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Generac QT04524ANSX manual

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Table of contents for the manual

  • Page 1

    This manual should remain with the unit. 2.4L 45kW Models EP A Cer tified Owner's Manual Stationar y Emergency Generator Cover193 Re v . A 04/10 Part No. 0H7318 n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLA TION! DEADL Y EXHA UST FUMES! OUTDOOR INST ALLA TI[...]

  • Page 2

    SECTION P AGE INTRODUCTION ........................................................... 1-1 Read this Manual Thoroughly ....................................................... 1-1 Operation and Maintenance .......................................................... 1-1 How to Obtain Ser vice ...........................................................[...]

  • Page 3

    INTRODUCTION Thank you for purchasing this model of the stationar y emergency generator product line. Ever y effor t was expended to make sure that the infor mation and instr uctions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reser ves the right to change, alter or other wise improve[...]

  • Page 4

    SAFETY RULES Study these SAFETY RULES carefully before installing, operating or ser vicing this equipment. Become familiar with this Owner ’s Manual and with the unit. The generator can operate safely , effi- ciently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and f[...]

  • Page 5

    If personnel must stand on metal or concrete while installing, • operating, ser vicing, adjusting or repairing this equipment, place insulative mats over a dr y wooden platform. Work on the equipment only while standing on such insulative mats. The National Electrical Code (NEC) requires the frame and • external electrically conductive par ts o[...]

  • Page 6

    IDENTIFICA TION RECORD DA T A L ABEL Ever y generator set has a DA T A L ABEL that contains impor tant information per tinent to the generator . The data label, which can be found attached to the generator ’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power factor[...]

  • Page 7

    EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur rent Stationar y Emergency Generator . It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The u[...]

  • Page 8

    ENGINE PROTECTIVE DEVICES The Stationar y Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically s[...]

  • Page 9

    FUEL SYSTEM FUEL REQUIREMENTS The Stationar y Emergency Generator may be equipped with one of the following fuel systems: Natural gas fuel system • Propane vapor (PV) fuel system • Liquid propane (LP) fuel system • Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu&ap[...]

  • Page 10

    SPECIFICA TIONS ST A TIONARY EMERGENC Y GENERA TOR T ype ............................................................................. Synchronous Rotor Insulation ................................................................... Class H Stator Insulation .................................................................. Class H T elephone Interf[...]

  • Page 11

    WEA THER AND MAINTENANCE KITS T o keep the generator r unning at its peak, the following kits are offered: Cold Weather Kit • ~ Recommended for climates with temperatures below 32° F . Extreme Cold Weather Kit • ~ Recommended Block Heater Kit for protection in tempera- tures below 32° F . Scheduled Maintenance Kit • ~ Kit includes the recom[...]

  • Page 12

    AL TERNA TOR AC LEAD CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase are described on the generator data label. The number of lead wires can be identified using the Specifications section and th[...]

  • Page 13

    Figure 7.4 — Stator P ower Winding Connections - 3-phase, 120/208V (6 Lead) E3 E2 00 (NEUTRAL) INTERNAL CONNECTIONS E1 L-L L-N S1 S1 S4 S4 S6 S6 S3 S3 S5 S5 S2 S2 Figure 7.5 — Stator P ower Winding Connections - 3-phase, 120/208V (12 Lead) E3 E2 E1 L-L L-N S7 S1 S10 S4 S12 S6 S9 S3 S5 S11 S2 S8 Figure 7.6 — Stator P ower Winding Connections -[...]

  • Page 14

    CONTROL P ANEL INTERF ACE USING THE AUTO/OFF/MANUAL SWITCH n With the switch set to AUTO , the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage droops below a preset level or during the normal exercise cycle. T o prevent possible injury that might be caused by such sudden start[...]

  • Page 15

    8-2 CntrlNex001 Rev . A 05/10 Control P anel ACTIVA TION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- guage. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Display Reads: Press ENTER to begin the activation pro- cess. If ESCAPE is pressed in[...]

  • Page 16

    INST ALLA TION ASSIST ANT Interconnect System Self T est Feature (follow the on-screen prompts). 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 connects AC utility power sense wires into the DC termi[...]

  • Page 17

    SEQUENCE OF AUTOMA TIC OPERA TION Initial Conditions: Generator in Auto ready to r un, load being sup- plied by the Utility Source through the transfer switch. 1. When the utility voltage fails (falls below 60% of nominal), a 10-30 second (programmable) “line interr upt” delay timer is star ted. The factor y set time delay is 10 seconds. If at [...]

  • Page 18

    UNDER-FREQUENC Y SHUTDOWN AL ARM Af ter star ting, if the generator stays under frequency for more than 30 seconds, it will shutdown. L OW BA TTERY ALARM While r unning if the average batter y voltage falls below 11.9 volts for one (1) minute, the low batter y alarm will be displayed. L OW BA TTERY W ARNING The microprocessor will continually monit[...]

  • Page 19

    MAINTENANCE ALERT CHART CONDITION 1.6 CHERY 2.4/1800 MITSU 2.4/3600 MITSU 4.2 FORD Change oil & filter aler t 3mo/30hrs break-in 1yr/100hrs 3mo/30hrs break-in 1yr/100hrs 3mo/30hrs break-in 1yr/100hrs 3mo/30hrs break-in 1yr/100hrs Inspect/clean air inlet & exhaust aler t 3mo/30hrs break-in 6mo/50hrs 3mo/30hrs break-in 6mo/50hrs 3mo/30hrs bre[...]

  • Page 20

    ACTIV A TION RUN LOG ALARM LOG HISTOR Y STA TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA TOR FREQUENCY ENGINE HOURS ENGINE RPM BA TTERY VO LTA G E DEBUG INPUTS OUTPUTS DISPLA YS EDIT CONTRAST LANGU AGE TIME/DA TE EXERCISE TIME/SPEED ESC Press the “ESCAPE” key to jump back up through the menu levels. + / - Use the “+/-” key to navigate throu[...]

  • Page 21

    ST A TIONARY EMERGENCY GENERA TOR CONTROL AND OPERA TION Refer to the appropriate control panel operator’s manual for this unit. OPERA TING UNIT WITH MANUAL TRANSFER SWITCH If the Stationar y Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only , the fol- lowing procedure applies. A manually ope[...]

  • Page 22

    GENERAL MAINTENANCE  Before working on the Stationary Emergency Generator , ensure the following: The AUTO/OFF/MANUAL switch is in the OFF position. • The control panel fuse has been removed from the control • box. The 120VAC supply to the battery charger is switched OFF . • The negative battery cable has been removed. • CHECK ENGINE OIL[...]

  • Page 23

    ENGINE COOLANT Check coolant level in coolant recover y bottle. See the Specifications and Ser vice Schedule sections. Add recommended coolant mixture as necessar y . • P eriodically remove radiator pressure cap (only when engine • has cooled down) to make sure the coolant recover y system is functioning properly . Coolant should be at bottom o[...]

  • Page 24

    Figure 10.4 – Engine Air Filter Air Filter SP ARK PLUGS Reset the spark plug gap or replace the spark plugs as neces- sar y . 1. Clean the area around the base of the spark plugs to keep dir t and debris out of the engine. Clean by scraping or washing using a wire br ush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the[...]

  • Page 25

    SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Y early - Y Inspect Change Clean Fuel Fuel Lines & Connections M X Lubrication Oil Level M X* Oil Y X** Oil Filter Y X** Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y X Enclosure Louvers W X X Engine Air Cleaner Y X X***[...]

  • Page 26

    T roubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. R eplace fuse.* 2. Loose or corroded or defective 2. Tighten, clean or replace batter y cables. batter y cables as necessar y .* 3. Defective star ter contactor . 3. R eplace contactor .* 4. Defective star ter motor . 4. R e[...]

  • Page 27

    13-1 EmsnWrnty001 Rev . C 05/10 United States Environmental Protection Agency W arranty Statement W arranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new stationar y emergency engine. If duri[...]

  • Page 28

    13-2 EmsnWrnty001 Rev . C 05/10 United States Environmental Protection Agency Compliance Requirements Purchaser’s/Owner’s Recordkeeping Responsibilities The United States Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac), are pleased to explain your recordkeeping requirements for compliance with Subpar t JJJJ – [...]

  • Page 29

    Notes[...]

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  • Page 31

    1 0F9677 1 ROTOR-2390-45 KD1 CPL 0G0056 1 ROTOR-2390- 35KD1 CPL 0G0959 1 ROTOR-2390- 45KD1 CPL (G2) 0G1155 1 ROTOR-2390- 35KD1 CPL (G2) 0G1931 1 ROTOR 25KW 3PH DIRECT 3 90 1800 0G2101 1 ROTOR 25KW 1PH DIRECT 3 90 1800 0G3734 1 RTR-2390-6 0KD2 CPL 0G6562 1 RTR 390 35AD 1 CPL 0G6564 1 RTR 390 35KD 1 CPL 2 0F9664 1 STATOR-390 45K 2 P 1PH DIRECT 0G0057[...]

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  • Page 33

    EXPLODED VIEW: CO NBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: -A- DATE: 3/31/10 ITEM P ART# QTY. DESCRIPTION 1 0H6266 1 BA CK PANEL CONBOX SUPPOR T C2 2 0H6265 1 TOP PA N EL CONBOX SUPPORT C2 3 0H6160 1 COVER WIRE ENTRY CONBOX 4 05 7073 2 JUNCTION BLOCK 3/8-16 5 05 6739 1 RELAY SOLENOID 12VDC PNL MN T (6)6 0H67330ST0R 1 BRACKET G[...]

  • Page 34

    EXPLODED VIEW: CO NBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: -A- DATE: 3/31/10 ITEM P ART# QTY. DESCRIPTION UL CIRCUIT BREAKER (225A F) A 0G5250 1 CB 175A 2 POLE 240V 225AF B 0H7356 1 COVER CB C2 CPL C 0F4186AGS0R 1 COVER CB DISH 2P G 225AF D 0F8432A 1 INSULATOR CB 2P 225AF E 0H7311 1 STANDOFF CB BOX CONBOX F 045771 2 NUT HEX M8[...]

  • Page 35

    [...]

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    EXPLODED VIEW: CO NBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: -A- DATE: 3/31/10 ITEM P ART# QTY. DESCRIPTION UL CIRCUIT BREAKER ( KG) A 0H5582 1 CB 0300 3P 600V E KG LL B 0H6740 1 COVER CB E KG C2 CONBOX C 0D3700 4 NUT FLANGE M6-1.0 NYLOK D 0H5581A 1 INS UL ATOR CB E 3P KG E 0H6734 1 STANDOFF CB MOUNT CONBO X F 045771 3 NUT HEX M[...]

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    EXPLODED VIEW: CO NBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: -A- DATE: 3/31/10 ITEM P ART# QTY. DESCRIPTION UL CIRCUIT BREAKER (QN) A 0E7284 1 CB 0175A 2P 240V S QN2 LL B 0H7356 1 COVER CB C2 CPL C 0H7429 1 COVER CB DISH 2P S QN D 0E3664 1 BASE, QN CIRCUIT BREAKER E 0H7311 1 STANDOFF CB BOX CONBOX F 074908 2 SCREW HHTT M5-0.8 X [...]

  • Page 39

    EXPLODED VIEW: CO NBOX C2 CPL DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: -A- DATE: 3/31/10 THIS PA GE LEFT I NTENTIONA LLY BLANK PAGE 8 OF 8[...]

  • Page 40

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  • Page 41

    1 0F9517 1 WELDMENT FRAME 2.4L C2 2 052860 4 NUT FL ANGED HEX M12-1.75 3 052251 4 DAMPE N E R VIBRATION 40 BLUE 4 052257 4 S PACER .49 X .62 X 1.87 PW DR/ZNC 5 052252 4 DAMPE N E R VIBRATION 6 052259 4 WASHE R FLAT M12 7 052891 4 S CR EW HH C M12-1.75 X 80 G8.8 8 0536210410 1 ASSY WI RE 14.00" 9 042909 1 S CR EW HH C M8-1.25 X 30 G 8 .8 10 047[...]

  • Page 42

    [...]

  • Page 43

    1 0F34 08B 1 BAT TERY T RAY C 1 CPL 2 0F3 4 11 1 S TRAP BA T TE RY RET AI NMENT 3 025507 REF W ASHER S HAKEP ROOF EX T 7/16 S TL 4 052212 REF S CREW HHC M 10-1. 25 X 25 G8.8 5 046526 REF WAS HER LO CK M1 0 6 022131 REF W ASHER F LAT 3/ 8-M10 Z INC 7 05033 1A REF BAT TERY PO ST COVE R RE D + 8 050331 REF BAT TERY P OST COV ER BL ACK - 9 038 805Y 1 C[...]

  • Page 44

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  • Page 45

    1 0E6586 1 GASKET BOS C H 32 & 40 2 0E0519A 1 ADAPTER CA RBURETOR W/PV C CONN 3 0C8127 1 ELEM ENT A I R C LE ANER 4 04981 5 4 SCREW HH C M 5-0 .8 X 16 G8.8 5 02212 7 1 NUT HEX 1/4- 20 STEE L (1) 6 06 2974 1 STUD TH 1/ 4 -20 X 4 -1 /2 G2 ZNC 7 0G0190 1 PLATE, AI R CL E ANER TOP 2.4L 8 03756 1 1 NUT WING 1/ 4-20 NYLK (1) APPLY M EDIUM STRENGTH BL[...]

  • Page 46

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  • Page 47

    1 0H30830ST 03 1 WELDMENT RADIATOR SUP PORT C2 2 0F2608 1 RADIATOR 598 X 568 X 4 9 CPL RH 3 0F5263 1 V-BELT 31/ 64" X 57-3/8" 4 04652 6 5 WASHER LOCK M 10 (1) 5 059981 4 SCREW HHC M10-1.5 X 30 G10.9 6 0F2776A 1 BR ACKET, SIGNAL CO NDITIONER (USED ONLY WITH QTA PRODUCT) 7 0F5050A 1 SHIE LD RADIATOR C4 8 02903 2 1 HOSE 9/32 ID (27 ”LG) 9 [...]

  • Page 48

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    EXPLODED VIEW: E NGINE COMMON PRT 2.4L G2 45KW DRAWING #: 0H7322 GROUP D APPLICABLE TO: REVISION: H-6789-B Page 3 of 4 DATE: 6/4/10 ITEM PART# QTY. DESCRIPTION 1 0H1619 1 E NGINE 2.4L G2 CERTIFIE D 2 046526 4 WASHER LO CK M10 3 039414 4 SCREW HH C M8-1.25 X 35 G8.8 4 0G01 49 1 SCREW SHC M14-1.5 X 35 G10.9 (4)5 0E9868A 1 ALTERNATOR DC W /OUT PULLEY [...]

  • Page 51

    EXPLODED VIEW: E NGINE COMMON PRT 2.4L G2 45KW DRAWING #: 0H7322 GROUP D APPLICABLE TO: REVISION: H-6789-B Page 4 of 4 DATE: 6/4/10 ITEM PART# QTY. DESCRIPTION 69 029333A 3 TIE WRAP UL 7. 4"X .19" BLK (2) 70 0 H001 5 1 HARN EMISSIONS OVE RLAY 2.4L (NOT S HOWN) 71 045772 1 NUT HEX M10-1.5 G8 YEL CHR (1) SUPPLIED W ITH ENGINE. (2) CALIFORNI[...]

  • Page 52

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  • Page 53

    EXPLODED VIEW: FUE L SYSTEM 2.4L 45KW DRAWING #: 0H7580 GROUP E APPLICABLE TO: REVISION: -A- Page 2 of 2 DATE: 3/19/10 ITEM PART# QTY. DESCRIPTION 1 026915 2 NIPPLE CLOSE 3/4 X 1.375 2 07 5580 1 FLANGE FUEL INLET 3 0F6390B 1 REGULATOR ASSY 2.4L 4 03 9253 2 SCREW HHC M8-1.25 X 20 G8.8 5 02 2145 2 W ASH ER FLAT 5/16-M8 ZINC 6 02 2129 2 W ASH ER LOCK [...]

  • Page 54

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    1 0F9794 2 MUFFLER 7" X 9" X 18-1/2" 2 " IN/OUT 2 0G01 13 1 EX HAUS T ELBOW 2 1/4 O D 2 1/2 OD 3 0G10 07 1 BRAC KET MUF FLER 4 0F283 0 2 MUFFLER BR ACKET STI FFENER 5 0F2962 2 MUFFLER STRAP 6 08 07 62 5 BO LT U 3/8-16 X 2.6 2 7 0E0 170A 1 E XHAUST BLANKE T 988M M (C2) 8 0C 24 5 4 4 S CREW TH F M6- 1 X 16 N WA Z/ JS 9 0G 0776 1 P[...]

  • Page 56

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  • Page 57

    (2) 1 0G00450ST 0R 1 REAR WR AP C2 CPL 2 0C245 4 54 S CREW THF M 6 -1 X 16 N WA Z/ JS (2) 3 0F 58490ST0R 2 DOO R C2 4 087233 2 RIVET POP .1875 X .45 0 SS 5 0E3 257 4 SCREW TH-FRM M6 W/ CAP SHKPRF W (2) 6 0F 58520ST0R 2 DISC HARGE DUCT LH & RH SIDE C2 (2) 7 0F 98330ST0R 2 FRO NT CORNERS C2 (2) 8 0F 58510ST0R 1 DISC HARGE CENTE R DUCT C2 9 049813[...]

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    Notes[...]

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    BackPg001 Re v . A 04/07[...]