Generac Power Systems 22 kW Owner's Manual
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Generac Power Systems 22 kW Owner's Manual

Generac Power Systems 22 kW Owner's Manual

Spark-ignited stationary emergency generators
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Spark-Ignited Stationary Emergency Generators
*
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.
Para español , visita:
http://www.generac.com/service‐support/product‐support‐lookup
Pour le français, visiter :
Owner's Manual
Residential and Commercial
http://www.generac.com/service‐support/product‐support‐lookup
For
22 kW
2.4L
25 kW
1.5L
27 kW
2.4L
30 kW
1.5L
32 kW
2.4L
36 kW
2.4L
38 kW
2.4L
45 kW
2.4L
48 kW
5.4L
60 kW
2.4L

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Summary of Contents for Generac Power Systems 22 kW

  • Page 1 Owner’s Manual Spark-Ignited Stationary Emergency Generators Residential and Commercial 22 kW 2.4L 25 kW 1.5L 27 kW 2.4L 30 kW 1.5L 32 kW 2.4L 36 kW 2.4L 38 kW 2.4L 45 kW 2.4L 48 kW 5.4L 60 kW 2.4L NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS.
  • 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 on the base frame adjacent to the front engine mount on all 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 Section 4 Operation 4.1 Control Panel ........................19 4.2 Auto/Manual/Off ........................19 4.3 Menu Navigation .........................20 4.4 Alarm/Warning Conditions ....................23 4.5 Change Time and Date .......................23 4.6 Programmable Timers ......................23 4.6.1 Dealer Programmable ........................ 23 4.6.1.1 Exercise Time ........................23 4.6.2 User Programmable ........................
  • Page 5 Table of Contents 5.7 Schedule A Maintenance ....................31 5.7.1 Schedule A Maintenance Item Locations ................... 31 5.7.2 Preliminary Instructions ......................31 5.7.3 Check Enclosure Louvers ......................31 5.7.4 Check Fuel Lines ........................31 5.7.5 Check Coolant Level and Hoses ....................32 5.7.6 Check Radiator for Clogging .......................
  • 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 Emergency 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 Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 48 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 5.4L 2.4L Generator Set Rotor Insulation...

  • Page 13: Engine Oil Recommendations

    Specifications Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 48 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 5.4L 2.4L Breather Closed Open Closed Open Closed Open...

  • Page 14: Weather And Maintenance Kits

    Specifications 2.4 — Weather and Maintenance Kits To keep the generator running at its peak, the following kits are offered: • Cold Weather Kit – Recommended for climates with temperatures below 32°F • Extreme Cold Weather Kit – Recommended Block Heater Kit for protection in temperatures below 32°F •...

  • Page 15: Reconfiguring The Fuel System

    Specifications 2.7 — Reconfiguring the Fuel System While some models are created fuel specific for either Natural gas (NG) or Liquid Propane vapor (LPV) and are not fuel convertible, others are configured at the factory for NG, but are field convertible to LPV. Units fitted with a dual fuel car- buretion system are generally configured for the selected fuel source during installation.

  • Page 16: Change Fuel Selection

    Specifications Serious injury, including death, or damage will occur if not configured properly. Consult an Authorized Dealer with any questions. 2.7.2— Change Fuel Selection Failure to convert both the hardware and software will result in decreased performance and an increase in emissions, which is a violation of Environmental Protection Agency (EPA) regulations.

  • Page 17: Section 3 Activation And Startup

    Activation and Startup Section 3 3.1 — Orientation NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. The location and appearance of some components may vary between engine models. 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.

  • Page 18: Install Battery

    Activation and Startup 3.3 — Install Battery CAUTION: Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the result- ing sparks may cause a battery explosion which could result in serious injury. Loosen two screws with nylon washers to release hold- down clamp from battery tray.

  • Page 19: Activate Unit

    Activation and Startup 3.5 — 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 20: Start And Run Engine

    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. Quiet Test Mode? Press ENTER. Yes No Display Reads: Set Exercise Time.

  • Page 21: Operational Checks

    Activation and Startup 3.7 — Operational Checks The following procedures require special tools and skills. Contact an authorized service provider to perform these tasks. 3.7.1— Self Test Upon power up, the controller goes through a system self test which checks for the presence of utility voltage on the DC circuits.

  • Page 22: Test Generator Under Load

    Activation and Startup Allow the engine to warm up for about five minutes. Move the Main Circuit Breaker switch on the generator con- trol panel up to the ON (or closed) position. Generator power voltage is now supplied to the transfer switch. Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock.

  • Page 23: Final Instructions

    Activation and Startup Verify that the generator is OFF. A red LED on the control panel illuminates to confirm that the system is in the OFF mode. Install front cover of the transfer switch. Turn ON the utility power supply to the transfer switch, using the means provided (such as a utility main line cir- cuit breaker).
  • Page 24 Activation and Startup This page intentionally left blank. Owner’s Manual for Stationary Emergency 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 panel 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 Panel 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 panel is not used for five minutes. The screen nor- mally 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 Operation Feature Description Navigation ESCAPE Used to abort a routine or back up to the preceding menu. ENTER Used to make a selection or save an entry. UP ARROW Used to move forward or backward from menu to menu or to scroll forward or backward (increment or dec- DOWN ARROW rement) through available selections.
  • Page 28 Operation Owner’s Manual for Stationary Emergency Generators...

  • Page 29: Alarm/Warning Conditions

    Operation Figure 4-3. Navigation Menu 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 30: 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 31: Automatic Sequence Of Operation

    Operation 4.9.1— Automatic Sequence of Operation 4.9.1.1—Utility Failure If the control panel is set to AUTO when the utility power fails, a ten second Start-Up Delay timer is started (user pro- grammable). If utility power is still absent when the time expires, the engine cranks and starts. Once started, a five second engine Warm-Up Delay timer starts (user programmable).

  • Page 32: 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 transfer switch, which is not used for three phase applications. See specific manual for three phase transfer switch. 4.10.1—...

  • 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. NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual.

  • Page 34: Access Panels

    Maintenance Coolant Overflow Reservoir Spark Plugs Coolant Drain Battery Drain Hose Figure 5-3. Left Side View NOTE: All normal maintenance and service items are easily accessible for consumer convenience. Wherever possible, touch points are colored orange to provide for quick and easy recognition. 5.2 —...

  • Page 35: 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 an authorized service provider or 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 36: 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 3.4 —Open Viewing Window. Move the Main Circuit Breaker switch down to the OFF (Open) position.

  • Page 37: 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. NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. For the general location of compo- nents in all other models, see Subsection 5.7.1—Schedule A Maintenance Item Locations.

  • Page 38: Check Coolant Level And Hoses

    Maintenance 5.7.5— Check Coolant Level and Hoses Do not add coolant when the engine is hot. Steam and scalding fluids can cause severe burns. Verify that the coolant level is between the HOT and COLD marks on the overflow reservoir. See Figure 5-6. NOTE: Coolant expands when hot, so the level may be higher than the HOT mark.

  • Page 39: Replace Lubricating Oil And Oil Filter

    Maintenance Verify that the oil level is at or near the FULL mark. Add oil as necessary. See A of Figure 5-7 NOTE: Observe the oil level on both sides of the dipstick. The lower of the two readings is the correct oil level measurement.
  • Page 40 Maintenance Use one wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug. Hot oil may cause burns. Allow engine to cool before draining oil. Avoid prolonged or repeated skin exposure with used oil. Thoroughly wash exposed areas with soap Drain oil into a suitable container.
  • Page 41 Maintenance Figure 5-8. Oil Drain Hose, Fill Cap, Dipstick and Filter Owner’s Manual for Stationary Emergency Generators...
  • Page 42 Maintenance Oil Fill Cap Air Cleaner Air Cleaner Oil Fill Cap Oil Filter Oil Filter Oil Level Dipstick Oil Level Dipstick 2.4L: 22/27/36/45 kW 2.4L: 32/38 kW Oil Fill Cap Oil Fill Cap Air Cleaner Air Cleaner Oil Filter Oil Filter Oil Level Oil Level Dipstick...

  • Page 43: Check Battery Condition/Fluid Level

    Maintenance Figure 5-9. Engine Oil and Air Cleaner Maintenance (All Models) 5.7.9— Check Battery Condition/Fluid Level 5.7.9.1— Check Condition and Clean 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 44: Check And Adjust Accessory/Drive Belt

    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 45: Replace Air Filter Element

    Maintenance Water Pump Pulley Belt Deflection Gauge Alternator Pulley 2.4L: Manual Adjustment Automatic Tensioner 1.5L: Manual Adjustment 5.4L: Automatic Adjustment Figure 5-12. Check Accessory/Drive Belt Deflection 5.7.11— Replace Air Filter Element Remove wing nut, lock washer and flat washer from threaded rod to release air cleaner cover. See Figure 5-13 Remove the air filter element and discard.

  • Page 46: Final Instructions

    Maintenance Element Cover Wing Nut Flat Washer Lock Washer Figure 5-13. Air Cleaner Cover and Filter Element NOTE: Service kits are available from Independent Authorized Service Dealers. 5.7.12— Final Instructions If only performing Schedule A maintenance procedures, proceed as follows: Install battery negative cable (black) onto battery negative (-) terminal.

  • Page 47: 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: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. For the general location of compo- nents in all other models, see Subsection 5.8.1—Schedule B Maintenance Item Locations.

  • Page 48: Clean/Gap/Replace Spark Plugs

    Maintenance Insert funnel into filler neck of radiator. See B of Figure 5-14 Slowly pour coolant into filler neck until radiator is full. Install radiator cap. Press MANUAL on the control panel to start the engine. A blue LED illuminates to confirm that the system is in the MANUAL mode.

  • Page 49: Final Instructions

    Maintenance Figure 5-15. Adjust Spark Plug Gap Check condition of threads in cylinder head and on spark plugs. If necessary, soften deposits with penetrating oil and clean out with a thread chaser. Clean spark plugs using a wire brush and commercial solvent. Do not blast spark plugs. Use new spark plugs if necessary.

  • Page 50: 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 an authorized service provider to perform these tasks.

  • Page 51: Lube Oil Maintainer System

    Maintenance 5.11 — Lube Oil Maintainer System 5.11.1— Description NOTE: Oil reservoir is empty when shipped from factory. Fill with clean engine oil to activate the system. The 36 kW, 45 kW, and 60 kW models are equipped with a Lube Oil Maintainer System. The system is installed at the factory and calibrated at the factory to the correct engine-running crankcase oil level.

  • Page 52: Test Functionality

    Maintenance 5.11.3— Test Functionality See A of Figure 5-17. Momentarily press the test button to confirm that the float is operating correctly. Do not hold the test button down for a prolonged period of time or the crankcase can be over filled. Over filling the crankcase can result in engine damage.

  • Page 53: 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 54: 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 55: 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 56: Return From Storage

    Troubleshooting NOTE: On 36 kW, 45 kW, and 60 kW models, close shutoff valve to avoid draining the oil supply tank with the crankcase oil. For more information, see Subsection 5.11 —Lube Oil Maintainer System. 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.

  • Page 57: Attention After Submersion

    Troubleshooting Press MANUAL on the control panel to start the engine. A blue LED illuminates to confirm that the system is in the MANUAL mode. Allow the engine to run until it is reaches normal operating temperature. Check for leaks while the engine is run- ning.
  • Page 58 Troubleshooting This page intentionally left blank. Owner’s Manual for Stationary Emergency Generators...
  • Page 59 This page intentionally left blank.
  • Page 60 Part No. 0K8185 Rev. A 02/16/2015 Printed in USA Generac Power Systems, Inc. ©2015 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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