlatch any active fault and clear the corresponding alarm message. 3.6.
Maintenance Figure 4.1 — Oil Dipstick, 10kW S AE 3 0 1 0 WW-30 Synthetic Synt het i c 5 5W-30 W- 3 0 Figure 4.2 — Oil Dipstick and Fill, 15 & 20kW attempt to crank or start the engine before it has been properly serviced with the nAny recommended oil may result in an engine failure. 4.3.3 OIL & OIL FILTER CHANGE PROCEDURE To change the oil, proceed as follows: 1. Start the engine by moving the AUTO/OFF/MANUAL switch to MANUAL and run until it is thoroughly warmed up.
Maintenance Figure 4.4 – Oil Drain Hose and Filter Low Oil Switch High Temp Switch 4.4.2 See "The Generator" section for the location of the air cleaner. Use the following procedure (Figure 4.6): 1. 2. Loos 3. 4. 5. 6. 7. en Oil Filter 10KW GENERATORS Lift the roof and remove the door. Turn the worm gear clamp screw counterclockwise to loosen. Pull the old filter off the divider panel hub. Wipe away dust or debris from the panel hub. Install the new air cleaner onto the hub.
Maintenance 4.6 BATTERY MAINTENANCE The battery should be inspected per the "Service Schedule" section. The following procedure should be followed for inspection: 1. 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.
Maintenance Figure 4.10 – Cooling Vent Locations When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. • Install new valve cover gasket. • Re-attach the valve cover. Figure 4.9 - Valve Clearance Adjustment Jam Nut Pivot Ball Stud Rocker Arm Valve Stem 4.
Maintenance 4.11.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: 1. Verify that utility power is turned off and that the AUTO/OFF/ MANUAL switch is set to OFF. 2. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see the Engine Oil Recommendations section). If necessary, drain and refill with the proper oil. 3. Check the state of the battery.
Maintenance 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed. W = Weekly Inspect Change Clean M = Monthly Y = Yearly FUEL Fuel lines and connections* X M X M or 24 hours of continuous operation. LUBRICATION Oil level Oil X 2Y or 200 hours of operation.** Oil filter X 2Y or 200 hours of operation.
Troubleshooting 5.1 TROUBLESHOOTING GUIDE Problem The engine will not crank. Cause Correction 1. Fuse blown. 1. 3. 4. Correct short circuit condition, replace 7.5A fuse in generator control panel. Tighten, clean or replace as necessary. * Charge or replace battery. 2. Loose, corroded or defective battery cables. Defective starter motor. Dead Battery. 2. 1. 2. 3. Replenish fuel/Turn on fuel valve. * * 4. 5. 6. Clean, re-gap or replace plug(s). Reset valve lash.
Appendix 6.1 MENU SYSTEM NAVIGATION 6.1.1 CHANGING SETTINGS (EDIT MENU) To get to the MENU, use the "Esc" key from any page. It may need to be pressed many times before getting to the menu page. The currently selected menu is displayed as a flashing word. Navigate to the menu required by using the +/- keys. When the menu required is flashing, press the ENTER key. Depending on the menu selected, there may be a list of choices presented.
28 ENTER +/- ESC ALARM LOG RUN LOG ESC Use the “ENTER” key to select items or enter data. Use the “+/-” key to navigate through the menu. Press the “ESCAPE” key to jump back up through the menu levels. HISTORY STATE HOURS UNDER LOAD BATTERY VOLTAGE RESET MAINTENANCE TIME/DATE LANGUAGE CONTRAST EDIT GENERATOR FREQUENCY VERSIONS ESC EXERCISE TIME/SPEED ESC COMMAND ESC MAIN MENU ENGINE RPM ENGINE HOURS DISPLAY STATUS Password is entered on this page.
Notes 29
Installation Diagrams 30 Drawing 0J3244-A
Drawing 0J3244-A Installation Diagrams 31
Installation Diagrams 32 Drawing 0J3381-A
Drawing 0J3381-A Installation Diagrams 33
Warranty FOR GENERATORS 10KW AND BELOW FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS 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 2008 and later equipment. New equipment that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-smog standards for the federal government.
Warranty EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines: (a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin on the date the new equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Warranty FOR GENERATORS 13KW AND ABOVE United States Environmental Protection Agency Warranty Statement 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.
Warranty United States Environmental Protection Agency Compliance Requirements 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.
Warranty GENERAC POWER SYSTEMS "FIVE YEAR" LIMITED WARRANTY FOR HONEYWELL AIR-COOLED EMERGENCY GENERATORS For a period of five (5) years from the date of successful activation of the unit, Generac Power Systems, Inc.
