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Generac QT06024AVSX manual

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Table of contents for the manual

  • Page 1

    This manual should remain with the unit. 2.4L 60kW Models EP A Cer tified Owner's Manual Stationar y Emergency Generator Cover195 Re v . A 04/10 Part No. 0H7320 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 (LPV) 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's per cubic foot for LP gas. Ask[...]

  • Page 10

    SPECIFICA TIONS GENERA TOR T ype...................................................................... Synchronous Rotor Insulation ............................................................. Class H Stator Insulation ............................................................ Class H T elephone Inter ference F actor (TIF) ......................[...]

  • 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  With the switch set to A UTO, the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. T o prevent possible injury that might be caused by such sudden star[...]

  • Page 15

    8-2 CntrlNexus001 Rev . D 04/11 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 [...]

  • 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

    CHECK ENGINE MESSAGE The control system has detected an emissions related fault. This fault cannot be cleared using the control panel inter face. The unit will continue to operate in automatic mode. Contact your local ser vicing dealer . UNDER-FREQUENC Y SHUTDOWN AL ARM Af ter star ting, if the generator stays under frequency for more than 30 secon[...]

  • Page 19

    OVERVOL T AGE AL ARM If the generator voltage rises above 110% for >3 seconds, an alarm will be issued. If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued. INTERNAL F AILURE SHUTDOWN ALARM Any internal failure that can be detected such as cor r upted firmware will cause this shutdown alar m. This alarm cannot [...]

  • Page 20

    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 21

    8-8 CntrlNexus001 Rev . D 04/11 Control P anel 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 LANGU AGE TIME/DA TE EXERCISE TIME/SPEED ESC Press the “ESCAPE” key to jump back up through the menu levels. + / - U[...]

  • Page 22

    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 23

    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 24

    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 25

    Figure 10.3 – 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 26

    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 27

    T roubleshooting TROUBLESHOOTING GUIDE PROBLEM C AUSE 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 [...]

  • Page 28

    [...]

  • Page 29

    1 0F9677 1 ROTOR-2390 -45KD1 CPL 0G0056 1 ROTO R -2 390-35KD1 CP L 0G0959 1 ROTO R -2 390-45KD1 CP L (G 2) 0G1155 1 ROTO R -2 390-35KD1 CP L (G 2) 0G1931 1 ROTO R 25 KW 3PH DIREC T 390 1800 0G2101 1 ROTO R 25 KW 1PH DIREC T 390 1800 0G3734 1 RTR- 2 390 -60KD2 CPL 0G6562 1 RTR 390 3 5AD1 CPL 0G6564 1 RTR 390 3 5KD1 CPL 2 0F9664 1 STATOR-39 0 45K 2P [...]

  • Page 30

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  • Page 33

    EXPLODED VIEW: CO NBOX C2 CP L DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 4 of 8 DATE: 9/26/11 ITEM P ART# QTY. DES CRIP TION 1 0H6266 1 BA CK PANEL CONBOX SUPPO RT C2 2 0H6265 1 TOP PA N EL CONBOX SUPPORT C2 3 0H6160 1 COVER WIRE ENTRY CONBOX 4 057073 2 JUNCTION BLOCK 3/8-16 5 056739 1 RELAY SOLENOID 12VDC PNL MN T (6)6 0H673[...]

  • Page 34

    EXPLODED VIEW: CO NBOX C2 CP L DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 5 of 8 DATE: 9/26/11 ITEM P ART# QTY. DES CRIP TION UL CIRCUIT BREAKER (225A F) A 0G5250 1 CB 175A 2 POLE 240V 225AF B 0H7356 1 COVER CB C2 C PL C 0F4186AGS0R 1 COVER CB DISH 2 P G 225AF D 0F8432A 1 INSULATOR CB 2P 225AF E 0H7311 1 STANDOFF C B BOX CONBO[...]

  • Page 35

    EXPLODED VIEW: CO NBOX C2 CP L DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 6 of 8 DATE: 9/26/11 ITEM P ART# QTY. DES CRIP TION 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 FLANG E M6-1.0 NYLOK D 0H 5581A 1 INSULATOR CB E 3P KG E 0H6734 1 STANDOFF C B MOUNT CONBOX [...]

  • Page 36

    EXPLODED VIEW: CO NBOX C2 CP L DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 7 of 8 DATE: 9/26/11 ITEM P ART# QTY. DES CRIP TION UL CIRCUIT BREAKER (QN) A 0E7284 1 CB 0175A 2P 240V S QN2 LL B 0H7356 1 COVER CB C2 C PL C 0H7429 1 COVER CB D ISH 2P S QN D 0E3664 1 BASE, QN CIRCUIT BR EAKER E 0H7311 1 STANDOFF C B BOX CONBOX F 07490[...]

  • Page 37

    EXPLODED VIEW: CO NBOX C2 CP L DRAWING #: 0H7326 GROUP A APPLICABLE TO: REVISION: H-9621-F Page 8 of 8 DATE: 9/26/11 THIS PAGE LEFT INTENTIONALLY BLANK[...]

  • Page 38

    [...]

  • Page 39

    1 0G37260ST03 1 WELDMENT FRAME 2.4L C2 60KW 2 05286 0 4 NUT FL A NGE D HEX M12-1.75 3 05225 1 4 DAMPENE R VIBRATION 40 BLUE 4 05225 7 4 SPACER .4 9 X . 62 X 1 .87 PWDR/ZNC 5 05225 2 4 DAMPENE R VIBRATION 6 05225 9 4 WASHE R FLAT M12 7 05289 1 4 SCREW HHC M12-1.75 X 80 G8.8 8 0536210410 1 A SSY WIRE 14.00" 9 04290 9 1 SCREW HHC M8-1.25 X 30 G8.[...]

  • Page 40

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  • Page 41

    1 0F3408C 1 BATTERY TRAY, C1 & C2 2 0F3411 1 S T RAP BAT TERY RETAINME NT 3 02550 7 REF WASHER SHAKEP ROOF EXT 7/16 STL 4 05221 2 REF SCREW HHC M 10 -1 .25 X 25 G8.8 5 04652 6 REF WASHER LOCK M10 6 02213 1 REF WASHER FLAT 3 /8 -M10 ZINC 7 05 0 331A REF BATTERY POST COVER RED + 8 05033 1 REF BAT TERY POST COVER BLACK - 9 03880 5 Y 1 CA BLE BATTE[...]

  • Page 42

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  • Page 43

    EXPLODED VIEW: AIR CL EANER 2.4 L G2 TUR B O DRAWING #: 0H1954 GROUP D APPLICABLE TO: REVISION: H-3963 –B PAGE 2 OF 2 DATE: 2/27/09 ITEM PART# QTY. DESCRIPTION 1 0F4269 2 GA S KET MIXER BODY 2 0H0030 1 ADAPTOR-MIXER 3 0G39340ST03 1 B RACK ET AIR INTAKE 4 035480 1 BOLT U 5/16-18 X 2.06 5 0H0028 1 ADAPTOR-AIR CLEANER 6 0F4271 1 BASE PLATE, AIR CLE [...]

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    1 0H30830ST03 1 WELDMENT RADIATO R SUP PORT C2 2 0F2608 1 RADIATOR 598 X 568 X 49 CPL RH 3 0F5263 1 V-BELT 31/64" X 57- 3/8" 4 04652 6 5 WASHE R LOCK M1 0 (1) 5 0599 81 4 SCREW HH C M10-1.5 X 30 G10.9 6 0D3700 4 NUT FLANGE M6-1 . 0 NYLO K 7 0F5050A 1 SHIELD RAD I ATOR C4 8 0G9332C 1 OIL LINE REM O TE F IL TE R/ EN GIN E 9 0F2573 1 PULLEY [...]

  • Page 47

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    EXPLODED VIEW: T URBO 2.4L G2 DRAWING #: 0H3356 GROUP D APPLICABLE TO: REVISION: -A- PAGE 1 OF DATE: 6/22/09 ITEM PART# QTY. DESCRIPTION 1 042574 1 ADAPTER 1/8NPTF TO 1/8 BSPT 2 064094 1 MALE E L BOW 45 #49X 3 3 064096B 1 OI L SUPPLY 3LHA(38") 4 0G8690 1 GASKET 2.4L G2 5 0G8692 1 GASKET 2.4L G2 6 0H2811 1 TURBOCHARGER G2 2.4L 7 0A 470 7B 1 ADA[...]

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  • Page 51

    EXPLODED VIEW: MUFFLER EXH 2.4 L G2 TURBO DRAWING #: 0H3357 GROUP F APPLICABLE TO: REVISION: H-5192-B PAGE 1 OF DATE: 10/12/09 ITEM PART# QTY. DESCRIPTION 1 0G86870ST03 1 BRACKET MUFFLER 2 0G8686 1 BRACKET STIFFENER 3 0G6150 1 MUFFLER 60kW 4 0G0113 1 EXHAUST ELBO W 5 0F2808D 1 EXHAUST PIPE 6 0G0007 1 DIFFUSER EXHAUST WE LDM ENT 7 0H3371 1 PIPE EXHA[...]

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    EXPLODED VIEW: ENG I NE COMMON P ARTS 2.4L G2 TURBO 60K DRAWING #:0H7323 GROUP D APPLICABLE TO: REVISION: H-7244-D Page 3 of 4 DATE: 8/10/10 ITEM PART# QTY. DESCRIPTION 1 0H1619 1 ENGINE 2.4L G2 CERTIFIED 2 035472 1 CLAMP HOSE #6 .43-.78 3 0G1 738 1 CAP ANTIFREEZE RUBBER 9.5DIA 4 0G0 950 1(REF) GASKET INTA KE MANIFOLD G2 5 0G8 488 1 MANIF OLD INTAK[...]

  • Page 55

    EXPLODED VIEW: ENG I NE COMMON P ARTS 2.4L G2 TURBO 60K DRAWING #:0H7323 GROUP D APPLICABLE TO: REVISION: H-7244-D Page 4 of 4 DATE: 8/10/10 ITEM PART# QTY. DESCRIPTION 66 0G8853 4 COIL- 2.4L G2 IGNITION 67 023897 8 W ASHER FLAT #10 ZI NC 68 022152 8 W ASHER LOCK #10 69 034413 8 S CREW HHM #10-32 X 1-1/4 70 0G9350 1 O- RING 2.5"X 2.75"X 1[...]

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    1 057147 1 HOSE 3/4 I D LPG & NG (43”LG) 2 065908 1 FLANGE F UEL IN L ET 3 039130 1 NIPPLE C LO SE 1.25 NPT X 1.625 4 030131 1 ELBOW 9 0D 1- 1/4 NPT 5 088963 1 NIPPLE PIPE 1.25 NPT X 5.5 BL I R N 6 026915 2 NIPPLE C LO SE 3/4 X 1.375 7 0A8064 2 BSHG R DCR HEX 1-1/4-3/4 8 064346 1 PIPE TEE 1 -1/ 4 NPT 9 0G9239C 1 RE G ASSY 2 .4L 60KW NG CPL 10[...]

  • Page 58

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  • Page 59

    1 057147 1 HOSE 3/4 I D LPG & NG (45”LG) 2 075580 1 FLANGE, F U EL IN LET 3 026915 1 NIPPLE C LO SE 3/4 X 1.375 4 026812 2 ELBOW 9 0D 3/4NP T 5 0F8379 1 NIPPLE PIPE 3 /4 NPT X 7 6 026915 2 NIPPLE C LO SE 3/4 X 1.375 7 022097 4 WASHER LOCK M6-1/4 8 0F3691 1 VENTURI THRO TT LE 32MM 9 0G9189C 1 RE G ASSY 2 .4L 60KW LPV CPL 10 046580 4 SCREW SH C[...]

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    (2) 1 0G80180AL0R 1 R EAR WRAP C2 G2 60KW 2 0C2454 58 SCREW T HF M6- 1 X 16 N W A Z/JS (2) 3 0F58490AL0R 2 DOOR C2 4 087233 2 RIVET POP . 1875 X .450 SS 5 0E3257 4 SCREW TH-FRM M6 W/CAP SHKP RF W (2) 6 0F58520AL0R 2 DUCT DSC H RG LH&RH (2) 7 0F98330AL0R 2 FRONT COR N ERS C2 (2) 8 0F58510AL0R 1 DUCT DISC H ARGE C 2 9 049813 2 NUT HEX M 6 X 1 .0 [...]

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