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! 2.4L 35kW Models EPA Certified This manual should remain with the unit. Cover202 Rev. B 03/11 Part No.
Table of Contents Alarm and Warning Messages..........................................................8-4 Low Oil Pressure Shutdown Alarm ...............................................8-4 High Coolant Temperature Shutdown Alarm ..................................8-4 Overcrank Shutdown Alarm ..........................................................8-4 Overspeed Shutdown Alarm .........................................................8-4 RPM Sensor Failure Shutdown Alarm ......................................
Safety Instructions THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential nSAVE hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION This symbol points out potential electrical shock hazard. This symbol points out potential fire hazard. Thank you for purchasing this model of the stationary emergency generator product line.
Safety Instructions SAFETY RULES • 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.
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.
General Information IDENTIFICATION RECORD 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. DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator.
Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Emergency Generator. 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.
Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN 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.
Fuel System FUEL SYSTEM NATURAL GAS 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. FUEL REQUIREMENTS 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.
Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............................................................Gear Oil Filter ......................................... Full Flow Spin-on, Cartridge Crankcase Oil Capacity ...........................................5.25 U.S. qts. (including filter capacity) STATIONARY EMERGENCY GENERATOR Type......................................................................Synchronous Rotor Insulation............................................
Specifications WEATHER AND MAINTENANCE KITS 9. Install the previously removed black pipe onto the outlet port of the demand regulator. Use pipe sealant on the pipe threads. 10. Reverse steps 1-4 in this procedure to reactivate the demand regulator. 11. Follow the instructions in the Control Panel section. To keep the generator running at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32° F.
General Information ALTERNATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS 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.
General Information 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Figure 7.4 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead) INTERNAL CONNECTIONS 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.
Control Panel CONTROL PANEL INTERFACE 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.
Control Panel 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.
Control Panel INSTALLATION ASSISTANT • 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.
Control Panel SEQUENCE OF AUTOMATIC OPERATION MANUAL START Initial Conditions: Generator in Auto ready to run, load being supplied by the Utility Source through the transfer switch. Allows the user to start and run the generator manually. 1. 2. 3. 4. 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).
Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM 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. UNDER-FREQUENCY SHUTDOWN ALARM This is a shutdown alarm.
Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an alarm will be issued. If the generator voltage rises above 130% for >0.2 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.
Control Panel MAINTENANCE ALERT CHART CONDITION 1.6 CHERY 2.4/1800 MITSU 2.4/3600 MITSU 4.
CntrlNexus001 Rev. D 04/11 8-8 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.
Operation STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION not crank the engine continuously for longer than 30 seconds, or the heat may nDo damage the starter motor. Refer to the appropriate control panel operator’s manual for this unit. • 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.
Maintenance GENERAL 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.
Maintenance ENGINE COOLANT CHECK FAN BELT 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.
Maintenance Figure 10.3 – Engine Air Filter electrolyte fluid is an extremely corronBattery sive 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. Air Filter not use any jumper cables or booster battery to crank and start the generator engine.
Service Schedule 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 Stat
Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION 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.
Warranty 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.
1 0F9677 0G0056 0G0959 0G1155 0G1931 0G2101 0G3734 0G6562 0G6564 1 1 1 1 1 1 1 1 1 ROTOR-2390-45KD1 CPL ROTOR-2390-35KD1 CPL ROTOR-2390-45KD1 CPL (G2) ROTOR-2390-35KD1 CPL (G2) ROTOR 25KW 3PH DIRECT 390 1800 ROTOR 25KW 1PH DIRECT 390 1800 RTR-2390-60KD2 CPL RTR 390 35AD1 CPL RTR 390 35KD1 CPL 2 0F9664 0G0057 0G0058 0G0059 0G0183 0G0184 0G1932 0G2098 0G2099 0G2100 0G3736 0G3737 0G3738 0G6104 0G6563 0G6565 0G6566 0G6567 0H0201 0H1299 0H1300 0H1301 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 STATOR-390
EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM 1 2 3 4 5 (6)6 7 8 9 10 11 12 13 14 (6)15 16 (3)17 (3)18 (3)19 (3)20 (3)21 (3)22 (2)23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 (4)42 (6)43 44 45 46 47 (1)48 (1)49 (1)50 (1)51 (2)52 (2)53 (2)54 55 56 57 58 59 60 PART# QTY.
EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION A B C D E F G H J K L M N P R S T U V 0G5250 0H7356 0F4186AGS0R 0F8432A 0H7311 045771 036261 0C2454 053640 038150 022264 022471 049897 022129 022145 058306 0F8843 0F8451 0G3259 1 1 1 1 1 2 4 12 2 2 2 2 4 6 4 2 2 2 1 UL CIRCUIT BREAKER (225AF) CB 175A 2 POLE 240V 225AF COVER CB C2 CPL COVER CB DISH 2P G 225AF INSULATOR CB 2P 225AF STANDOFF CB BOX CONBOX NUT HEX M8-1.25 G8 CLEAR ZINC RIVET POP .125 X .
EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. A B C D E G H J K L 0H5582 0H6740 0D3700 0H5581A 0H6734 022129 0C2454 0D2157 049897 022145 1 1 4 1 1 3 12 4 3 3 UL CIRCUIT BREAKER (KG) CB 0300 3P 600V E KG LL COVER CB E KG C2 CONBOX NUT FLANGE M6-1.0 NYLOK INSULATOR CB E 3P KG STANDOFF CB MOUNT CONBOX WASHER LOCK M8-5/16 SCREW HWHT M6-1 X 16 N WA Z/JS SCREW SHC M6-1.0 X 50 C8.8 SCREW SHC M8-1.
EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. A B C D E F G H 0E7284 0H7356 0H7429 0E3664 0H7311 074908 036261 0C2454 1 1 1 1 1 2 4 12 UL CIRCUIT BREAKER (QN) CB 0175A 2P 240V S QN2 LL COVER CB C2 CPL COVER CB DISH 2P S QN BASE, QN CIRCUIT BREAKER STANDOFF CB BOX CONBOX SCREW HHTT M5-0.8 X 10 BP RIVET POP .125 X .
EXPLODED VIEW: CONBOX C2 CPL DRAWING #: 0H7326 APPLICABLE TO: GROUP A THIS PAGE LEFT INTENTIONALLY BLANK REVISION: H-8608-E DATE: 5/12/11 Page 8 of 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 0F9517 052860 052251 052257 052252 052259 052891 0536210410 042909 047411 055414 022447 022097 022473 049813 022261 0F9597A 045764 062963 022302 022131 065852 0F9597 022129 026204 022145 045771 0F9596 0F9596A 052212 0C2454 0H5718 1 4 4 4 4 4 4 1 1 1 1 1 1 2 1 1 1 1 4 5 5 1 1 1 1 1 1 1 1 1 3 1 WELDMENT FRAME 2.4L C2 NUT FLANGED HEX M12-1.75 DAMPENER VIBRATION 40 BLUE SPACER .49 X .62 X 1.
1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 0F3408B 0F3411 025507 052212 046526 022131 050331A 050331 038805Y 03880400AE 045771 022129 0F3976 0C2454 022145 077483 1 1 REF REF REF REF REF REF 1 1 REF REF 1 4 REF REF BATTERY TRAY C1 CPL STRAP BATTERY RETAINMENT WASHER SHAKEPROOF EXT 7/16 STL SCREW HHC M10-1.25 X 25 G8.8 WASHER LOCK M10 WASHER FLAT 3/8-M10 ZINC BATTERY POST COVER RED + BATTERY POST COVER BLACK CABLE BATTERY BLACK #1 X 18.00 CABLE BATT RED #1 X 18.00 NUT HEX M8-1.
EXPLODED VIEW: AIR CLEANER 2.4L G2 TURBO GROUP D DRAWING #: 0H1955 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 1 2 3 4 5(1) 6 7 8 9(2) 10 11(3) 0E6586 0H0295 0A6593A 0C8127 062974 022127 0G0190 037561 0H1712 050830 0H0896 0H1644 (6) 0G10080103 (6) 057822 059057 047527 0H1787 0H1787A 0E8286 0H1801 2 1 1 1 1 1 1 1 1 4 1 1 1(REF) 2 1 1 1 1 1 1 GASKET BOSCH 32 & 40 ADAPTOR PCV INTAKE ADAPTOR - CARBURETOR ELEMENT, AIR CLEANER STUD TH 1/4-20 X 4-1/2 G2 ZNC NUT HEX 1/4-20 STEEL PLATE, AIR CLEANER TOP 2.
1 2 3 4 (1) 5 6 7 (3) 8 9 10 11 (1) 12 13 14 15 16 17 18 19 20 21 22 23 (1) 24 25 26 (2) 27 28 29 (1) 30 31 32 0H30830ST03 0F2608 0E3256 046526 059981 0A5259A 0F5050A 0H2844 0F2573 0F4011 0H20620ST03 0H2051 0F2862 0F2560 022131 0E2507 0H1827 035685 0F2561 0C8145 052250 0C7043 080713 022473 0C8146 022097 076749 048031C 031971 0H0696 042911 0F2872 022304 1 1 1 5 4 2 1 2 (REF) 1 1 1 1 1 1 4 1 1 2 1 8 2 12 1 8 4 16 1 2(REF) 1 1 1 1 1 WELDMENT RADIATOR SUPPORT C2 RADIATOR 598 X 568 X 49 CPL RH V-BELT A58 (60I
EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM 1 2 3 4 (2)5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 (1) 36 37 38 39 40 41 42 43 (1) 44 45 46 47 48 49 50 51 52 (1) 53 54 56 57 58 59 (1) 60 61 62 63 64 (1) 65 66 67 68 69 70 71 72 PART# QTY.
EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. 73 74 75 76 77 052265 0H07280ST03 0H0723BST03 084750 045772 1(REF) 1 1 4 1 DESCRIPTION SCREW HHC M8-1.25 X 65 C8.8 BRKT-EXH MANF 2.4L 36KW LWR BRKT ASM HT SHIELD G2 36KW PLUG SPARK NUT HEX M10-1.5 G8 YEL CHR (1) SUPPLIED WITH ENGINE. (2) APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS.
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART# QTY. 0G9936 0H0788 064096B 0A4707F 0A4707B 0C4973C 0A8830 070006 070010 0C4975 064094 0C2454 055934C 0H0746 090388 1 1 1 1 1 1 2 4 4 1 1 2 2 1 2 DESCRIPTION TURBOCHARGER 2.4L 36KW 1800RPM GASKET EXH MAN/TURBO OIL SUPPLY 3LHA(38") ADAPTER 1/2NPT X M16-1.5 ADAPTER 1/4NPT X M12-1.5 ADAPTER 90D JIC37 1/4NPT X 1/2 WASHER FLAT .34ID X .75OD WASHER LOCK M8 SS SCREW HHC M8-1.
EXPLODED VIEW: FUEL SYSTEM 2.4L 36KW TURBO GROUP E DRAWING #: 0H7579 APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 REVISION: -ADATE: 3/22/10 PART# QTY.
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART# QTY. 0G86870ST03 0G8686 0G3919 0G6150 0F2808D 0G0007 0H0748 0G8685 080762 0C2454 022473 022097 049721 0H0789 070006 070002 022237 022241 0H1310 0G3770 0G3770A 1 1 1 1 1 1 1 1 3 4 2 2 2 1 3 3 6 6 1 1 1 DESCRIPTION BRACKET MUFFLER BRACKET STIFFENER UPPER EXHAUST PIPE ASM MUFFLER 60kW EXHAUST PIPE DIFFUSER EXHAUST WELDMENT EXHAUST PIPE STRAP MUFFLER BOLT U 3/8-16 X 2.
EXPLODED VIEW: EV ENCLOSURE C2 GROUP F DRAWING #: 0J2818 APPLICABLE TO: ITEM PART# QTY.
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Warranty GENERAC POWER SYSTEMS “FIVE YEAR” LIMITED WARRANTY FOR HONEYWELL SINGLE-PHASE LIQUID-COOLED EMERGENCY GENERATORS BELOW 50KW For a period of five (5) years from the date of successful activation of the unit, Generac Power Systems, Inc.
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