GE 76080 User Manual

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Generator Systems

30,000 Watt Generator System

Model 076080

Operator’s Manual

This generator is rated in accordance with UL (Underwriters Laboratories) 2200 (stationary engine generator assemblies) and CSA (Canadian Standards Association) standard C22.2 No. 100-4 (motors and generators).

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Thank you for purchasing this quality-built GE generator. We’re pleased that you’ve placed your confidence in the GE brand. When operated and maintained according to the instructions in this manual, your generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with standby generators and how to avoid them. Because we do not necessarily know all the applications this equipment could be used for, it is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment. Save these

instructions for future reference.

This generator requires professional installation before use. Refer to the separate installation manual for full information.

Your installer should follow the instructions completely.

Where to Find Us

You never have to look far to find GE support and service for your generator. For quick service when you need it, keep your original receipt with this manual. You may contact Customer Service at 888‑575‑8226 between 8:00 AM and 5:00 PM CT, or click on SERVICE & SUPPORT at www.standbygeneratorsystems.com, which provides a list of authorized dealers.

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Table of Contents

Safety Rules................................................4

Installation ................................................7

For the Owner................................................ 7

For the Installing Dealer/Contractor.................................... 7

Owner Orientation.................................................... 8

Fuel Factors..........................................................8

Generator Location ...................................................9

Delivery Inspection ...................................................9

Controls ..................................................10

Operation.................................................18

Automatic Operation ................................................18

Setting the Exercise Timer ............................................19

Maintenance ..............................................20

Service Code Detection System .......................................20

Generator Maintenance ..............................................22

Engine Oil...........................................................22

Synthetic Oils .......................................................22

Oil Recommendation.................................................23

Checking Engine Oil Level ............................................23

Engine Drive Belts ...................................................24

Engine Coolant System...............................................25

Engine Air Cleaner ..................................................25

Generator Electrical System Maintenance .............................26

Battery

Fuel System Inspection and Maintenance ..............................27

Storage.............................................................28

Troubleshooting ...........................................30

Warranty .................................................31

Product Specifications .....................................34

.................................................... 26

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Safety Rules

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains

important instructions that should be followed during installation and maintenance of the generator and batteries.

Safety Symbols and Meanings

Fire

Toxic Fumes

Explosive Pressure

Rotating Fan Blade

Electrical ShockExplosion

Hot SurfaceRotating Parts

Chemical BurnAuto Start

Exploding BatteryRotating Belt/Pulley

The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the generator system unsafe.

WARNING Running engine gives off carbon monoxide, an

odorless, colorless, poison gas. Breathing carbon monoxide could result in death, serious injury, headache, fatigue, dizziness, vomiting, confusion, seizures, nausea or fainting.

• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.

• Keep exhaust gas away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure.

• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/ recommendations. Smoke alarms cannot detect carbon monoxide gas.

Lift Hazard Read Manual

The safety alert symbol indicates a potential personal injury hazard. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to designate a degree or level of hazard seriousness. A safety symbol may be used to represent the type of hazard. The signal word NOTICE is used to address practices not related to personal injury.

DANGER indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, could result in minor or moderate injury.

NOTICE addresses practices not related to personal injury.

WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING Certain components in this product and related accessories contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.

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WARNING Storage batteries give off explosive hydrogen gas

during recharging. Slightest spark will ignite hydrogen and cause explosion, resulting in death or

serious injury. Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery contents could cause severe chemical burns. A battery presents a risk of electrical shock and high short circuit current.

• DO NOT dispose of battery in a fire. Recycle battery.

• DO NOT allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

• DO NOT open or mutilate the battery.

• Wear protective goggles, rubber apron, rubber boots and rubber gloves.

• Remove watches, rings, or other metal objects.

• Use tools having insulated handles.

WARNING Propane and Natural Gas are extremely flammable

and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• Install the fuel supply system according to NFPA 37 and other applicable fuel-gas codes.

• Before placing the generator into service, the fuel system lines must be properly purged and leak tested.

• After the generator is installed, you should inspect the fuel system periodically.

• NO leakage is permitted.

• DO NOT operate engine if smell of fuel is present or other explosive conditions exist.

• DO NOT smoke around the generator. Wipe up any oil spills immediately. Ensure that no combustible materials are left in the generator compartment. Keep the area near the generator clean and free of debris.

WARNING Generator produces hazardous voltage.

Failure to properly ground generator could result in electrocution. Failure to isolate generator from utility power could result in death or serious injury to electric utility workers due to backfeed of electrical energy.

• DO NOT touch bare wires or bare receptacles.

• DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged.

• DO NOT handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet.

• If you must work around a unit while it is operating, stand on an insulated dry surface to reduce the risk of a shock hazard.

• DO NOT allow unqualified persons or children to operate or service generator.

• In case of an accident caused by electrical shock, immediately shut down the source of electrical power and contact the local authorities. Avoid direct contact with the victim.

• Despite the safe design of the generator, operating this equipment imprudently, neglecting its maintenance or being careless could cause possible injury or death.

• Remain alert at all times while working on this equipment. Never work on the equipment when you are physically or mentally fatigued.

• Before performing any maintenance on the generator, disconnect the battery cable indicated by a Negative (NEG or ‑) first. When finished, reconnect that cable last.

• After your system is installed, the generator may crank and start without warning any time there is a power failure. To prevent possible injury, always set the generator’s system switch to OFF, remove the service disconnect from the disconnect box AND remove the 15 Amp fuse BEFORE working on the equipment.

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WARNING Exhaust heat/gases could ignite combustibles or

structures resulting in death or serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Exhaust outlet side of weatherproof enclosure must have at least 5 ft. (1.5m) minimum clearance from any structure, shrubs, trees or any kind of vegetation.

• Standby generator weatherproof enclosure must be at least 5 ft. (1.5m) from windows, doors, any wall opening, shrubs or vegetation over 12 inches (30.5 cm) in height.

• Standby generator weatherproof enclosure must have a minimum of 5 ft. (1.5 m) overhead clearance from any structure, overhang, or trees.

• DO NOT place weatherproof enclosure under a deck or other type of structure that may confine airflow.

• Use only flexible fuel line provided. Connect provided fuel line to generator. DO NOT use with or substitute any other flexible fuel line.

• Smoke detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/recommendations. Carbon monoxide alarms cannot detect smoke.

• Keep at least minimum distances shown in General Location Guidelines to insure for proper generator cooling and maintenance clearances.

• Replacement parts must be the same and installed in the same position as the original parts.

WARNING Moving parts could crush and cut.

Starter and other rotating parts could entangle hands, hair, clothing, or accessories resulting in serious injury.

• NEVER operate generator without protective housings, covers, or guards in place.

• DO NOT wear loose clothing, jewelry or anything that could be caught in the starter or other rotating parts.

• Tie up long hair and remove jewelry.

• Before servicing, remove 15 Amp fuse from control panel and disconnect Negative (NEG or ‑) battery cable.

WARNING Hot pressurized coolant could cause serious injury.

• DO NOT open radiator cap when hot.

• Before servicing, allow coolant to cool.

CAUTION Installing the 15 Amp fuse could cause the engine

to start at any time without warning resulting in minor or moderate injury.

• Observe that the 15 Amp fuse has been removed from the control panel for shipping.

• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.

CAUTION Excessively high operating speeds could result in minor injury and/or equipment damage. Excessively low speeds impose a heavy load on generator.

• DO NOT tamper with governed speed. Generator supplies correct rated frequency and voltage when running at governed speed.

• DO NOT modify generator in any way.

NOTICE Exceeding generators wattage/amperage capacity could damage generator and/or electrical devices connected to it.

• Start generator and let engine stabilize before connecting electrical loads.

NOTICE Improper treatment of generator could damage it and shorten its life.

• Use generator only for intended uses.

• If you have questions about intended use, contact your authorized dealer.

• Operate generator only on level surfaces.

• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.

• The access panels/door must be installed whenever the unit is running.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• Remain alert at all times while working on this equipment. Never work on the equipment when you are physically or mentally fatigued.

• DO NOT start engine with air cleaner or air cleaner cover removed.

• DO NOT insert any objects through cooling slots.

• DO NOT use the generator or any of its parts as a step. Stepping on the unit could cause stress and break parts. This may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

• If connected devices overheat , turn them off and disconnect them from generator.

• Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

-unit makes unusual noises.

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Installation

We sincerely appreciate your patronage. For this reason, we have made every effort to provide for a safe, streamlined and cost-effective installation. Because each installation is unique, it is impossible to know of and advise the trade of all conceivable procedures and methods by which installation might be achieved. Neither could we know of possible hazards and/or the results of each method or procedure. For these reasons,

For the Owner

To help you make informed choices and communicate effectively with your installation contractor(s),

Read and understand Owner Orientation in this manual before contracting or starting your generator installation.

To arrange for proper installation, contact the store at which you purchased your generator, your dealer, a licensed electrician or your utility power provider.

Only current licensed electrical and plumbing professionals should attempt generator system installations. Installations must strictly comply with all applicable codes, industry standards and regulations.

Your generator is supplied with this “Operator’s Manual” and a separate “Installation Manual”. These are important documents and should be retained by the owner after the installation has been completed.

The generator warranty is VOID unless the system is installed by licensed electrical and plumbing professionals.

Every effort has been made to ensure that information in this manual is accurate and current. However, we reserve the right to change, alter, or otherwise improve the product and this document at any time without prior notice.

The Emission Control System for this generator is warranted for standards set by the U.S. Environmental Protection Agency and by the California Air Resources Board (CARB).

For the Installing Dealer/Contractor

For most applications, the Installation manual contains all the information required to properly install and start the generator. This Operator’s Manual describes routine operation and owner maintenance procedures.

If you need more information in this matter, please call 888 575‑8226 between 8:00 AM and 5:00 PM CT..

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Owner Orientation

This section provides generator owners with the information necessary to achieve the most satisfactory and cost effective installation possible.

The illustrations are for typical circumstances and are meant to familiarize you with the installation options available with your generator. A thorough understanding of these options will provide fundamental control over the cost of your installation, as well as ensure your final satisfaction and security.

Federal and local codes, appearance, noise levels, fuel types, and distances are the factors that must be considered when negotiating with an installation professional. Remember that as the distance from the existing electrical service and

Fuel Factors

gaseous fuel supply increases, and the number of 90 degree bends in the fuel supply increases; compensations in piping and wiring materials must be made. This is necessary to comply with local codes and overcome electrical voltage drops and gaseous fuel pressure drops.

The factors mentioned above will have a direct affect on the overall price of your generator installation.

In some areas you may need to acquire electrical permits for installing the generator, building permits for installing gas lines, and permits for noise allowances. Your installer should check your local codes AND obtain the permits before installing the system.

An important consideration affecting the entire installation is the type of fuel used by your generator. The system was factory tested and adjusted using either natural gas or liquid propane (LP vapor). For proper engine function, factors that are inherent to each of these fuels, your location and the duration of possible utility interruptions are important considerations in the following fuel guidelines:

• Use clean, dry fuel, free of moisture or any particulate material. Using fuels outside the following recommended values may cause performance problems.

• In engines set up to run on propane (LP), commercial grade HD5 propane with a minimum fuel energy of 2500 BTUs/ft 5% and butane and heavier gas content of 2.5% and minimum propane content of 90%.

with maximum propylene content of

WARNING Propane and Natural Gas are extremely flammable

and explosive, which could cause burns, fire or explosion resulting in death or serious injury.

• The residential generator is equipped with an automatic safety gas “fuel shut-off” valve.

• DO NOT operate the equipment if the “fuel shut-off” valve is missing or inoperative.

Power Decrease at High Altitude or High Temperature

Air density is less at high altitudes, resulting in less available engine power. Specifically, engine power will decrease 3.5% for each 1,000 feet (300 meters) above sea level and 1% for each 10° F (5.6°C) above 77°F (25°C). Make sure you and your installer consider these factors when determining total generator load.

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Generator Location

The actual physical location of your generator has a direct affect on:

1. The amount of plumbing required to fuel your generator.

2. The amount of wiring required to control and connect your generator.

Specific location guidelines are discussed in the installation manual. Acquaint yourself with that information and confer with your installer. Be sure to ask how your site might affect installation costs and compliance with local codes and standards.

The generator must be installed outdoors. DO NOT install generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from any windows, doors, ventilation intakes or other openings that can allow exhaust gas to collect in a confined area. Prevailing winds and air currents should be taken into consideration when positioning generator. See the installation manual for full details on safe generator location.

Delivery Inspection

WARNING Running engine gives off carbon monoxide, an

odorless, colorless, poison gas. Breathing carbon monoxide could result in death, serious injury, headache, fatigue, dizziness, vomiting, confusion, seizures, nausea or fainting.

• Operate this product ONLY outdoors.

• Install a battery operated carbon monoxide alarm near the bedrooms.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings.

WARNING Exhaust heat/gases could ignite combustibles or

structures resulting in death or serious injury.

• DO NOT install the generator closer than 5 feet (1.5 m) from any combustibles or structures with combustible walls having a fire resistance rating of less than 1 hour.

Carefully inspect the generator for any damage that may have occurred during shipment.

If loss or damage is noted at time of delivery, have the person(s) making delivery note all damage on the freight bill and affix his signature under the consignor’s memo of loss or damage. If loss or damage is noted after delivery, separate the damaged materials and contact the carrier and your installer for claim procedures. Missing or damaged parts are not warranted.

The generator system is supplied with:

• Fully-serviced coolant system

• Fully-serviced oil/lubricating system

• Flexible fuel hook-up

• Installation and start-up manual

• Operator’s manual

• Spare access door keys

• Spare 15 Amp ATO-type fuse

• Touch up paint

• Remote wireless monitor

• Antenna

To be supplied by Installer:

• Starting battery

• Reinforced concrete mounting pad

• Connecting wire and conduit

• Fuel supply valves/plumbing

• Various specialty tools/equipment

• Two (2) AA batteries for remote wireless monitor

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Controls

30 kW Generator

Read this operator’s manual and Important Safety Instructions before operating your generator. Compare the illustrations of this model with your generator to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.

Back Top

Front

B C D

Generator is pictured with access doors removed for clarity and screen guard open for clarity.

Exhaust Port — High-performance muffler lowers engine

noise to comply with most codes.

Engine Label — Identifies engine model and type.

Oil Dip Stick — Used to check the engine oil level.

Roof Access Opening — Provides access to control panel,

oil filter, etc.

Circuit Breaker Enclosure — Equipped with removable top

to assist with conduit connection.

Control Panel — Used for various test, operation and

maintenance functions. See System Control Panel.

Air Cleaner — Protects engine by filtering dust and debris

out of intake air.

Fuel Selection Switch — Select natural gas or liquid

propane (LP vapor) supply.

Oil Fill Cap — Remove to service the engine with

recommended oil.

Coolant Fill — Provides access for filling engine coolant.

Coolant Recovery Bottle — Provides visual indicator of

engine coolant level.

Fuel Inlet — Fuel supply is connected here.

ID Label — Identifies unit by serial number.

Rear Access Panel Opening — Provides access to various

components of generator.

Oil Filter — Filters engine oil to prolong system life.

Front Access Panel Opening — Provides access to various

components of generator.

Battery Location — Battery located for convenient access.

Fuel Type Selector — Position selector for Natural Gas (NG)

or Liquid Propane (LP vapor) supply.

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Access Ports

The generator is equipped with an enclosure that has several access panels, as shown.

The access panels and the components located behind them are listed below:

A -

B -

C -

D -

E -

Roof (Control Panel, internal guard)

Front Access Panel (oil drain and oil filter)

Internal Guard (air filter, oil dipstick, coolant

bottle)

Rear Access Panel (fuel regulator, fuel selector,

and engine starter)

Control Panel Cover (field wiring and control wires)

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