Generac Power Systems 4.6L Owner's Manual
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Generac Power Systems 4.6L Owner's Manual

Generac Power Systems 4.6L Owner's Manual

Stationary emergency generator 80kw
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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!
This manual should remain with the unit.
4.6L
80kW Models
EPA Certified

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Summary of Contents for Generac Power Systems 4.6L

  • Page 1 Owner's Manual Stationary Emergency Generator 4.6L NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT 80kW Models APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST EPA Certified FUMES! OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Table of Contents SECTION PAGE OPERATION ................9-1 Stationary Emergency Generator Control and Operation ..9-1 INTRODUCTION ..............1-1 Operating Unit with Manual Transfer Switch ......9-1 Operating Unit with Automatic Transfer Switch ......9-1 SAFETY RULES ..............1-2 MAINTENANCE ..............10-1 IDENTIFICATION RECORD ............2-1 Maintenance Performed by Authorized Service Dealers ..10-1 Cooling System..............

  • Page 3: Introduction

    Safety Instructions 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. INTRODUCTION ...

  • Page 4: Safety Rules

    Safety Instructions SAFETY RULES • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient Study these SAFETY RULES carefully before installing, operating concentrations, can cause unconsciousness or even death. For or servicing this equipment.
  • Page 5 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 • Keep a fire extinguisher near the generator at all times. Do NOT equipment only while standing on such insulative mats.

  • Page 6: Identification Record

    General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular model, please DATA LABEL refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit. Every generator set includes DATA LABEL that contains important information pertinent to the generator.

  • Page 7: Equipment Description

    Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Use a mixture of half low silicate ethylene glycol base anti-freeze Emergency Generator set. It is powered by a gaseous fueled and deionized water. Cooling system capacity is listed in the engine operating at 1800 rpm for 4-pole direct drive units, 3600 specifications.

  • Page 8: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate After a prespecified duration of cranking, this function ends the for long periods of time without an operator on hand to monitor cranking if the engine has failed to start. The overcrank message such engine conditions as coolant temperature, oil pressure or will turn ON.

  • Page 9: Fuel Systems

    Fuel System FUEL SYSTEM NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state. In most cases, the gas FUEL REQUIREMENTS distribution company provides piping from the main gas distribu- tion line to the standby generator site. The following information The Stationary Emergency Generator may be equipped with one of applies to natural gas fuel systems.

  • Page 10: Specifications

    Specifications SPECIFICATIONS COOLING SYSTEM Type Closed STATIONARY EMERGENCY GENERATOR Water Pump ............. Belt Driven Fan Speed .................1600 Type..............Synchronous Rotor Insulation .............Class H Fan Diameter ..............26 inches Stator Insulation ............Class H Fan Mode ................. Puller Total Harmonic Distortion ..........< 5% Air Flow (inlet air including alternator and combustion air) ..........
  • Page 11 Specifications 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. • Scheduled Maintenance Kit ~ Kit includes the recommended parts to maintain the genera- tor.

  • Page 12: General Information

    General Information ALTERNATOR AC LEAD ALTERNATOR POWER WINDING CONNECTIONS CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel 3-PHASE ALTERNATORS ("Y" CONFIGURATION) should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label.
  • Page 13 General Information Figure 7.4 — Stator Power Winding 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Connections - 3-phase, 120/208V (6 Lead) The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna- INTERNAL CONNECTIONS tor power windings. These windings were connected at the factory to the main circuit breaker with a "Delta"...

  • Page 14: Control Panel

    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 USING THE AUTO/OFF/MANUAL SWITCH connects AC utility power sense wires into the DC terminal block.
  • Page 15 Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- If the wrong language is chosen, it can be guage. Press ENTER to select. changed later using the “edit” menu. Language English Escape Enter Display Reads: Press ENTER to begin the activation pro-...

  • Page 16: Setting The Exercise Timer

    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 con- Interconnect System Self Test Feature (follow the on-screen troller will exit the exercise routine and assume full automatic prompts).

  • Page 17: Auto Start

    Control Panel MANUAL START SEQUENCE OF AUTOMATIC OPERATION Initial Conditions: Generator in Auto ready to run, load being sup- Allows the user to start and run the generator manually. plied by the Utility Source through the transfer switch. Transfer of the load to the generator will occur if utility is lost while When the utility voltage fails (falls below 60% of nominal), a the unit is running in the manual mode (only if activated).
  • Page 18 Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This This is a shutdown alarm. The alarm will activate after five (5) fault cannot be cleared using the control panel interface. The unit seconds of continuously missing cam pulses.

  • Page 19: Common Alarm Relay

    Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an When the generator is shut down due to a latching alarm, the Auto alarm will be issued. /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding If the generator voltage rises above 130% for >0.2 seconds, an fault alarm message.
  • Page 20 Control Panel...

  • Page 21: Operation

    Operation STATIONARY EMERGENCY GENERATOR CONTROL AND Do not crank the engine continuously for lon- OPERATION ger than 30 seconds, or the heat may damage the starter motor. Refer to the appropriate control panel operator’s manual for this • Let engine stabilize and warm up. unit.

  • Page 22: Maintenance

    Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change fre- quencies. Drain the oil while the engine is still warm from running. This  Before working on the Stationary Emergency means warm up the engine, shut it down and drain immediately as follows: Generator, ensure the following: •...
  • Page 23 Maintenance ENGINE COOLANT CHECK FAN BELT Check coolant level in coolant recovery bottle. See the Specifications • Inspect fan belts every year. Replace any damaged, deterio- and Service Schedule sections. rated, worn or otherwise defective belt. • Check fan belt tension. Thumb pressure, exerted midway •...
  • Page 24 Maintenance Figure 10.3 – Engine Air Filter Battery electrolyte fluid is an extremely corro- sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective Air Filter goggles, protective clothing and gloves when handling a battery.

  • Page 25: Service Schedule

    Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Inspect Change Clean Yearly - Y Fuel Fuel Lines & Connections Lubrication Oil Level Oil Filter Cooling Engine Coolant Lines & Connections Engine Coolant Level Engine Coolant Enclosure Louvers Engine...

  • Page 26: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 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.
  • Page 27 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. If during the warranty period, any emission control system or compo- nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace- ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
  • Page 28 (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping 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.

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