Generac Power Systems 005467-1 Owner's Manual
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Generac Power Systems 005467-1 Owner's Manual

Generac Power Systems 005467-1 Owner's Manual

Stationary emergency generator
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STATIONARY EMERGENCY GENERATOR
OWNER'S MANUAL
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
—CAUTION—
DEADLY EXHAUST FUMES!
005467-1
005709-1
005376-0
005230-0
005710-0
This manual should remain with the unit.
SG30
GENERATOR
EPA CERTIFIED
TANK SET
NATURAL GAS
RISER FRAME
OPEN SET
RISER FRAME

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  • Page 1 005467-1 SG30 Serial Number 005709-1 GENERATOR EPA CERTIFIED 005376-0 TANK SET 005230-0 NATURAL GAS RISER FRAME 005710-0 OPEN SET RISER FRAME STATIONARY EMERGENCY GENERATOR OWNER'S MANUAL   Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Stationary Emergency Generator Table of Contents SECTION PAGE Electical Connections .............. 8-4 Grounding the Generator ............ 8-4 SAFETY RULES ............1-1 Battery Charger Connection ..........8-5 INTRODUCTION .............1-3 Battery Installation .............. 8-5 Read this Manual Thoroughly ..........1-3 Table 1 - Vapor Capacity of Propane Storage Tanks .... 8-6 Operation and Maintenance..........

  • Page 3: Safety Rules

    Safety Rules INTRODUCTION  This symbol points out potential electrical shock hazard. Thank you for purchasing this model of the Stationary Emergency The operator is responsible for proper and safe use of the equip- Generator set product line. ment. The manufacturer strongly recommends that the operator Every effort was expended to make sure that the information and read this Owner's Manual and thoroughly understand all instruc- instructions in this manual were both accurate and current at the...
  • Page 4 Safety Rules Save These Instructions – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. Study these SAFETY RULES carefully before installing, operating •...
  • Page 5 Safety Rules 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 • Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher.

  • Page 6: Identification Record

    • B – Indicates a brushless unit (“D” indicates a direct excited unit with brushes and slip rings; “P” indicates a permanent magnet excitation). GENERAC POWER SYSTEMS, INC. • Y – Unit is equipped with a standard enclosure (“N” indicates no enclo- WAUKESHA, WI sure;...

  • Page 7: Equipment Description

    Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur-rent Stationary Use a mixture of propylene glycol base anti-freeze and deionized Emergency Generator. It is powered by a propane vapor or natural water. Cooling system capacity is listed in the "Specifications" gas fueled engine operating at 1800 rpm for 4-pole direct drive section.

  • Page 8: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OIL PRESSURE SENSING The Stationary Emergency Generator may be required to operate An analog Oil Pressure Sender (OPS) is used for monitoring the for long periods of time without an operator on hand to monitor engine oil pressure.

  • Page 9: Fuel Systems

    Fuel System FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid FUEL REQUIREMENTS fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor This Stationary Emergency Generator is equipped with one of the state.

  • Page 10: Specifications

    Stationary Emergency Generator Specifications SPECIFICATIONS COOLING SYSTEM Type ...........Pressurized Closed Recovery STATIONARY EMERGENCY GENERATOR Water Pump ..............Belt Driven Fan Speed .................1300 rpm Type ................Synchronous Fan Diameter ..............22 inches Rotor Insulation ..............Class H Fan Mode ................Puller Stator Insulation ..............Class H Air Flow (inlet air including alternator and Total Harmonic Distortion ............<5% combustion air) ............2460 ft...

  • Page 11: Ignition Description

    Stationary Emergency Generator Specifications Figure 1 — Interconnections *2 WIRE SHIELDED CABLE W/GROUND TO ALTERNATOR ALTERNATOR ALTERNATOR CONNECTION BOX CONNECTION CONNECTION *Ground shield on one end only. 4.2L IGNITION DESCRIPTION RED LED Fault Codes with priority as shown: This single-fire ignition is intended to operate a 6-cyl- 1.

  • Page 12: General Information

    General Information ALTERNATOR AC LEAD CONNECTIONS FOUR-LEAD, SINGLE-PHASE STATOR Four-lead alternators (see Figure 7.1) are designed to supply elec- trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical power is produced in the stator power windings. These windings were connected at the factory to the main circuit breaker as shown in Figure 7.1.

  • Page 13: Installation

    Installation INSTALLATION For Open Unit Install the generator set in a protective shelter with adequate cool- UNPACKING ing and ventilating air. Consider these additional factors: Handle shipping cartons and crates with care. Use care to avoid • Engine exhaust MUST be piped to the outside of the shelter. damage from dropping, bumping, collision, etc.

  • Page 14: Installation Rules

    Installation INSTALLATION RULES This equipment is a liquid-cooled, generator set. The generator is After the system has been installed, do noth- designed to supply electrical power that operates critical electrical ing that might render the installation in non- loads during utility power failure. compliance with such codes, standards and regulations.

  • Page 15: Preparation Before Start-Up

    Installation PREPARATION BEFORE START-UP Stationary Emergency Generator Lubrication The instructions in this section assume that the standby generator Check the engine crankcase oil level before operating and add has been mechanically properly installed, serviced, adjusted and oil to the proper level, the dipstick "FULL" mark. Never operate otherwise prepared for use by a competent, qualified installation the engine with the oil level below the dipstick "ADD"...

  • Page 16: Start-Up Checklist

    Installation START-UP CHECK LIST START-UP INSPECTION FORM When a start-up is performed by an Authorized Service Dealer, a standard three form titled "Start-up Inspection for Standby Power Before working on the generator, ensure the Systems" (part no. 067377), should be completed by the installa- following: tion technician or engineer.

  • Page 17: Battery Charger Connection

    Installation BATTERY CHARGER CONNECTION Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause The generator has been equipped with a 10 Amp battery charger severe burns. Do not permit fluid to contact installed. This charger needs to be plugged into an appropriate eyes, skin, clothing, painted surfaces, etc.
  • Page 18 Installation TABLE 1 — VAPOR CAPACITY OF PROPANE STORAGE TANKS (FOR REFERENCE) To Use: Go to the First column and pick the required kW load and then pick the minimum ambient temperature (40º, 20º or 0º F) that the generator would be operating in. The third column (tank capacity) will give the required tank size to continually produce the given fuel flow. Operating Max kW Minimum...

  • Page 19: Operation

    Operation STATIONARY EMERGENCY • Set the transfer handle to its UTILITY (NORMAL) position with load circuits connected to the utility power supply. GENERATOR CONTROL AND • Set the generator’s main line circuit breaker to its OFF (or OPEN) position. OPERATION •...

  • Page 20: Total Circuit Isolation Method

    Operation BASIC STATIONARY EMERGENCY TOTAL CIRCUIT ISOLATION GENERATOR ELECTRIC SYSTEM METHOD Figure 9.1 shows a schematic diagram of a basic standby elec- When a generator capable of powering all electrical loads in the tric system. Both the UTILITY power supply and the Stationary circuit is to be installed, use the “Total Circuit Isolation Method.”...

  • Page 21: Maintenance

    Maintenance MAINTENANCE PERFORMED BY FIRST 30 OPERATING HOURS SERVICE DEALER Change engine "break-in" oil and oil filter. FIRST 100 OPERATING HOURS Change engine oil and oil filter. (After initial change, service  Before working on the Stationary Emergency engine oil and filter at 150 operating hours or six (6) months, Generator, ensure the following: whichever comes first.) •...

  • Page 22: Battery Fluid

    Maintenance Figure 10.2 - Oil Dipstick and Oil Fill Cap CHECK BATTERY • Check battery fluid level each week as outlined under “Check OIL FILL Fluid Levels”. • Check battery cables for condition, tightness, corrosion or dam- age. Clean, tighten or replace as necessary. EXERCISE SYSTEM Start the Stationary Emergency Generator engine at least once every seven days and let it run at least 20 minutes.

  • Page 23: Changing Engine Oil

    Maintenance CHANGING ENGINE OIL Figure 10.4 — Engine Air Filter Refer to "Maintenance Performed by Service Dealer" 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: Remove OIL DRAIN HOSE from its retaining clip.

  • Page 24: Miscellaneous Maintenance

    Maintenance MISCELLANEOUS MAINTENANCE  Storage batteries give off explosive hydrogen CLEANING THE STATIONARY EMERGENCY GENERATOR gas. This gas can form an explosive mixture Keep the generator as clean and as dry as possible. Dirt and around the battery for several hours after moisture that accumulates on internal generator windings have an charging.

  • Page 25: Service Schedule

    Service Schedule SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
  • Page 26 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level 5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
  • Page 27 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
  • Page 28 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...

  • Page 29: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3. Replace contactor.* 4.
  • Page 30 The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty related information, Generac Power Systems, Inc. P .O. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www. generac.com.
  • Page 31 (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Recordkeeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record- keeping 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.
  • Page 33 0G6601 ASSY RTR 390 45AB3 CPL 0G6600 STATOR 390 45AB1 CPL 068405 EXCITER FIELD 15" 2" LG 087272 ASSY EXCITER 2.00" STK 072878 KEY SQ 3/8 X 3-1/4 STEEL 0C2454 SCREW THF M6-1X16 N WA Z/JS 0F5767B FLYWHEEL,MACHINED &ASSY C4 CPL 023484K BUSHING SNAP SB-1750-22 023454...
  • Page 35 0F3137 PAN CB CO NN BOX 0F7655 STAND, R/H CONRTOL UL CIRCUIT BREAKER (2P 225AF) 0F7656 STAND, L/H CO NTROL 0F8453 CO VER CB C3 225AF 023484N BUSHING SNAP SB-2.5-31 022188 NUT HEX #6- 32 STEEL 0F4677 ASSY PCB INTERFACE 1PH 240V 0G5249 CB 150A 2 POLE 240V 225AF 022152...
  • Page 37 COMPONENTS INCLUDED IN 0G4140E COMPONENTS NOT INCLUDED IN 0G4140E OR WIRE HARNESS 0F1823CST06 ENCL H/G CONTROL PANEL 056739 RELAY CONTACTOR 12VDC 0F1824AST06 COVER CONTROL PANEL 048476 CB 4.5X1 AUT30KW CNT45K 0F2606 HINGE CONTINUOUS H PANEL 0F5752B RES WW 25R 5% 25W QK CONN 036261 RIVET POP .125 X .275 SS 0G3226...
  • Page 39 0F6956 PAN, FLUID CONTAINMENT 0F7837 FRAME NATURAL GAS UNIT RISER 096500V ASSY FUEL LEAK DET ALARM W/CON 074908 SCREW HHTT M5-0.8 X 10 BP 066428 SCREW HHL 3/8 X 2-1/2 ZINC 022131 WASHER FLAT 3/8-M10 ZINC 0E0767A CRATE BASE 34" X 81" 0F8113 HARNESS, NAT GAS RISER FRAME (NOT SHOWN) (1) 9...
  • Page 41 0F6830 REWORK L/P TANK 120 GAL 022097 WASHER LOCK M6-1/4 0F7534 POL VALVE TUBE 1/4" NPT 049813 NUT HEX M6 X 1.0 G8 YEL CHR 033930 ELBOW 90D 1/4 NPT 036902 SCREW PPHM #6-32 X 1/2 026942 NIPPLE CLOSE 1/4 NPT X .875 022985 WASHER FLAT #6 ZINC 0F7530...
  • Page 43 0G66880ST03 WELDMENT FRAME 4.2L VZW 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210214 ASSY WIRE #0 15.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 45 0F7037 TRAY, BATTERY BOX 0F7036 BATTERY BOX (24F) VENTED 058208 BATT 12VDC 24F 625 036833 SCREW HHC 3/8-16 X 1 G8 022237 WASHER LOCK 3/8 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATT POST COVER RED + 050331 BATT POST COVER BLK - 038805J CABLE BATT BLK #1 X 30.00 038804U...
  • Page 47 EXPLODED VIEW: LEVEL 1 GUARD 4.2L G3 TELECOM GROUP D DRAWING #: 0G9440 ITEM PART# QTY. DESCRIPTION 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G96020ST03 GUARD CUTOUT LEVEL ONE 4.2L 056326 TRIM VINYL BLACK 1/8GP (11”LG) 0G95970ST03 GUARD TOP LEVEL ONE 4.2L 0G95980ST03 GUARD BOTTOM LEVEL ONE 4.2L 0G95990ST03...
  • Page 49 0H05390AL03 PAN, FLUID CONTAINMENT 0G97060ST03 BASE RISER FRAME 096500V ASSY FUEL LEAK DET ALARM W/CON 074908 SCREW HHTT M5-0.8 X 10 BP 066428 SCREW HHL 3/8 X 2-1/2 ZINC 022131 WASHER FLAT 3/8-M10 ZINC 0E0767A CRATE BASE 34" X 81" 0F8113 HARNESS, NAT GAS RISER FRAME (NOT SHOWN) (1) 9...
  • Page 51 0G 4969 ENG INE 4.2L G3 (FWD) 0E0992A PLUG EXPANSIO N 14 OD 047411 SCREW HHC M6-1.0 X 16 C8.8 0F2776C BRACKET, SIG NAL COND. 2 PLACE 022097 WASHER LOCK M6-1/4 (1) 46 REF. RETAINER SPARK PLUG WIRE-ATTACHED TYPE 022473 WASHER FLAT 1/4-M6 ZINC 057823 CLAMP HOSE #10 .56- 1.06...
  • Page 55 0E6586 GASKET BOSCH 32 & 40 0E0519A ADAPTER CARBURETOR W/PVC CONN 0C8127 ELEMENT AIR CLEANER 049815 SCREW HHC M5-0.8 X 16 G8.8 022127 NUT HEX 1/4-20 STEEL 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 0G31200ST03 TOP PLATE AIR CLEANER 037561 NUT WING 1/4-20 NYLK 022097...
  • Page 57 084918G HEATER BLOCK 1500W 120V 050967 HOSE COOL 5/8 ID 20R3 (29.5“LG) 042568 SCREW HHC M6-1.0 X 20 G8.8 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC 049813 NUT HEX M6 X 1.0 G8 YEL CHR 084427 BRACKET HEATER W/WELDNUTS 0G0015 CLAMP, HOSE 7/8"...
  • Page 59 0G66870ST 03 W ELDMENT, RADIATOR 4.2L TELECOM 035685 CLAMP HOSE #28 1.32-2.25 0F2608A RADIATO R 598 X 568 X 49,CPL LH 0G6930 HOSE COOLNT REDCR 1 3/4X1 1/2 0G6926 TUBE UPPER COOL ANT 4.2L G 3 0G6689 SPACER, 4.2L G3 FAN 0F2820 FAN 22"...
  • Page 61 0G66870ST 03 W ELDMENT, RADIATOR 4.2L TELECOM 035685 CLAMP HOSE #28 1.32-2.25 0F2608A RADIATO R 598 X 568 X 49,CPL LH 0G6930 HOSE COOLNT REDCR 1 3/4X1 1/2 0G6926 TUBE UPPER COOL ANT 4.2L G 3 0G6689 SPACER, 4.2L G3 FAN 0F2820 FAN 22"...
  • Page 63 048031J CLAMP HOSE BAND .63 0G7564 HOSE, VACUUM AIR CLEANER 4.2L 048031P CLAMP HOSE BAND .88" 022097 WASHER LOCK M6-1/4 047487 SCREW SHC M6-1.0 X 18 G12.9 0E6123A INTAKE ADAPTER 4.2L G3-BOSCH 0E6586 GASKET BOSCH 32 & 40 0E4394 ACTUATOR BOSCH 40, GOVERNOR 046580 SCREW SHC M6-1.0 X 45 G12.9 035685...
  • Page 65 0C9650 MUFFLER 2-1/2" INLET/OUTLET 0G7047 ELBOW EXHAUST 2ID X 2 3/8 O.D. 0G70430ST03 BRACKET, MUFFLER 0G3163 BLANKET EXHAUST MUFFLER 450MM (NOT SHOWN) 0C4114A CLAMP 6.5" BAND MUFFLER 080762 BOLT U 3/8-16 X 2.62 0G6697 PIPE, EXHAUST LH SIDE 4.2L VZW 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G6696...
  • Page 67 0G46640AL08 DUCT AIR REAR TOP 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F5849AG DOOR C2 ALUM GRAY (1) 4 077992 NUT HEX LOCK M6-1.0 SS NY INS 0F3890A RETAINER INSULATION (740) 0F6647 DISCHARGE DUCT L/H & R/H SIDE 0F6642 FRONT CORNERS 0F6650...
  • Page 69 059939 RAIN CAP 2.37 I.D. 059109 NIPPLE TOE 2NPT X 9 BLK IRON 0D2736 NIPPLE PIPE 2 NPT X18" BLK IRN 059933 ELBOW 90D 2NPT 0G3770 EXHAUST BLANKET 737MM (NOT SHOWN)
  • Page 71 0C9650 MUFFLER 2-1/2" INLET/OUTLET 0G7047 ELBOW EXHAUST 2ID X 2 3/8 O.D. 0G70430ST03 BRACKET, MUFFLER 0G96960ST10 BRACKET EXHAUST PIPE SUPPORT 0C4114A CLAMP 6.5" BAND MUFFLER 080762 BOLT U 3/8-16 X 2.62 0G6697 PIPE, EXHAUST LH SIDE 4.2L VZW 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G6696 PIPE, EXHAUST RH SIDE 4.2L VZW 0A4621C...
  • Page 73 EXPLODED VIEW: FRONT AIR DUCT 4.2L G3 TEL GROUP D DRAWING #: 0G9755 ITEM PART# QTY. DESCRIPTION 0C2634A ASSY ACCESS COVER 0G9523 PANEL FRONT RAD DUCT OUTLET 0G9521 PANEL SIDE RAD DUCT OUTLET 0G9522 PANEL TOP RAD DUCT OUTLET 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC...
  • Page 86 Notes...
  • Page 87 Notes...
  • Page 88 NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER. For a period of five (5) years or two thousand (2,000) hours of operation from the date of start-up, which ever occurs first, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

This manual is also suitable for:

005709-1005376-0005230-0005710-0

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