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Generac 6461 manual

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Table of contents for the manual

  • Page 1

    Owne r ’s M a nua l Automatic Standby Generator Reference all appropriate documentation. This manual should remain with the unit. n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. n ONL Y QUALIFIED ELECTRICIANS OR CONTRACT ORS SHOULD A TTEMPT INST ALLA TION. n DEADL Y EXHAUST FUMES! OUTDOOR INST ALLA TION ONL Y! LISTED C US 8 kW to 2[...]

  • Page 2

    i ii W ARNING! 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. W ARNING! California Proposition 65 This product contains or emits chemicals known to the state of California to cause cancer , birth defects, and other reproductive [...]

  • Page 3

    T able of Content s iii Section 1 — Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 — General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    iv This p age intentionally lef t blank.[...]

  • Page 5

    Automatic S tandby Gene rator Owner ’s Manual 1 Section 1 Safety INTRODUCTION: Thank you for purchasing this compact, high performance, air-cooled , engine-driven stationary automatic standby generator set. Every effort was made to make sure that the information and instructions in this manual were both accurate and current at the time the man- u[...]

  • Page 6

    2 Automati c S tandby Generator Owner ’s Manual 1.1 — General Safety Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Manual and w ith the unit. The generator can operate safely , efficiently and reliably only if it is properly insta lled, operated and maintained. Many accident[...]

  • Page 7

    Automatic S tandby Gene rator Owner ’s Manual 3 1.3 — Exhaust Hazards • Generator engine exhaust contains DEADL Y carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, w eakness, sleepiness, inability to think clearly , fainting[...]

  • Page 8

    4 Automati c S tandby Generator Owner ’s Manual If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a transfer switch . The transfer switch mu st effectively isolate th e electrical system from the utility distribution system when the generator i s operating (NE[...]

  • Page 9

    Automatic St andby Generator Owner ’s Manual 5 Section 2 General Information 2.1 — The Generator Figure 2-1: GH-410 Engine 8 kW Unit Figure 2-2: GH-530 Engine 1 1 kW Unit EXHAUST E NCLOSURE COMPOSITE BASE OIL FILTER OIL FILL CAP BATTERY COMPARTMEN T FUEL REGULATOR CIRCUIT BREAKERS FUEL INLET (BACK) CONTROL PANEL OIL DIPSTICK AIR FILTER DATA LAB[...]

  • Page 10

    6 Automatic St andby Generato r Owner ’s Manual Figure 2-3: GT -990/GT -999 Engines, 16-22 kW Unit s 2.2 — Protection Systems The generator may have to run for long periods of time with no operator present to monitor the engine/generator conditions. The refore, the gen- erator is equipped with a number of systems to automatically shut down the [...]

  • Page 11

    Automatic St andby Generator Owner ’s Manual 7 2.3 — Emission Information The U.S. Environmental Protection Agency (E P A) requires that this generator comply wi th exhaust emission standards. This genera tor is certified to meet the applicable EP A emission levels , and is certified for use as a statio nary engine for standby power generation.[...]

  • Page 12

    8 Automatic St andby Generato r Owner ’s Manual 2.4 — Specifications 2.4.1 — Generator 2.4.2 — Engine The specification sheet for your generator was included in the documentation provided with the unit at the time of purchase. Fo r additional copies, consult your local Authorized Servic e Dealer for your s pecific generator model. Model 8 k[...]

  • Page 13

    Automatic St andby Generator Owner ’s Manual 9 2.4.3 — Fuel Requirements The engine has been fitted with a dual fuel car buretion system. The unit will run on natural gas or LP gas (vapor), but it has been factory set to run on natural gas. The fuel system will be configured for the available fuel s ource during installation. Recommended fuels [...]

  • Page 14

    10 Automatic St andby Generato r Owner ’s Manual Contact an independent authorized Dealer fo r additional information on accessories. Wireless Local Mon itor Completely wireles s and battery powe red, the Wireles s Local Monitor prov ides you with instan t status with out ever leaving the hous e. Status lights (red, yellow and green) al ert owne [...]

  • Page 15

    Section 3 Operation Automatic S tandby Gene rator Owner ’s Manual 11 3.1 — Control Panel Interface The control panel on this unit is intended to only be operated by qu alified service personnel. The Control panel interface is located under the lid of the enclo sure. Before attempting to lift the lid of the enclosure, veri fy that both left and [...]

  • Page 16

    12 Automati c S tandby Generator Owner ’s Manual Figure 3-2: Generator Control Panel 3.2 — Using the Auto/Off/Manual Buttons NOTE: Damage caused by mis-wiring of th e interconnect wires is not warrantable. 3.3 — Interface Menu Displays The LCD display: 3.3.1— Menu System Navigation T o get to the MENU, use the “Escape” button from any p[...]

  • Page 17

    Automatic S tandby Gene rator Owner ’s Manual 13 Figure 3-3: Navigation Menu 2014 HOME ST ANDBY MENU MAP UP ARROW = + DOWN ARROW = - “Run Log” ESC ENTER ENTER ESC SYSTEM BA TTERY DA TE/TIME SUB MENUS HISTORY EDIT MAINT DEALER EXAMPLE: Inspect Battery 200 RnHr or 12/27/13 and Next Maintenance 200 RnHr or 12/27/13 Exercise Time Å Frequency Æ [...]

  • Page 18

    14 Automati c S tandby Generator Owner ’s Manual 3.4 — Automatic T ransfer Operation T o select automatic operation: 1. Make sure the transfer switch main contact s are set to their UTILITY posi tion (loads connected to the utility power source). 2. Be sure that normal UTILITY power sour ce voltage is av ailable to transfer switch termin al lug[...]

  • Page 19

    Automatic S tandby Gene rator Owner ’s Manual 15 3.5 — T urning th e Generator Off When Operating Under Load NOTE: Important! T o turn the generator off during prolon ged utility outages to perform maintenance or conserve fuel, follow these simp le, but important steps: T o turn the generator OFF (while running in AUTO and online): 1. T urn OFF[...]

  • Page 20

    16 Automati c S tandby Generator Owner ’s Manual 3.6.2— T ransfer Back to Utility Power Source When utility power has been restored, transfer back to utility s ource and shut down the generator . T o manually transfer back to utility power and shut down the generator: 1. Set the Main Circuit Breake r (Generator Disconnect) to its OFF (OPEN) pos[...]

  • Page 21

    Automatic S tandby Gene rator Owner ’s Manual 17 3.7 — Side Comp artment Local codes may require this compartment to be locked. A hasp is provided so the owner/operator can secure the compartment with his or her own padlock. Check local codes for side compartment locking requirements. Figure 3-6: Open Side Compartment 3.7.1— Main Circuit Brea[...]

  • Page 22

    18 Automati c S tandby Generator Owner ’s Manual 3.9 — Setting the Exercise T imer This generator is equipped with a c onfigurable exercise timer . Ther e are two settings for the exercise timer . One is Day/Time. Once it is set, the generator will start and exercise for the period defined, on the day of the week and at the time of day specifie[...]

  • Page 23

    Automatic S tandby Gene rator Owner ’s Manual 19 Figure 3-8: Low Speed Exerci se Profile - 16-20 kW unit s 2600 2800 3000 3200 c ise Speed (RPM) Low Speed Ex ercise Pr ŽĮůĞ - 16 to 20 kW Gener ators 2000 2200 2400 0 5 c e s 0 1 s s 1 min 5 min Exe r c Exercise Time[...]

  • Page 24

    20 Automati c S tandby Generator Owner ’s Manual This p age intentionally lef t blank.[...]

  • Page 25

    Automatic S tandby Gene rator Owner ’s Manual 21 Section 4 Maintenance NOTE: Proper maintenance and proper and safe operation is crucial to the life of the ge nerator . Genu ine Generac parts MUST be u sed to ensure warranty coverage NOTE: Since most maintenance alerts occur at the same time (mos t have two year intervals), only one will appear a[...]

  • Page 26

    22 Automati c S tandby Generator Owner ’s Manual 4.2.1— Maintenance Log 1. Battery inspection and charge check (recommended every year (1) for the life of the battery) NOTE: Check electrolyte level (unsealed batteries only) every 6 months. Dates Performed: 2. Oil, oil filter and air filter replac ement (recommended after the first 25 hours a ft[...]

  • Page 27

    Automatic S tandby Gene rator Owner ’s Manual 23 4.3.1— Engine Oil Recommendations T o maintain the warranty , genuine Generac replacement parts MUST be used, including Generac o il kits (which include an oil and air filter). Gen- erac oil kits can be obtained through an Aut horized Dealer or purchased on-line. T o purchase on-line, access the [...]

  • Page 28

    24 Automati c S tandby Generator Owner ’s Manual Figure 4-2: Oil Filt er and Drain Location 4.4 — Changing the Engine Air Cleaner 1. With the generator shut down, lift the lid and remove the front panel. 2. Remove the cover clips and air cleaner co ver (1 1-22 kW), or disengage the wire clip and open the air cleaner access door (8 k W). 3. Pull[...]

  • Page 29

    Automatic S tandby Gene rator Owner ’s Manual 25 4.6 — V alve Lash Adjustment After the first 25 hours of operation and then after every 400 hours of operation, check the valve clearance. Adjust if necessa ry . Important: Please contact the Dealer for se rvice assistance. This is a very import ant step to ensure longest life for the engin e. T [...]

  • Page 30

    26 Automati c S tandby Generator Owner ’s Manual Figure 4-4: V alve Clearance Adjustment 4.7 — Battery Maintenance The battery should be regularly in spected per the Service Schedule: 1. With the generator shut down, lift the lid and remove the front panel. 2. Inspect the battery posts and cables for tight ness and corrosion. T ighten and clean[...]

  • Page 31

    Automatic S tandby Gene rator Owner ’s Manual 27 Do not open or mutilate the battery . Re leased e lectrolyte has be en known to be harmful to the skin and eyes , and to be toxic. The elect rolyte is a d ilute su lfuric ac id that i s harmful to the s kin an d eyes. I t is electrical ly cond ucti ve and corrosive. Strictly obse rv e the follo win[...]

  • Page 32

    28 Automati c S tandby Generator Owner ’s Manual 4.10.2— Return to Service T o return the unit to service after storage: 1. V erify that utility power is turned off. 2. Check the tag on the engine for oil viscosity and classi ficat ion. If necessary , drain and refill with proper oil. 3. Check the state of the battery . Fill all cells of unseal[...]

  • Page 33

    Automatic S tandby Gene rator Owner ’s Manual 29 Section 5 T roubleshooting Problem Cause Correctio n The engine wil l not crank. 1. Fuse blown. 1. Correct short circuit con dition by replacing 7.5 Amp fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary.* 3. Defective starter [...]

  • Page 34

    30 Automatic S tandby Generator Owner ’s Manual This p age intentionally lef t blank.[...]

  • Page 35

    Automatic S tandby Gene rator Owner ’s Manual 31 Section 6 Quick Reference Guide Active Alarm Problem LED Things to Check Solution NONE Unit ru nning in AUTO but no power in house. GREEN Check MLCB. Check MLCB. Contact servic ing dealer if MLCB is in the ON position. HIGH TEMPERA TURE Unit shut s down during operation. RED Check the LEDs/Screen f[...]

  • Page 36

    32 Automatic S tandby Generator Owner ’s Manual STEPPER OVERCURRENT Unit will not start in AUTO with utility loss. RED Check the LEDs/Screen for alarms. Contact se rvicing dealer . MISWIRE Unit will not start in AUTO with utility loss. RED Check the LEDs/Screen for alarms. Contact se rvicing dealer . OVER VOL T AGE Unit will not start in AUTO wit[...]

  • Page 37

    Notes ____________ ________________ _____________ ________________ ________________ _______________ _____ ____________ ________________ _____________ ________________ ________________ _______________ _____ ____________ ________________ _____________ ________________ ________________ _______________ _____ ____________ ________________ _____________ [...]

  • Page 38

    _____________ _______________ _____________ ________________ ________________ ________________ ___ _____________ _______________ _____________ ________________ ________________ ________________ ___ _____________ _______________ _____________ ________________ ________________ ________________ ___ _____________ _______________ _____________ _________[...]

  • Page 39

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  • Page 40

    Part No. 0K5801 Rev . C 06/18/2014 Printed in USA © Generac Power Systems, Inc. All rights reserved S pecification s are subject to change without notice. No reproduction allowed in any form without prior written consent from Genera c Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy . 59 W aukesha, WI 53189 1-888-GENERAC (1-888-436-3[...]