Generac Power Systems RD015 Owner's Manual
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Generac Power Systems RD015 Owner's Manual

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*
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.
This manual must be used in conjunction
with the appropriate installation manual.
Owner's Manual
Stationary Diesel Generators
Residential and Commercial
Model
RD015 -
RD020 -
RD030 -
RD048 -
RD050 -
0066781 - 30 kW
For
15 kW
60 Hz
20 kW
60 Hz
30 kW
60 Hz
48 kW
60 Hz
50 kW
60 Hz
60 Hz
Protector
Series
™
(Single Phase Only)
(Three Phase Only)

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Summary of Contents for Generac Power Systems RD015

  • Page 1 Protector Series ™ Owner’s Manual Stationary Diesel Generators Residential and Commercial Model RD015 - 15 kW 60 Hz RD020 - 20 kW 60 Hz RD030 - 30 kW 60 Hz RD048 - 48 kW 60 Hz (Single Phase Only) RD050 -...
  • Page 2 Use this page to record important information about the generator set. For quick and easy reference, copy the information printed on the Unit Identification Label onto the sample label printed here. The Unit Identification Label is located at the rear of the alternator on 15/20 kW (2.3L) units, and on the front engine mount on 30 kW (2.4L) and 50 kW (3.4L) models.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Section 1 Safety 1.1 Introduction .......................... 1 1.2 Safety Information ........................ 2 1.3 General Hazards ........................2 1.4 Exhaust Hazards ........................3 1.5 Electrical Hazards ........................ 3 1.6 Fire Hazards .......................... 3 1.7 Explosion Hazards ....................... 3 Section 2 Specifications 2.1 Emission Information ......................
  • Page 4 Table of Contents 3.8.3 Electrical Checks ........................16 3.8.4 Test Generator Under Load ......................16 3.8.5 Check Automatic Operation ......................17 3.9 Final Instructions ........................17 Section 4 Operation 4.1 Control Panel ........................19 4.2 Auto/Manual/Off ........................19 4.3 Menu Navigation .........................20 4.4 Alarm/Warning Conditions ....................22 4.5 Change Time and Date .......................22 4.6 Programmable Timers ......................22 4.6.1 Dealer Programmable ........................
  • Page 5 Table of Contents 5.6 Daily Maintenance (If Running Continuously) ..............31 5.7 Schedule A Maintenance ....................32 5.7.1 Preliminary Instructions ......................32 5.7.2 Check Fuel Level and Fill ......................32 5.7.3 Drain Fuel Filter and Check Fuel Lines/Hoses ................32 5.7.4 Check Coolant Level and Hoses ....................
  • Page 6 Table of Contents WARNING California Proposition 65. Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. (000004) WARNING California Proposition 65. This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.

  • Page 7: Section 1 Safety

    Safety Section 1 1.1 — Introduction Thank you for purchasing this stationary automatic standby generator set. Every effort was made to ensure that the information in this manual was both accurate and complete at the time it was released. However, the manufacturer reserves the right to change, alter or otherwise improve this product at any time without prior notice.

  • Page 8: Safety Information

    Safety 1.2 — Safety Information Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Man- ual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained.

  • Page 9: Exhaust Hazards

    Safety 1.4 — Exhaust Hazards • Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even death. If any carbon monoxide poisoning symptom is experienced, move into fresh air and immediately seek medical attention.
  • Page 10 Safety This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 11: Section 2 Specifications

    Specifications Section 2 2.1 — Emission Information The U.S. Environmental Protection Agency (EPA) requires that the generator comply with exhaust emission standards. The generator is certified to meet the applicable EPA emission levels, and is certified for use as a stationary engine for standby power generation.

  • Page 12: Specifications

    Specifications 2.2 — Specifications 2.2.1— Engine General 2.3L Engine 2.4L-49 Engine 3.4L Engine Engine System Type 4 cylinder, in-line, 4 cycle 4 cylinder, in-line, 4 cycle 4 cylinder, in-line, 4 cycle Fuel Type Ultra Low Sulfur Diesel Ultra Low Sulfur Diesel Ultra Low Sulfur Diesel Fuel Filtering 5 Microns...

  • Page 13: Engine Oil Recommendations

    Specifications 2.3 — Engine Oil Recommendations To maintain the product warranty, use only genuine Generac replacement parts. Generac maintenance kits include both the oil filter and air filter, and can be obtained through any Authorized Dealer. All Generac maintenance kits meet minimum American Petroleum Institute (API) Service Class CD or better. Select the appropriate viscosity oil grade according to the expected operating temperature.

  • Page 14: Fuel Maintenance

    Specifications NOTE: Low ambient temperatures as well as engine operation at high altitudes may require the use of fuels with higher Cetane ratings. Allow at least 5 percent of the tank capacity for fuel expansion. DO NOT OVERFILL! 2.5.1— Fuel Maintenance Always treat diesel fuel for long term storage.
  • Page 15 Specifications Figure 2-3. Product Accessories Owner’s Manual for Stationary Diesel Generators...
  • Page 16 Specifications This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 17: Section 3 Activation And Startup

    Activation and Startup Section 3 IMPORTANT NOTE: The unit fuel tank has been inspected by AHJ (authority having local jurisdiction) or fire marshal and meets all requirements. Unit is fueled and the fuel is treated as per additive directions. 3.1 — Orientation NOTE: The 3.4L engine is depicted in the artwork used in this manual.

  • Page 18: Prime Fuel System

    Activation and Startup 3.3 — Prime Fuel System See Figure 3-3. Loosen the air bleed screw and work priming pump until bubbles are observed. Place a shop rag around the air bleed screw to catch any loss of fuel. When all bubbles are purged and replaced by a solid stream of fuel, tighten the air bleed screw. Check for leaks.

  • Page 19: Open Viewing Window

    Activation and Startup 3.5 — Open Viewing Window Rotate viewing window upward to access control panel. To hold viewing window in the open position, remove rod from clip at back of window and insert into hole in frame. See Figure 3-5. Figure 3-5.

  • Page 20: Activate Unit

    Activation and Startup 3.7 — Activate Unit Display Reads: Generator Active is displayed on the If the wrong language is selected, it may be changed LCD screen when the unit is first later using the Edit menu. Up Arrow = (+) powered up.

  • Page 21: Operational Checks

    Activation and Startup Display Reads: Use UP ARROW or DOWN ARROW to Select YES to perform exercise at low speed. Select select either Yes or No. NO to perform exercise at normal operating speed. Quite Test Mode? Press ENTER. Yes No Display Reads: Set Exercise Time.

  • Page 22: Electrical Checks

    Activation and Startup 3.8.3— Electrical Checks Complete electrical checks as follows: Verify that the generator is OFF. A red LED on the control pad illuminates to confirm that the system is in the OFF mode. Verify that the Main Circuit Breaker switch on the generator control panel is in the OFF (Open) position. Turn OFF all circuit breakers/electrical loads that will be powered by the generator.

  • Page 23: Check Automatic Operation

    Activation and Startup Press MANUAL on the control pad. The engine will crank and start. Allow the engine to warm up for a few minutes. Move the Main Circuit Breaker switch on the generator control panel up to the ON (or closed) position. The switch is now powered by the standby generator.
  • Page 24 Activation and Startup This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 25: Section 4 Operation

    Operation Section 4 4.1 — Control Panel NOTE: The control panel is intended for use by qualified service personnel only. The control panel is located behind the viewing window at the rear of the unit. With the control pad set to AUTO, the engine may crank and start at any time without warning. Such automatic starting occurs during the programmed exercise cycle or when utility power source voltage drops below the configured level.

  • Page 26: Menu Navigation

    Operation LCD Screen UP ARROW Green Blue ENTER AUTO MANUAL DOWN ARROW ESCAPE Figure 4-2. Control Pad and LCD Screen 4.3 — Menu Navigation See Figure 4-3. Feature Description System Menus The system returns to the Home screen if the control pad is not used for five minutes. The screen normally displays a Status message, such as Ready to Run (Auto mode) or Switched to OFF (Off mode), and the total Hours of Protection.

  • Page 27: Home Screen

    Operation Switched to “OFF” Home Screen Up Arrow = (+) Hours of Protection Current Date/Time 0 (H) 02/14/13 07:40 Running Manual Running-Utility Lost SYSTEM DATE/TIME ENTER Running-Remote Start Down Arrow = (-) ENTER Running-2 Wire Start Running - Exercise Run Hours (H) Battery Condition ENTER Switched Off...

  • Page 28: Alarm/Warning Conditions

    Operation 4.4 — Alarm/Warning Conditions The owner/operator is alerted to Alarm and/or Warning conditions via the control panel LCD screen. All Alarm condi- tions cause the generator to shut down. The Warning messages alert the operator to conditions that do not disable the unit or require immediate correction.

  • Page 29: User Programmable

    Operation 4.6.2— User Programmable 4.6.2.1—Start-Up Delay Timer A programmable line interrupt delay (or Start-Up Delay) timer is provided. When utility voltage fails (falls below 60% of nominal), the start-up delay timer is started. If the voltage rises above the Utility Volts Low threshold, the timer is reset. If the utility voltage remains below the threshold during the duration of the timer, the unit cranks and starts.

  • Page 30: Automatic Sequence Of Operation

    Operation 4.9.1— Automatic Sequence of Operation 4.9.1.1—Utility Failure If the control pad is set to AUTO when the utility power fails (falls below 60% of nominal, dealer programmable), a ten second Start-Up Delay timer is started (user programmable). If utility power is still absent when the time expires, the engine cranks and starts.

  • Page 31: Transfer To Generator Power

    Operation IMPORTANT NOTE: Always use the applicable transfer switch owner's manual for actual manual transfer switch operation instructions. The information presented here describes a typical V-style transfer switch, which is not used for three phase applications. 4.10.1— Transfer to Generator Power When utility power fails, manually transfer to standby power and start the generator as follows: Press OFF on the control pad.
  • Page 32 Operation This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 33: Section 5 Maintenance

    Maintenance Section 5 5.1 — Component Locations The side of the enclosure with the viewing window is identified as the rear of the generator set. The right and left sides are identified by standing at the rear and looking towards the front of the unit. Viewing 7.5 Amp Fuse Window...
  • Page 34 Maintenance Breather Canister Fuel Return Hose Fuel Filter/Air Bleed Fuel Supply Hose and Filter Coolant Governor Coolant Overflow Battery Drain Hose Linkage Reservoir Figure 5-3. Left Side View Fuel Tank Primary Vent Emergency Vent Primary Tank Fuel Filler Spout Emergency Vent Fuel Level Gauge Secondary Tank Figure 5-4.

  • Page 35: Access Panels

    Maintenance 5.2 — Access Panels Access panels are located at both the front and sides of the enclosure. 5.2.1— Removal Insert key into latch and rotate counterclockwise 1/2 turn. See Figure 5-5. Raise panel using thumb latch. 5.2.2— Installation Lower panel into position using thumb latch. Insert key into latch and rotate clockwise 1/2 turn.

  • Page 36: Service Maintenance Intervals

    Maintenance 5.3 — Service Maintenance Intervals NOTE: Use only Genuine Generac parts to ensure warranty coverage. All generator service must be performed by a qualified service person only. It is important to perform all maintenance at the interval specified in the Service Maintenance Schedule. This ensures safe and proper operation, as well as compliance with applicable emissions standards.

  • Page 37: Remove From Service

    Maintenance 5.4 — Remove From Service To ensure safety, follow the steps below prior to inspection, maintenance or service. IMPORTANT NOTE: If currently experiencing a utility outage, see Subsection 6.3 —Removal From Service During Utility Outages for special instructions. Open the viewing window. See Subsection 3.5 —Open Viewing Window. Move the Main Circuit Breaker switch down to the OFF (Open) position.

  • Page 38: Schedule A Maintenance

    Maintenance 5.7 — Schedule A Maintenance NOTE: Perform Schedule A maintenance once each year or after 125 hours of service, whichever comes first. 5.7.1— Preliminary Instructions See Subsection 5.4 —Remove From Service. Remove access panels at the front and both sides of the enclosure. See Subsection 5.2 —Access Panels. Remove battery negative cable (black) from battery negative (-) terminal.

  • Page 39: Check Coolant Level And Hoses

    Maintenance Priming Pump Fuel Filter Water Drain Plug Figure 5-8. Drain Water From Fuel Filter 5.7.4— Check Coolant Level and Hoses Do not add coolant when the engine is hot. Steam and scalding fluids can cause severe burns. NOTE: On 2.3L models, remove ten screws to release louvered air discharge panel on left side of enclosure. Verify that the coolant level is between the HOT and COLD marks on the overflow reservoir.

  • Page 40: Check Radiator For Clogging

    Maintenance 5.7.5— Check Radiator for Clogging Direct beam of flashlight through openings in fan guard to inspect the radiator fins. Carefully look for debris, accumula- tions of dirt or other deposits. If necessary, clean as follows: On right side of enclosure, loosen two clamps at each end of turbocharger exhaust outlet pipe. Remove pipe, clamps and rubber couplings from engine.

  • Page 41: Check Battery Condition/Fluid Level

    Maintenance 5.7.7— Check Battery Condition/Fluid Level 5.7.7.1— Check Condition and Clean NOTE: On 2.3L models, remove ten screws to release louvered air intake panel on left side of enclosure. Verify that top of battery is clean and dry. Dirt and electro- lyte on top of the battery can cause battery to self-dis- charge.
  • Page 42 Maintenance Installation Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in seri- ous injury. Install rubber protective cover over battery posi- tive (+) terminal.

  • Page 43: Check And Adjust V-Belt

    Maintenance 5.7.8— Check and Adjust V-Belt 5.7.8.1— Check Check the V-belt deflection. Too little belt deflection accelerates belt wear, while too much deflection leaves the pulley idle, overheats the engine, and no-load is generated. Adjust the belt deflection as follows: On right side of enclosure, loosen two clamps at each end of turbocharger exhaust outlet pipe.

  • Page 44: Adjust

    Maintenance 5.7.8.2— Adjust Loosen tension adjuster screw (top). Loosen hex nut on pivot screw (bottom). Rotate alternator outward to reduce belt deflection, rotate inward to increase belt deflection. Tighten tension adjuster screw (top) to 17-22 ft-lbs (23-30 N-m). Tighten hex nut on pivot screw (bottom) to 33-43 ft-lbs (45-58 N-m).

  • Page 45: Lubricate Governor Rod Linkage

    Maintenance Filter Element Clamp Drain Plug Sight Glass Figure 5-15. Drain Breather Canister and Replace Filter 5.7.11— Lubricate Governor Rod Linkage Lubricate both ends of rod with a silicone spray. See Figure 5-16. Verify that rod moves freely without binding. Figure 5-16.

  • Page 46: Schedule B Maintenance

    Maintenance 5.8 — Schedule B Maintenance NOTE: Perform Schedule B maintenance every two years or after 250 hours of service, whichever comes first. Before proceeding below, first perform all tasks listed under Schedule A Maintenance. NOTE: For general location of components, see Subsection 5.1 —Component Locations. 5.8.1—...

  • Page 47: Replace Fuel Filter

    Maintenance 5.8.2— Replace Fuel Filter Slowly loosen water drain plug. See Figure 5-18. Rotate filter counterclockwise to remove from filter adapter. Install new filter by hand until gasket just contacts filter adapter. Tighten filter an additional 3/4 to one full turn. Tighten water drain plug.

  • Page 48: Final Instructions

    Maintenance Remove coolant drain hose from holding clamp. Use wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug. Drain coolant into a suitable container. Install plug at end of drain hose. Install drain hose in holding clamp.

  • Page 49: Schedule C Maintenance

    Maintenance 5.9 — Schedule C Maintenance NOTE: Perform Schedule C maintenance after 1000 hours of service. Before proceeding below, first perform all tasks listed under Schedule A Maintenance and Schedule B Maintenance. The following procedures require special tools and skills. Contact a Generac Dealer or an authorized service provider to perform these tasks.
  • Page 50 Maintenance This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 51: Section 6 Troubleshooting

    Troubleshooting Section 6 6.1 — Engine Troubleshooting Problem Cause Correction Replace 7.5 amp fuse in generator con- Fuse blown. trol panel. Correct short circuit condi- tion if fuse blows again. Loose, corroded or defective bat- Tighten, clean or replace as neces- tery cables.

  • Page 52: Controller Troubleshooting

    Troubleshooting 6.2 — Controller Troubleshooting Active Alarm Problem Solution NOT ACTIVATED Unit will not start in AUTO with utility loss. Refer to activation section in Owner’s Manual. Check MLCB. Contact servicing dealer if MLCB is in the ON NONE Unit running in AUTO but no power in house. position.

  • Page 53: Removal From Service During Utility Outages

    Troubleshooting 6.3 — Removal From Service During Utility Outages If, during prolonged utility outages, the user wishes to remove the unit from service to conserve fuel, reduce run hours, or to perform maintenance tasks, then complete the steps listed below. IMPORTANT NOTE: Failure to abide by this procedure can result in equipment damage.

  • Page 54: Return From Storage

    Troubleshooting Remove right side access panel. See Subsection 5.2 —Access Panels. Remove oil drain hose from holding clamp. Use one wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug. Drain oil into a suitable container. Install drain plug onto end of oil drain hose.

  • Page 55: Attention After Submersion

    Troubleshooting Install left side access panel. See Subsection 5.2 —Access Panels. NOTE: On 2.3L models, start ten screws to install louvered air intake panel. Alternately tighten screws to 90 in- lbs. Remove right side access panel. See Subsection 5.2 —Access Panels. Check oil level and add oil as necessary.
  • Page 56 Troubleshooting This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...
  • Page 57 Troubleshooting NOTES Owner’s Manual for Stationary Diesel Generators...
  • Page 58 Troubleshooting NOTES Owner’s Manual for Stationary Diesel Generators...
  • Page 60 Part No. 0K3220 Rev. J 05/07/2015 Printed in USA Generac Power Systems, Inc. © Generac Power Systems, Inc. All rights reserved S45 W29290 Hwy. 59 Specifications are subject to change without notice. Waukesha, WI 53189 No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722) consent from Generac Power Systems, Inc.

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