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Generac RG03015GNAX manual

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Table of contents for the manual

  • Page 1

    Owner ’ s Manual For Sp ark-Ignited S t ationary Emergency Generators Residential and Commercial This manual should re main with the unit. This manual must be used in conjunction with the appropriate inst allation manual. * NOT INTENDED FOR USE IN CRITICAL LIFE SUPPOR T APPLICA TIONS. * ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT [...]

  • Page 2

    ii Owner ’s Manual for S tationary Emergency Generators Use this p age to record import ant information about the generator set. For quick and easy re ferenc e, copy the information printed on the Unit Identification Label onto the sample label printed here. The Unit Identification Label is located on the base frame ad jacent to the front e ngine[...]

  • Page 3

    T able of Conten ts Owner ’s Manual for S tationary Emergency Generators iii Section 1 Safety 1.1 Introduction ............ ................................. ................................................. ................ ............ 1 1.2 Safety Information ....... .................................................................. ..........[...]

  • Page 4

    T able of Content s iv Owner ’s Manual for S tationary Emergency Generators Section 4 Operation 4.1 Control Panel ...... ........................................................................... ............................ ......... 19 4.2 Auto/Manual/Off .... ................. ..................................................................[...]

  • Page 5

    T able of Conten ts Owner ’s Manual for S tationary Emergency Generators v 5.7 Schedule A Maintenance ............ ............................................................. .............. ............ 3 1 5.7.1 Schedule A Maintenance I tem Locations ................................................... ................................ 31 5.7.2 [...]

  • Page 6

    T able of Content s vi Owner ’s Manual for S tationary Emergency Generators (000004) W ARNING California P roposition 65. Engine exhaust and some of its constituents are known to the state of Calif ornia to cause cancer , birth defects, and other reproductive harm. (000005) W ARNING California P roposition 65. This product contains or emits chemi[...]

  • Page 7

    Owner ’s Manual for S tationary Emergency Generators 1 Section 1 Safety 1.1 — Introduction Thank you for purchasing this st ationary automatic st andby generator set. Every ef fort was made to ensure that the information in this manual was both accurate and co mplete at the time it was released . Howeve r , the manufactur er reserves the right [...]

  • Page 8

    Safety 2 Owner ’s Manual for S tationary Emergency Generators 1.2 — Safety Information S tudy these safety rules carefully before operating or servicing th is equipment. Become fam iliar with this Owner ’s Man- ual and with the unit. The gener ator can operate safely , efficien tly and r eliably only if it is properly installed, o perated and[...]

  • Page 9

    Safety Owner ’s Manual for S tationary Emergency Generators 3 1.4 — Exhaust Hazards • Generator eng ine exhaust cont ains DEADL Y carbon monoxi de, an odorles s, colorless, poison ous gas. Breathing carbon monoxide can cause dizziness, throbbin g temples, nausea , mu scular twitching, he adache, vomiting, weakness, slee piness, inabilit y to [...]

  • Page 10

    Safety 4 Owner ’s Manual for S tationary Emergency Generators This p age intentionally lef t blank.[...]

  • Page 11

    Owner ’s Manual for S tationary Emergency Generators 5 Section 2 Specifications 2.1 — Emission Information The U.S. Environmental Protection Agency (EP A) require s that the generator comp ly with exhaust emission st andards. The generator is cert ified to meet the applicable EP A emission levels, and is certified for use as a stationa ry engin[...]

  • Page 12

    S pecifications 6 Owner ’s Manual for S tationary Emergency Generators 2.2 — S pecifications Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 48 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2 . 4L 2.4L 2.4L 2.4L 5.4L 2.4L Generator Set Rotor Insulation Class H Class F Class H Class F Class H Class F Class H S tator Insulation Class H Dimensions L x[...]

  • Page 13

    S pecifications Owner ’s Manual for S tationary Emergency Generators 7 A complete specification sheet is included in the do cumentat ion provided with the unit at the time of purchase. For additional copies, consult your local Indepen dent Authorized Service Dealer . 2.3 — Engine Oil Recommendations T o maintain the product warran ty , use only[...]

  • Page 14

    S pecifications 8 Owner ’s Manual for S tationary Emergency Generators 2.4 — We ather and Maintenance Kit s T o keep the generator running at its peak, the follo wing kits are of fered: • Cold We ather Kit – Recommended for climates with temp eratures below 32°F • Extreme Cold W eather Kit – Recommended Block Heater Kit for protection [...]

  • Page 15

    S pecifications Owner ’s Manual for S tationary Emergency Generators 9 2.7 — Reconfiguring the Fuel System While some models are crea ted fuel specific for either Natural gas (NG) or Liq uid Propan e vapor (LPV) and are no t fuel convertible, others are configu red at the factor y for NG , but ar e field conver tible to LPV . Units fitted with [...]

  • Page 16

    S pecifications 10 Owner ’s Manual for S tationary Emergency Generators Serious injury , including death, or damage will occu r if not configure d properly . Consult an Authorized Dealer with any questio ns. 2.7.2— Change Fuel Selection Failure to convert bot h the hardware and sof tware will result in decreased pe rformance and an increa se in[...]

  • Page 17

    Owner ’s Manual for S tationary Emergency Generators 11 Section 3 Activation and S t artup 3.1 — Orient ation NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual. The location and appeara nce of some component s may vary between engine models. The side of the enclosure with the viewing window is identifi ed as the re ar o[...]

  • Page 18

    Activation and S tartup 12 Owner ’s Manual for S tationary Emergency Generators 3.3 — Inst all Battery CAUTION: Always connect t he positive battery cable first. If the posi tive cable should cont act ground with the negative cable inst alled, the result- ing sp arks may cause a ba ttery explosion which could result in serious injury . 1. Loose[...]

  • Page 19

    Activation and S tartup Owner ’s Manual for S tationary Emergency Generators 13 3.5 — Activate Unit Display Reads: Generator Active is displayed on the LCD screen when the unit is first powered up. After displaying firmware and hardware version codes, as well as other system information, the Installation Wizard is launched, and the Language scr[...]

  • Page 20

    Activation and S tartup 14 Owner ’s Manual for S tationary Emergency Generators 3.6 — S t art and Run Engine 1. Pull up rubber flap covering fuse holder and verify installation of 7.5 amp fuse. See A of Figure 3-5. 2. Move the Main Circuit Breaker switch down to the OFF (Open ) position. See B of Figure 3-5 . 3. Press MANUAL on the control pane[...]

  • Page 21

    Activation and S tartup Owner ’s Manual for S tationary Emergency Generators 15 3.7 — Operational Checks The following procedures req uire special tools and skills. Cont act an authorized service provider to perform these tasks. 3.7.1— Self T est Upon power up, the controller goes thro ugh a system self te st which checks for the presenc e of[...]

  • Page 22

    Activation and S tartup 16 Owner ’s Manual for S tationary Emergency Generators 9. Allow the engine to warm up for about five min utes. Move the Main Circuit Breake r switch on the generator con- trol panel up to the ON (or closed) position. Generator power volt age is now supplied to the transfer switch. Cont act with live transf er switch p a r[...]

  • Page 23

    Activation and S tartup Owner ’s Manual for S tationary Emergency Generators 17 1. V erify that the generator is OFF . A re d LED on the control panel illuminates to confirm that the s ystem is in the OFF mode. 2. Install front cover of the transfer switch. 3. T urn ON the utility power supply to t he transfer switch, using the means prov ided (s[...]

  • Page 24

    Activation and S tartup 18 Owner ’s Manual for S tationary Emergency Generators This p age intentionally lef t blank.[...]

  • Page 25

    Owner ’s Manual for S tationary Emergency Generators 19 Section 4 Operation 4.1 — Control Panel NOTE: The control p a nel is intende d for use by q ualified service personn el only . The control pane l is located behind the vi ewing window at the rear of the unit. With the control p anel set to AUTO, the engine may cran k and st art at any time[...]

  • Page 26

    Operation 20 Owner ’s Manual for S tationary Emergency Generators Figure 4-2. Control Panel and LCD Screen 4.3 — Menu Navigation See Figure 4-3. Feature Description System Menus HOME Screen The system returns to the Home screen if the control panel is not used for five minutes. The screen nor- mally displays a S tatus message, such as Ready to [...]

  • Page 27

    Operation Owner ’s Manual for S tationary Emergency Generators 21 Navigation ESCAPE Used to abort a routine or back up to the preceding menu. ENTER Used to make a select ion or save an entry . UP ARROW DOWN ARROW Used to move forward or backward from menu to menu or to scroll forward or backward (increment or dec- rement) through available sel ec[...]

  • Page 28

    Operation 22 Owner ’s Manual for S tationary Emergency Generators “Run Log” ESC ENTER ENTER ESC SYSTEM BA TTERY DA TE/TIME SUB MENUS HISTORY EDIT MAINT DEALER Exercise Time Å 14:00 Wednesday Æ ESC ESC ENTER ESC ENTER Current Date/Time Å 9/12/14 12:22 Æ ESC ESC ESC ESC ENTER ENTER ESC ESC ESC ENTER ENTER ENTER ENTER ESC ESC ENTER MAINT : M[...]

  • Page 29

    Operation Owner ’s Manual for S tationary Emergency Generators 23 Figure 4-3. Navigation Menu 4.4 — Alarm/W arning Conditions The owner/operator is alerted to Alar m and/or W arning conditions via the cont rol p anel LCD screen. All Alarm condi- tions cause the gene rator to shut down. T he W arning messages alert the oper ator to conditions th[...]

  • Page 30

    Operation 24 Owner ’s Manual for S tationary Emergency Generators 4.6.2— User Programmable 4.6.2.1—St art-Up D elay Timer A programmable line inte rrupt delay (or S tart-Up Delay) timer is provided. When utility vo ltage fails (falls below 60% of nominal), the start-up delay timer is started. If the volt age rises above the Utility V olts Low[...]

  • Page 31

    Operation Owner ’s Manual for S tationary Emergency Generators 25 4.9.1— Automatic Sequence of Operation 4.9.1.1—Utility Failure If the control panel is set to AUTO when the utility power fails, a ten second S tar t-Up Delay timer is started (user pro- grammable). If utility power is still absent when th e time ex pires, the engi ne cranks an[...]

  • Page 32

    Operation 26 Owner ’s Manual for S tationary Emergency Generators IMPORT ANT NOTE: Always use the applicable transf er switch owner's manual for actual manua l transfer switch op eration in structions . The information presented here describes a tra nsfer switch, which is not used for three phase applicat ions. See specific ma nual for three[...]

  • Page 33

    Owner ’s Manual for S tationary Emergency Generators 27 Section 5 Maintenance 5.1 — Component Locations The side of the enclo sure with the vi ewing window is identified as the rear of the generato r set. The right and le ft sides are identified by st anding at the re ar an d looking towards the front of the unit. NOTE: The 2.4L (32 kW) unit is[...]

  • Page 34

    Maintenance 28 Owner ’s Manual for S tationary Emergency Generators Figure 5-3. Left Side V iew NOTE: All normal maintenance and service ite ms are easily accessible for cons umer convenience. Wherever possible, touch point s are colored orange to provide for quick and easy recogn ition. 5.2 — Access Panels Access panels are loca ted at both th[...]

  • Page 35

    Maintenance Owner ’s Manual for S tationary Emergency Generators 29 5.3 — Service Main tenance Intervals NOTE: Use only Genuine Generac p arts to ensure warr anty coverage. All generator service must be performed by an au thorized service pro vider or a qualified service per son- nel only . It is important to perform all maintenanc e at the int[...]

  • Page 36

    Maintenance 30 Owner ’s Manual for S tationary Emergency Generators 5.4 — Remove From Service T o ensure safety , follow the steps below pr ior to inspection, ma inte nance or service. IMPORT ANT NO TE: If currently experiencing a utility out age, see Subsection 6.3 —Removal From Service During Utility Outages fo r special instr uctions. 1. O[...]

  • Page 37

    Maintenance Owner ’s Manual for S tationary Emergency Generators 31 5.7 — Schedule A Maintenance NOTE: Perform Schedule A maintenance once each year or af ter 125 hours of service, whichever comes first. NOTE: The 2.4L (32 kW) unit is depicted in the art work used in this manual. For the gen eral location of compo- nent s in all other models, s[...]

  • Page 38

    Maintenance 32 Owner ’s Manual for S tationary Emergency Generators 5.7.5— Check Coolant Level and Hoses Do not add coolant when the engine is hot. S team and scalding fluids can cause severe burns. 1. V erify that the coolant level is between t he HOT and COLD marks on the overflow reservoir . See Figure 5-6. N O TE : Coolant exp ands when hot[...]

  • Page 39

    Maintenance Owner ’s Manual for S tationary Emergency Generators 33 7. V erify that the oil level is at or near the FULL mark. Add oil as necessary . See A of Figure 5-7 NOTE: Observe the oil lev el on both sides of the dip stick. The lower of the two readings is the co rrect oil level measurement. 8. If necessary , remove the oil fill cap and sl[...]

  • Page 40

    Maintenance 34 Owner ’s Manual for S tationary Emergency Generators 2. Use one wrench to hold hex on hose fitting (to prevent r otation), an d use second wrench to remove drain plug . Hot oil may cause burns. Allow engine to cool befor e draining oil. A void prolonged or repeated skin exposure with used oil. Thor oughly wash exposed area s with s[...]

  • Page 41

    Maintenance Owner ’s Manual for S tationary Emergency Generators 35 Figure 5-8. Oil Drain Hose, Fi ll Cap, Dipstick and Filter A B[...]

  • Page 42

    Maintenance 36 Owner ’s Manual for S tationary Emergency Generators Oil Fill Cap Oil Fill Cap Oil Fill Cap Oil Fill Cap Oil Fill Cap Oil Filter Oil Filter Oil Filter Oil Filter Oil Filter Air Cleaner Air Cleaner Air Cleaner Air Cleaner Oil Level Dipstick Oil Level Dipstick Oil Level Dipstick Air Cleaner Oil Level Dipstick Oil Level Dipstick 2.4L:[...]

  • Page 43

    Maintenance Owner ’s Manual for S tationary Emergency Generators 37 Figure 5-9. Engine O il and Air Cleaner Main tenance (All Models) 5.7.9— Check Batter y Condition/Fluid Level 5.7.9.1— Check Con dition and Clean 1. V erify that top of battery is clean a nd dry . Dirt and electro- lyte on top of the batter y can cause batt ery to self-dis- c[...]

  • Page 44

    Maintenance 38 Owner ’s Manual for S tationary Emergency Generators Inst allation Always connect the positive bat tery cable first. If the positive cable sh ould cont act ground with the negative cable ins t alled, the resulting sp arks may cause a battery explos ion which could result in seri- ous injury . 1. Install rubber protective cover over[...]

  • Page 45

    Maintenance Owner ’s Manual for S tationary Emergency Generators 39 Figure 5-12. Check Accesso ry/Drive Belt Deflection 5.7.1 1— Rep lace Air Filter Element 1. Remove wing nut, lock washer and flat washer from threade d rod to release air clean er cover . See Figure 5-13 2. Remove the air filter element and discard . 3. Thoroughly clean air cle[...]

  • Page 46

    Maintenance 40 Owner ’s Manual for S tationary Emergency Generators Figure 5-13. Air Cleaner Co ver and Filter Element NOTE: Service kit s are available from Independ ent Authoriz ed Service Dealers. 5.7.12— Final Instructions If only performing Sche dule A maintenance procedures, proceed as follows: 1. Install b attery negative cable ( black) [...]

  • Page 47

    Maintenance Owner ’s Manual for S tationary Emergency Generators 41 5.8 — Schedule B Maintenance NOTE: Perform Schedule B maintenance every two years or af ter 250 hours of s ervice, whichever c omes first. Before proceeding below , first perform all t asks listed under Schedule A Maintenance. NOTE: The 2.4L (32 kW) unit is depicted in the art [...]

  • Page 48

    Maintenance 42 Owner ’s Manual for S tationary Emergency Generators 14. Insert funnel into filler neck of radiator . See B of Figure 5-14 15. Slowly pour coolant into filler neck until radiator is full. 16. Install radiator ca p. 17. Press MANUAL on the control panel to start the engine. A blue LED illuminates to conf irm that the system is in th[...]

  • Page 49

    Maintenance Owner ’s Manual for S tationary Emergency Generators 43 Figure 5-15. Adjust Spark Plug Gap 5. Check condition of threads in cylinder head and on sp ark plugs. If necessary , soften deposit s with penetrating oil and clean out with a thread chaser . 6. Clean spa rk plugs using a wire brush and comm er cial solvent. Do not blast spark p[...]

  • Page 50

    Maintenance 44 Owner ’s Manual for S tationary Emergency Generators 5.9 — Schedule C Maintenance NOTE: Perform Schedule C maint enance af ter 1000 hours of service. Before proce eding below , first perform all t asks listed under Sch edule A Maintenance and Schedule B Maintenan ce. The following procedures req uire special tools and skills. Con[...]

  • Page 51

    Maintenance Owner ’s Manual for S tationary Emergency Generators 45 5.1 1 — Lube Oil Maint ainer System 5.1 1.1— Des cription NOTE: Oil reservoir is empty when shippe d from factory . Fill with clean engine oil to activate the system. The 36 kW , 45 kW , and 60 kW models are equipped with a Lube Oil Maint ainer System. The system is inst alle[...]

  • Page 52

    Maintenance 46 Owner ’s Manual for S tationary Emergency Generators 5.1 1.3— T est Functionality See A of Fi gure 5-17. Mo mentarily press the te st button to c onfirm that th e float is oper ating correctly . Do not hold the tes t button down fo r a prolonged period of t ime or the crankc ase can be over f illed. Over filling the crankcase can[...]

  • Page 53

    Owner ’s Manual for S tationary Emergency Generators 47 Section 6 T roubleshooting 6.1 — Engine T roubleshooting Problem Cause Correction The engine will not crank. Fuse blow n. Replace 7.5 a mp fuse in gene rator con- trol panel. Cor rect short circuit condi- tion if fuse blows again. Loose, co rroded or de fective bat- tery cables. T ighten, [...]

  • Page 54

    T r oubleshoot ing 48 Owner ’s Manual for S tationary Emergency Generators 6.2 — Controller T roubleshooting Active Alarm Problem Solution NOT ACTIV A TED Unit will not start in AUTO with utility loss. Refer to activation sectio n in Owner ’s Manual. NONE Unit running in AUTO but no power in house. Check MLCB. Contact servicing dealer if MLCB[...]

  • Page 55

    T roubleshooting Owner ’s Manual for S tationary Emergency Generators 49 6.3 — Removal From Servic e During Utility Out ages If, during prolonged utility outages, the us er wishes to remove the unit from serv ice to conserve fuel, reduce run hours, or to perform main tenanc e tasks, then complete the steps listed be low . IMPORT ANT NOTE: Failu[...]

  • Page 56

    T r oubleshoot ing 50 Owner ’s Manual for S tationary Emergency Generators NOTE: On 36 kW , 45 kW , and 60 kW models, close shutoff valve to avoid dr aining the oil supply t ank with the crankcase oil. For more infor mation, see Subsection 5.1 1 —Lube Oil Maintainer System. 11 . Remove oil drain hose from holding clamp. 12. Use one wrench to ho[...]

  • Page 57

    T roubleshooting Owner ’s Manual for S tationary Emergency Generators 51 12. Press MANUAL on the control panel to st art the engine. A blue LED illuminates to confirm that the system is in the MANUAL mode . 13. Allow the engine to run until it is reaches normal o perat ing temperature. Ch eck for leaks while the engine is run- ning. 14. Press OFF[...]

  • Page 58

    T r oubleshoot ing 52 Owner ’s Manual for S tationary Emergency Generators This p age intentionally lef t blank.[...]

  • Page 59

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

  • Page 60

    Part No. 0K8185 Rev . A 02/16/2015 Printed in USA ©2015 Generac Power Systems, Inc. All rights reserved S pecifications a re subject to change wi thout notice. No reproduction allowed in any form without pri or written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy . 59 W aukesha, WI 53189 1-888-GENERAC (1-888-[...]