Generac Power Systems 45kW Owner's Manual

Stationary emergency generator

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Owner's manual (60 pages)

Owner's manual (77 pages)

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Summary of Contents for Generac Power Systems 45kW

Page 1 Owner's Manual Stationary Emergency Generator 2.4L 45kW Models NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS EPA Certified SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.
Page 2: Table Of Contents
Table of Contents SECTION PAGE Alarm and Warning Messages ............8-4 INTRODUCTION ............1-1 Low Oil Pressure Shutdown Alarm ..........8-4 Read this Manual Thoroughly ............1-1 High Coolant Temperature Shutdown Alarm ........8-4 Operation and Maintenance ............1-1 Overcrank Shutdown Alarm ............8-4 How to Obtain Service ..............1-1 Overspeed Shutdown Alarm ............8-4 SAFETY RULES ............
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: Fire Hazards
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: General Information
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 has a 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. It is powered by a gaseous fueled engine and deionized water. Cooling system capacity is listed in the operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 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 System
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 The Stationary Emergency Generator may be equipped with one of state.
Page 10: Specifications
Sensing ................ Single-phase Regulation ................± 1% Exhaust System Features ..........Adjustable Voltage and Gain Exhaust Flow at Rated Output 60 Hz (45kW) ..... 420 cfm Power Adjustment for Ambient Conditions Exhaust Temp. at Rated Output (45kW) ......1100° F Temperature Deration 3% for every 10°...
Page 11: Weather And Maintenance Kits
Specifications WEATHER AND MAINTENANCE KITS Install the previously removed NG jet into the jet keeper port on the side of the regulator housing. To keep the generator running at its peak, the following kits are Install the previously removed black pipe onto the outlet offered: port of the demand regulator.
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: 3-Phase Alternators ("Delta" Configuration)
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- tor power windings. These windings were connected at the factory INTERNAL CONNECTIONS 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: Activation Chart
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: Sequence Of Automatic Operation
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: Under-Frequency Shutdown Alarm
Control Panel Figure 1 – Generator Control Panel UNDER-FREQUENCY SHUTDOWN ALARM MISSING CRANK PULSE ALARM After starting, if the generator stays under frequency for more than This is a shutdown alarm. The alarm will activate after 12 con- 30 seconds, it will shutdown. secutive revs where crank pulses are missing.
Page 19: Overvoltage Alarm
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: Engine Coolant
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: Spark Plugs
Maintenance Figure 10.4 – 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, Air Filter clothing, painted surfaces, etc. Wear protective 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 United States Environmental Protection Agency Warranty Statement 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...
Page 28 United States Environmental Protection Agency Compliance Requirements Purchaser’s/Owner’s Recordkeeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac), are pleased to explain your recordkeeping 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 29 Notes...
Page 31 STATOR-390 45K 2P 1PH DIRECT 0G0057 STATOR-2390-35AD1 CPL 0G0058 STATOR-2390-35KD1 CPL 0G0059 STATOR-2390-35GD1 CPL 0G0183 STATOR-2309-45KW 2P 3PH 208V 0G0184 STATOR-2309-45-KD1 CPL 0G1932 ASSY STR 390 25GD3 CPL 0G2098 ASSY STR 390 25AD1 CPL 0G2099 ASSY STR 390 25KD3 CPL...
Page 33 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H6266 BACK PANEL CONBOX SUPPORT C2 0H6265 TOP PANEL CONBOX SUPPORT C2 0H6160 COVER WIRE ENTRY CONBOX 057073 JUNCTION BLOCK 3/8-16 056739 RELAY SOLENOID 12VDC PNL MNT (6)6 0H67330ST0R BRACKET GIMBAL CONTROL PNL RAW...
Page 34 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (225AF) 0G5250 CB 175A 2 POLE 240V 225AF 0H7356 COVER CB C2 CPL 0F4186AGS0R COVER CB DISH 2P G 225AF 0F8432A INSULATOR CB 2P 225AF 0H7311 STANDOFF CB BOX CONBOX...
Page 36 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (KG) 0H5582 CB 0300 3P 600V E KG LL 0H6740 COVER CB E KG C2 CONBOX 0D3700 NUT FLANGE M6-1.0 NYLOK 0H5581A INSULATOR CB E 3P KG 0H6734...
Page 38 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (QN) 0E7284 CB 0175A 2P 240V S QN2 LL 0H7356 COVER CB C2 CPL 0H7429 COVER CB DISH 2P S QN 0E3664 BASE, QN CIRCUIT BREAKER 0H7311...
Page 39 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: THIS PAGE LEFT INTENTIONALLY BLANK PAGE 8 OF 8 REVISION: -A- DATE: 3/31/10...
Page 41 0F9517 WELDMENT FRAME 2.4L C2 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 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
Page 43 0F3408B BATTERY TRAY C1 CPL 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 052212 SCREW HHC M10-1.25 X 25 G8.8 046526 WASHER LOCK M10 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLACK - 038805Y CABLE BATTERY BLACK #1 X 18.00 03880400AE...
Page 45 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 (1) 6 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 0G0190 PLATE, AIR CLEANER TOP 2.4L 037561 NUT WING 1/4-20 NYLK (1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON...
Page 47 0H30830ST03 WELDMENT RADIATOR SUPPORT C2 0F2862 SPRING TENSION CPL 0F2608 RADIATOR 598 X 568 X 49 CPL RH 0F2560 PULLEY V-BELT 4" FLANGED 0F5263 V-BELT 31/64" X 57-3/8" 022131 WASHER FLAT 3/8-M10 ZINC 046526 WASHER LOCK M10 0E2507 PROBE, COOLANT LEVEL 3/8NPTF (1) 5 059981 SCREW HHC M10-1.5 X 30 G10.9...
Page 50 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 45KW GROUP D DRAWING #: 0H7322 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H1619 ENGINE 2.4L G2 CERTIFIED 046526 WASHER LOCK M10 039414 SCREW HHC M8-1.25 X 35 G8.8 0G0149 SCREW SHC M14-1.5 X 35 G10.9...
Page 51 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 45KW GROUP D DRAWING #: 0H7322 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 029333A TIE WRAP UL 7.4"X .19" BLK (2) 70 0H0015 HARN EMISSIONS OVERLAY 2.4L (NOT SHOWN) 045772 NUT HEX M10-1.5 G8 YEL CHR (1) SUPPLIED WITH ENGINE.
Page 53 EXPLODED VIEW: FUEL SYSTEM 2.4L 45KW GROUP E DRAWING #: 0H7580 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 026915 NIPPLE CLOSE 3/4 X 1.375 075580 FLANGE FUEL INLET 0F6390B REGULATOR ASSY 2.4L 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16-M8 ZINC...
Page 55 0F9794 MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT 0G0113 EXHAUST ELBOW 2 1/4 OD 2 1/2OD 0G1007 BRACKET MUFFLER 0F2830 MUFFLER BRACKET STIFFENER 0F2962 MUFFLER STRAP 080762 BOLT U 3/8-16 X 2.62 0E0170A EXHAUST BLANKET 988MM (C2) 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G0776 PIPE EXHAUST G2 0G0007...
Page 57 (2) 1 0G00450ST0R REAR WRAP C2 CPL 0C2454 SCREW THF M6-1 X 16 N WA Z/JS (2) 3 0F58490ST0R DOOR C2 087233 RIVET POP .1875 X .450 SS 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W (2) 6 0F58520ST0R DISCHARGE DUCT LH & RH SIDE C2 (2) 7 0F98330ST0R FRONT CORNERS C2...
Page 70 Notes...
Page 71 Notes...