Generac G007171-0, G007172-0, G007223-0, G007224-0, G007225-0 Owner's Manual

...

Owner’s Manual

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.

60 Hz Air-Cooled Generators

10 kW to 24 kW

WWW.GENERAC.COM

1-888-GENERAC

(888-436-3722)

Para español, visita: http://www.generac.com/service-support/product-support-lookup

Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup

SAVE THIS MANUAL FOR FUTURE REFERENCE

Use this page to record important information about this generator.

(000393a)

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

Record the information found on the unit data label on this

Model:

Serial:

Production Date:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

STA MAC ID:

page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Fig-

ure 2-1, Figure 2-2, or Figure 2-3. See Operation for

directions on how to open the top lid and remove the front panel.

Always supply the complete model and serial numbers of the unit when contacting an Independent Authorized Service Dealer (IASD) about parts and service.

Operation and Maintenance: Correct maintenance and care of the unit ensures a minimum number of problems, and keeps operating expenses at a minimum. It is the operator’s responsibility to perform all safety inspections, to verify all maintenance for safe operation is performed promptly, and to have the equipment inspected periodically by an IASD. Normal maintenance, service, and replacement of parts are the responsibility of the owner/operator and are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage may contribute to the need for additional maintenance or service.

When the generator requires servicing or repairs, Generac recommends contacting an IASD for assistance. Authorized service technicians are factory-trained and are capable of handling all service needs. To locate the nearest IASD, please visit the dealer locator at:

www.generac.com/Dealer-Locator.

SSID:

ii Owner’s Manual for 60 Hz Air-Cooled Generators

Table of Contents

Section 1: Safety Information

Introduction ..................................................................1

Read This Manual Thoroughly ....................................1

Safety Rules .................................................................1

How to Obtain Service .................................................1

General Hazards ...........................................................2

Exhaust Hazards ..........................................................3

Electrical Hazards ........................................................3

Fire Hazards .................................................................3

Explosion Hazards .......................................................4

Battery Hazards ............................................................4

Section 2: General Information

Generator Components and Control Locations ........7

Data Decals .................................................................10

Specifications .............................................................11

Generator ..................................................................11

Engine .......................................................................11

Protection Systems ...................................................12

Emissions ...................................................................12

Fuel Requirements .....................................................12

Battery Requirements ................................................12

Battery Charger ..........................................................12

Engine Oil Requirements ..........................................12

Activating the Generator ...........................................13

Wi-Fi Module ...............................................................13

Replacement Parts .....................................................13

Accessories ................................................................13

Section 3: Operation

Site Prep Verification .................................................15

Generator Enclosure .................................................15

Opening the Lid .........................................................15

Front Access Panel Removal ....................................15

Intake Side Panel Removal .......................................16

Main Line Circuit Breaker (Generator Disconnect) ....16

LED Indicator Lights ..................................................16

Auxiliary Shutdown Switch .......................................17

Control Panel Interface ..............................................17

Using the AUTO/OFF/MANUAL Buttons ..................17

Operating Modes ........................................................18

Interface Menu Displays ............................................18

LCD Panel .................................................................18

Menu System Navigation ..........................................19

Setting the Exercise Timer ........................................ 21

Battery Charger ..........................................................21

Manual Transfer Operation .......................................21

Transfer to Generator Power Source ........................21

Transfer to Utility Power Source ................................22

Automatic Transfer Operation ..................................22

Automatic Sequence of Operation ...........................22

Utility Failure ..............................................................22

Cranking ....................................................................22

Cold Smart Start ........................................................ 22

Cleaning Cycle ..........................................................22

Load Transfer ............................................................23

Shutting Generator Down While Under

Load or During a Utility Outage ................................23

Section 4: Maintenance

Maintenance ............................................................... 25

Preparing for Maintenance ........................................25

Performing Scheduled Maintenance ........................ 25

Service Schedule .......................................................26

Maintenance Log .......................................................26

Checking Engine Oil Level ........................................ 27

Engine Oil Requirements ..........................................27

Changing the Oil and Oil Filter .................................27

Servicing the Air Cleaner .......................................... 28

Spark Plug(s) .............................................................. 29

Valve Clearance Adjustment .....................................29

Checking Valve Clearance ........................................29

Adjusting Valve Clearance ........................................30

Battery Maintenance .................................................. 30

Inspecting the Battery ................................................31

Cleaning the Sediment Trap ..................................... 32

Post Maintenance Checks .........................................32

Performing Fuel System Leak Test ...........................33

Attention After Submersion ......................................33

Corrosion Protection .................................................33

Remove From and Return To Service Procedure ...33

Remove From Service ...............................................33

Return to Service .......................................................34

Section 5: Troubleshooting / Quick

Reference Guide

Generator Troubleshooting ...................................... 35

Quick Reference Guide .............................................37

Owner’s Manual for 60 Hz Air-Cooled Generators 0

Table of Contents

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i Owner’s Manual for 60 Hz Air-Cooled Generators

Section 1: Safety Information

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

(000001)

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Safety Information

Introduction

Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal enclosure intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

NOTE: This generator is suitable for supplying typical residential loads such as induction motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), electronic components (computer, monitor, TV, etc.), lighting loads, and microwaves, when sized correctly. This unit is equipped with a Wi-Fi tor owner to monitor generator status from anywhere they have Internet access.

NOTE: Wi-Fi

ance

The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

module, which allows the genera-

is a registered trademark of Wi-Fi Alli-

Safety Rules

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows:

Read This Manual Thoroughly

If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GENERAC), or visit www.generac.com for starting, operating, and servicing procedures. The owner is responsible for correct maintenance and safe use of the unit.

This manual must be used in conjunction with all other supporting product documentation supplied with the product.

SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be followed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency.

Owner’s Manual for 60 Hz Air-Cooled Generators 1

NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.

These safety alerts cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

How to Obtain Service

When the unit requires servicing or repairs, contact Generac Customer Service at 1-888-GENERAC (1-888-436-

3722) or visit www.generac.com for assistance.

When contacting Generac Customer Service about parts and service, always supply the complete model and serial number of the unit as given on its data decal located on the unit. Record the model and serial numbers in the spaces provided on the front cover of this manual.

Safety Information

(000190)

DANGER

Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury.

(000191)

DANGER

Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.

(000247a)

Equipment damage. This unit is not intended for use as a prime power source. It is intended for use as an intermediate power supply in the event of temporary power outage only. Doing so could result in death, serious injury, and equipment damage.

WARNING

(000130)

Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

WARNING

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000187)

WARNING

Electrocution. Potentially lethal voltages are generated by this equipment. Render the equipment safe before attempting repairs or maintenance. Failure to do so could result in death or serious injury.

(000155a)

WARNING

Electric shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000115)

Moving Parts. Do not wear jewelry when starting or operating this product. Wearing jewelry while starting or operating this product could result in death or serious injury.

WARNING

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000146)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury.

(000215a)

WARNING

(000228)

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

(000216)

WARNING

Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.

General Hazards

• Inspect generator regularly, and contact the near-

est IASD for parts needing repair or replacement.

2 Owner’s Manual for 60 Hz Air-Cooled Generators

Exhaust Hazards

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

(000178a)

WARNING

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury.

(000146)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

WARNING

(000281)

Fire risk. Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage.

(000144)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000150)

Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury.

DANGER

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.

(000152)

DANGER

Electrocution. Verify electrical system is properly grounded before applying power. Failure to do so will result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.

WARNING

(000217)

Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury.

WARNING

(000218)

Fire and explosion. Installation must comply with all local, state, and national electrical building codes. Noncompliance could result in unsafe operation, equipment damage, death, or serious injury.

WARNING

(000219)

Fire hazard. Use only fully-charged fire extinguishers rated “ABC” by the NFPA. Discharged or improperly rated fire extinguishers will not extinguish electrical fires in automatic standby generators.

Safety Information

Electrical Hazards

Fire Hazards

Owner’s Manual for 60 Hz Air-Cooled Generators 3

Safety Information

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

Electrocution. Refer to local codes and standards for safety equipment required when working with a live electrical system. Failure to use required safety equipment could result in death or serious injury.

(000257)

(000147)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury.

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000151a)

DANGER

Explosion and fire. Connection of fuel source must be completed by a qualified professional technician or contractor. Incorrect installation of this unit will result in death, serious injury, and property and equipment damage.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000162)

Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

(000137a)

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000164)

WARNING

Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.

(000138a)

WARNING

Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000163a)

Risk of burn. Do not open or mutilate batteries. Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

Comply with regulations the local agency for workplace health and safety has established. Also, verify that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws, and regulations.

Battery Hazards

Explosion Hazards

4 Owner’s Manual for 60 Hz Air-Cooled Generators

Always recycle batteries in accordance with local laws

WARNING

(000228)

and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org

Safety Information

Owner’s Manual for 60 Hz Air-Cooled Generators 5

Safety Information

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6 Owner’s Manual for 60 Hz Air-Cooled Generators

Section 2: General Information

Generator Components and Control Locations

General Information

Figure 2-1. 10 kW—Components and Control Locations

A Lock with cover F Oil fill cap/dipstick K Oil drain hose O Fuel inlet

B Main line circuit breaker

(generator disconnect)

C Control panel H Airbox with air cleaner M Sediment trap Q Data decal location

D Battery compartment

(battery not supplied)

E Exhaust enclosure

G Status LED indicators L Composite base P Wi-Fi module

J Oil filter N Fuel regulator R Auxiliary shutdown switch

001818

Owner’s Manual for 60 Hz Air-Cooled Generators 7

General Information

009340a

Figure 2-2. 14 kW–18 kW—Components and Control Locations

A Lock with cover F Exhaust enclosure L Composite base Q Data decal location

B Main line circuit breaker

(generator disconnect)

C Airbox with air cleaner H Oil drain hose N Fuel regulator S Auxiliary shutdown switch

D Control panel J Oil fill cap/dipstick O Fuel inlet

E Battery compartment

(battery not supplied)

G Status LED indicators M Sediment trap R Auxiliary shutdown switch

K Oil filter P Wi-Fi module

8 Owner’s Manual for 60 Hz Air-Cooled Generators

General Information

001786

Figure 2-3. 20 kW–24 kW—Components and Control Locations

A Lock with cover F Exhaust enclosure L Composite base Q Wi-Fi module

B Main line circuit breaker

(generator disconnect)

C Airbox with air cleaner H Oil drain hose N Sediment trap S Auxiliary shutdown switch

D Control panel J Oil fill cap O Fuel regulator T Auxiliary shutdown switch

E Battery compartment

(battery not supplied)

G Status LED indicators M Oil dipstick R Data decal location

K Oil filter P Fuel inlet

Owner’s Manual for 60 Hz Air-Cooled Generators 9

General Information

Data Decals

Two decals on the generator provide information about the unit itself and required fuel inlet pressure for correct operation.

Model Data Decal

Includes important information about the unit including:

• model number

• serial number

• production date

• voltage

• frequency

• amps

• country of origin

• rated ambient temperature

The model data decal also displays certifica-

tion symbols by Underwriter’s Laboratory (UL) and the Southwest Research Institute (SwRI).

Fuel Inlet Pressure

Displays unit serial number, along with minimum and maximum inlet pressures for natural gas (NG) and liquid propane (LP) supply. Space is provided for installer to enter maximum flow rates based on installed pipe sizes and lengths.

10 Owner’s Manual for 60 Hz Air-Cooled Generators

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