Generac Power Systems Protector Series Owner's Manual
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Generac Power Systems Protector Series Owner's Manual

Stationary diesel generators 15-30 kw, 12-24 kva
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Owner's Manual
Stationary Diesel Generators
Residential and Commercial
15–30 kW, 12–24 kVA
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.
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
Protector
(000209b)
®
Series
™

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Summary of Contents for Generac Power Systems Protector Series

  • Page 1 ® Protector Series ™ Owner’s Manual Stationary Diesel Generators Residential and Commercial 15–30 kW, 12–24 kVA 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.
  • 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 into the table provided below. The Unit Identification Label is located on the left engine mount on 15/20 kW (2.5L) units, and on the left side of the radiator shroud on 30 kW (2.2L) models.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Safety Operational Checks ........... 15 Self Test ..............15 Introduction ............1 Check Manual Transfer Switch Operation ....15 Read this Manual Thoroughly ........1 Electrical Checks ............15 Safety Alerts ............1 Test Generator Under Load ........16 Safety Information ..........1 Check Automatic Operation ........16 General Hazards ..........2 Final Instructions ..........
  • Page 4 Table of Contents Section 5: Maintenance Section 6: Troubleshooting Component Locations ........27 Engine Troubleshooting ........41 Access Panels ............29 Controller Troubleshooting ......42 Removal ..............29 Removal From Service During Installation ..............29 Utility Outages............ 43 Service Maintenance Intervals ......29 Storage ...............

  • Page 5: Section 1: Safety Introduction

    Safety Section 1: Safety Introduction Safety Alerts Thank you for purchasing this stationary automatic Throughout this manual, and on tags and decals affixed standby generator set. Every effort was made to ensure to the unit, DANGER, WARNING, CAUTION and NOTE that the information in this manual was both accurate and blocks are used to alert personnel to special instructions complete at the time it was released.

  • Page 6: General Hazards

    Safety General Hazards DANGER WARNING Loss of life. Property damage. Installation must always Equipment damage. This unit is not intended for use as a prime power source. It is intended for use as an intermediate comply with applicable codes, standards, laws and power supply in the event of temporary power outage only.

  • Page 7: Electrical Hazards

    Safety Electrical Hazards Fire Hazards DANGER DANGER Explosion and fire. Fuel and vapors are extremely Electrocution. Contact with bare wires, flammable and explosive. No leakage of fuel is terminals, and connections while generator permitted. Keep fire and spark away. Failure to do is running will result in death or serious injury.
  • Page 8 Safety This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 9: Section 2: Specifications

    Specifications Section 2: Specifications Emission Information Emissions Data Plate A data plate is riveted to the cylinder head cover to verify The U.S. Environmental Protection Agency (EPA) compliance with EPA emissions regulations. requires that the generator comply with exhaust emission standards.

  • Page 10: Specifications

    Specifications Specifications Engine General 2.5L Engine 2.2L Engine Engine System Type 4 cylinder, in-line, 4 cycle 4 cylinder, in-line, 4 cycle Fuel Type Ultra Low Sulfur Diesel Ultra Low Sulfur Diesel Fuel Filtering 6 Microns 25 Microns (maximum) Bore and Stroke 3.30 in x 3.90 in (84 mm x 100 mm) 3.30 in x 3.90 in (84 mm x 100 mm) Displacement...

  • Page 11: Engine Oil Recommendations

    Specifications Engine Oil Recommendations Fuel Requirements To maintain the product warranty, the engine oil should IMPORTANT NOTE: DO NOT use Home Heating Oil or be serviced in accordance with the recommendations of Bio-Diesel Fuel. this manual. For your convenience, maintenance kits Use No.

  • Page 12: Battery Requirements

    Specifications Battery Requirements Group 27F, 12 Volt 2.5L & 2.2L engine: For areas where temperatures regularly drop below 32° F (0° C). NOTE: Battery dimensions (L x W x H) for Group 27F battery must not exceed 12-1/2" x 6-13/16" x 8-15/16" (318 mm x 173 mm x 227 mm).
  • Page 13 Specifications 006368 Figure 2-3. Product Accessories Owner’s Manual for Stationary Diesel Generators...
  • Page 14 Specifications This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 15: Section 3: Activation And Startup

    Activation and Startup Section 3: Activation and Startup IMPORTANT NOTE: Before startup, the unit fuel tank may need to be inspected by the local AHJ (authority having jurisdiction) or fire marshal meet requirements. User must fill the fuel tank and treat the fuel according to additive specifications.

  • Page 16: 2.5L Models

    Activation and Startup 6. Thread ten screws into louvered air intake panel. Alternately tighten screws to 90 in-lb (10 Nm) using a crosswise pattern. 006371 Figure 3-4. Prime Fuel System (2.5L Engines) 2. When all bubbles are purged and replaced by a solid 006372 stream of fuel, lower pump handle (or release Figure 3-5.

  • Page 17: Start And Run Engine

    Activation and Startup Start and Run Engine Test engine shutdown switches after installation to verify proper operation. 1. See Figure 3-7. Pull up rubber flap covering fuse 1. Verify rocker switches are ON (I). holder and verify installation of 7.5 amp fuse (A). 2.

  • Page 18: Activate Unit

    Activation and Startup 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. After displaying firmware and hardware version codes, as well as Language other system information, the Installation...

  • Page 19: 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 20: Test Generator Under Load

    Activation and Startup 3. Turn OFF the utility power supply to the transfer switch, using the means provided (such as a utility DANGER main line circuit breaker). Electrocution. High voltage is present at transfer switch and terminals. Contact with live DANGER terminals will result in death or serious injury.

  • Page 21: Final Instructions

    Activation and Startup Shutting Generator Down While NOTE: Transfer Switch will transfer back to utility position. Under Load Or During A Utility 4. Move the Main Circuit Breaker switch on the Outage generator control panel up to the ON (or closed) position.
  • Page 22 Activation and Startup This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 23: Section 4: Operation

    Operation Section 4: Operation Control Panel always set the control pad to OFF and remove the 7.5 amp fuse before working on or around the generator or NOTE: The control panel is intended for use by qualified transfer switch. For added security, place a DO NOT service personnel only.

  • Page 24: Auto/Manual/Off

    Operation Auto/Manual/Off Feature Description Press to activate fully automatic operation. Green LED illuminates to confirm that system is in AUTO mode. AUTO Transfer to standby power occurs if utility power fails. Functionality of exercise timer is enabled, if set. Press to crank and start engine. Blue LED illuminates to confirm that system is in MANUAL mode. MANUAL Transfer to standby power occurs if utility power fails.
  • Page 25 Operation 005801 Figure 4-2. Navigation Menu Owner’s Manual for Stationary Diesel Generators...

  • Page 26: Alarm/Warning Conditions

    Operation Alarm/Warning Conditions Programmable Timers The owner/operator is alerted to Alarm and/or Warning Dealer Programmable conditions via the control panel LCD screen. All Alarm conditions cause the generator to shut down. The Exercise Time Warning messages alert the operator to conditions that A programmable exercise time is provided.

  • Page 27: Battery Charger

    Operation Battery Charger Cranking The cyclic cranking is controlled as follows: NOTE: The battery charger is integrated into the control Fifteen (15) seconds crank, seven (7) seconds rest, panel module. seven (7) seconds crank, seven (7) seconds rest; this The battery charger ensures: sequence is repeated for a total of six (6) crank cycles.

  • Page 28: Transfer Switch Manual Operation

    Operation Load Transfer With the generator running, the transfer of load is dependent upon the operating mode as follows: • Starts and runs if utility power fails (falls below 65% of nominal) for five consecutive seconds (adjustable). • Starts a five second (adjustable) engine warm-up timer. •...

  • Page 29: Transfer Back To Utility Power

    Operation 006375 Figure 4-3. Manual Transfer Switch Operation (Typical) NOTE: V-style transfer switch not used for three phase applications. Transfer Back to Utility Power When utility power is restored, manually transfer back to utility power and shut down the generator as follows: NOTE: Verify that utility voltage has returned and is at the proper value.
  • Page 30 Operation This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...

  • Page 31: Section 5: Maintenance

    Maintenance Section 5: Maintenance Component Locations NOTE: The 2.2L engine is depicted in the artwork used in this manual. The location and appearance of some The side of the enclosure with the viewing window is components may vary between engine models. identified as the rear of the generator set.
  • Page 32 Maintenance Governor Linkage (2.5L engines; not shown) Battery Coolant Drain Hose Coolant Overflow Reservoir 006380 Figure 5-3. Left Side View Fuel Tank (Primary Vent) Fuel Filler Spout Fuel Level Gauge Emergency Vent (Secondary Tank) Emergency Vent (Primary Tank) 006381 Figure 5-4. Front View Owner’s Manual for Stationary Diesel Generators...

  • Page 33: Access Panels

    Maintenance Access Panels Access panels are located at both the front and sides of the enclosure. Removal 1. See Figure 5-5. Insert key (B) into latch (A) and rotate counterclockwise 1/2 turn. 006370 Figure 5-5. Access Panel Key 2. Raise panel using thumb latch. Installation 1.

  • Page 34: Remove From Service

    Maintenance Observe the maintenance tasks and intervals shown in the table below. Schedule A Schedule B Schedule C Daily If Running 30 Hours Every Every Every Continuously Engine Break In Service Year or 2 Years or 1000 Hours 125 Hours 250 Hours •...

  • Page 35: 30 Hour Break-In

    Maintenance PUSH TO TRIP 006374 Figure 5-6. Generator Control Panel 30 Hour Break-In 3. Remove negative battery cable (black) from negative (-) battery terminal. Perform the following task: NOTE: For general location of components, see • Replace Lubricating Oil and Oil Filter Component Locations.

  • Page 36: Drain Fuel Filter And Check Fuel Lines/Hoses

    Maintenance Drain Fuel Filter and Check Fuel Lines/Hoses 4. Check hoses for nicks, cuts, tears or general deterioration. Replace as necessary. 1. See Figure 5-8. Place a shop rag beneath the fuel NOTE: On 2.5L models, install louvered air discharge filter (A) to catch water or fuel drips.

  • Page 37: Check Lubricating Oil Level

    Maintenance 9. Install clamps and rubber couplings onto each end of air intake pipe. Install pipe to air heater and radiator shroud. Tighten clamps. 10. On right side of enclosure, install four screws with nylon washers to fasten fan guard to radiator shroud.

  • Page 38: Battery Replacement

    Maintenance NOTE: On 2.5L models, start ten screws to install louvered air intake panel. Alternately tighten screws to 90 in-lb (10 N-m) using a crosswise pattern. Check Fluid Level Check the fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water. Check State of Charge Check the state of charge using a Digital Multimeter.

  • Page 39: Adjust V-Belt Tension

    Maintenance NOTE: Use a solution of soap and warm water to clean 6. Install four screws with nylon washers to fasten fan pulleys, if necessary. Avoid use of solvents, but if used, guard to radiator shroud. always follow by a soap and water wash. 7.

  • Page 40: Replace Air Filter Element-2.5L Engine

    Maintenance Replace Air Filter Element—2.5L Replace Air Filter Element—2.2L Engine Engine NOTE: The 2.2L engine is equipped with an alternate- 1. See Figure 5-14. Remove wing nut (A), flat washer style air cleaner. (B), and lock washer (C) from threaded rod to release air cleaner cover (D).

  • Page 41: Lubricate Governor Rod Linkage (2.5L Engine)

    Maintenance Lubricate Governor Rod Linkage Schedule B Maintenance (2.5L Engine) NOTE: Perform Schedule B maintenance every two years or after 250 hours of service, whichever comes 1. Lubricate both ends of rod (A) with a silicone spray. first. Before proceeding below, first perform all tasks Figure 5-18.

  • Page 42: Drain Fuel Filter And Check Fuel Lines/Hoses

    Maintenance Drain/Flush Coolant System NOTE: On 2.5L models, remove ten screws to release louvered air discharge panel on left side of enclosure. 1. Disconnect and empty coolant overflow reservoir. 2. Install and connect coolant overflow reservoir. IMPORTANT NOTE: Verify that the engine is cool before removing the radiator cap.

  • Page 43: Final Instructions

    Maintenance RADIATOR DRAIN 001493 NOTE: Drain hose removed for illustration 001497 purposes. Figure 5-21. Drain/Fill Coolant System Final Instructions 1. Install left and right side access panels. See Access Panels. 2. See Return To Service. Owner’s Manual for Stationary Diesel Generators...

  • Page 44: Schedule C Maintenance

    Maintenance Schedule C Maintenance Return To Service After inspection, maintenance or service of the generator, NOTE: Perform Schedule C maintenance after 1000 return the unit to service following the steps below. hours of service. Before proceeding below, first perform all tasks listed under Schedule A Maintenance and 1.

  • Page 45: Section 6: Troubleshooting

    Troubleshooting Section 6: Troubleshooting Engine Troubleshooting Problem Cause Correction Replace 7.5 amp fuse in generator Fuse blown. control panel. Correct short circuit condition if fuse blows again. Loose, corroded or defective Tighten, clean or replace as battery cables. necessary.* The engine will not crank. Tighten, clean or replace as Defective starter contact.

  • Page 46: Controller Troubleshooting

    Troubleshooting 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. AUXILIARY SHUTDOWN Unit will not start in AUTO with utility loss. Verify both auxiliary shutdown switches are ON (I). NONE Unit running in AUTO but no power in house.

  • Page 47: Removal From Service During Utility Outages

    Troubleshooting Removal From Service During Storage Utility Outages Prepare For Storage If, during prolonged utility outages, the user wishes to If the generator cannot be exercised every seven days remove the unit from service to conserve fuel, reduce run and will be out of service longer than 90 days, prepare for hours, or to perform maintenance tasks, then complete storage as follows: the steps listed below.

  • Page 48: Return From Storage

    Troubleshooting NOTE: On 2.5L models, remove ten screws to release louvered air intake panel. WARNING Explosion. Batteries emit explosive gases. WARNING Always connect positive battery cable first to avoid spark. Failure to do so could result in Explosion. Batteries emit explosive gases. death or serious injury.

  • Page 49: Attention After Submersion

    Troubleshooting Attention After Submersion Do NOT start and operate the generator if it has been submerged in water. Have an Independent Authorized Service Dealer thoroughly clean, dry, and inspect the generator following any submersion. If the structure (home) has been flooded, it should be inspected by a certified electrician to ensure there won’t be any electrical problems during generator operation or when utility power is returned.
  • Page 50 Troubleshooting This page intentionally left blank. Owner’s Manual for Stationary Diesel Generators...
  • Page 52 ©2018 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.

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