Generac 10 kW LP - Manual

Generac 10 kW LP

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Table of Contents:

  • Page 2 – ElEctrical formulas
  • Page 3 – contents; Test 4 – Fixed Excitation Test/Rotor
  • Page 6 – Stator WindinG reSiStance ValueS / rotor reSiStance; sPEcificatioNs
  • Page 7 – SpecificationS; Fuel Consumption; engine
  • Page 8 – mountinG dimenSionS
  • Page 10 – major FeatureS
  • Page 11 – standby Generators; taBlE of coNtENts
  • Page 12 – introduction; GENErator iDENtificatioN; Figure 1. Typical Data Plates; RAINPROOF ENCLOSURE FITTED; FOR STANDBY SERVICE, NEUTRAL FLOATING
  • Page 13 – iNstallatioN Basics; recommended Wire size; GroundinG the Generator; lP; Minimum water column; DaNGEr: lP aND Natural Gas arE BotH; the tranSFer SWitch / load center
  • Page 14 – Figure 1. Typical Installation
  • Page 15 – poWer Source and load lineS; Figure 2. Proper Fuel Installation; natural GaS Fuel interconnectionS
  • Page 16 – non-PrePackaged interconnectionS; ConneCt a pre-2008 load Center switCh to a; PRE “08” LOAD CENTER; Figure 2. Post 2008 HSB Interconnections
  • Page 17 – NoN-PrEPacKaGED iNtErcoNNEctioNs; connect a 2008 and later load center SWitch; Figure 3. Wire Connections; PRE “08” HSB AIR-COOLED GENERATORS
  • Page 18 – General; • An adequate supply of the correct fuel must be; Fuel requirementS; DANGER; Gaseous fuels such as natural gas and liquid; reconFiGurinG the Fuel SyStem; supplied with the generator.; PrEParatioN BEforE usE
  • Page 19 – in the selector knob and pull out to overcome spring; Figure 1. Demand Regulator; Loosen clamp and slide back the; • Slide fuel selector on carburetor out towards the
  • Page 20 – enGine oil recommendationS; 0° F and below
  • Page 21 – tEstiNG, clEaNiNG aND DrYiNG; meterS; “Hertz” or “cycles per second”.; the Vom; Figure 1. Digital VOM; meaSurinG ac VoltaGe; a. Some VOM’s may be equipped with a polarity; meaSurinG ac Frequency
  • Page 22 – meaSurinG current; meaSurinG reSiStance; • A “short-to-ground” condition in any Stator or Rotor
  • Page 23 – electrical unitS; Figure 5. Electrical Units; ohm’S laW; VOLTS
  • Page 24 – ViSual inSpection; • Burned or broken wires, broken wire connectors,; inSulation reSiStance; rotor miNimum iNsulatioN rEsistaNcE:; cautioN: Before attempting to measure insu-
  • Page 25 – TESTING ALL STATOR WINDINGS TO GROUND:; Wire; TEST BETWEEN WINDINGS:; Stator inSulation reSiStance teSt
  • Page 26 – rotor inSulation reSiStance teSt; cautioN: Do not use sprayed water to clean; dryinG the Generator
  • Page 27 – ENGiNE-GENErator ProtEctiVE DEVicEs; • If an RPM signal is not detected within the first three; OIL FILTER; Figure 1. Engine Protective Switches on an
  • Page 28 – oVercrank ShutdoWn
  • Page 29 – oPEratiNG iNstructioNs; control panel; kW UNITS; Figure 1. Generator Control Panel; DaNGEr: WHEN tHE GENErator is; seconds. All the red LED’s will stop flashing immediately
  • Page 30 – to Select automatic operation
  • Page 31 – automatic oPEratiNG ParamEtErs; The system will control the cyclic cranking as follows:
  • Page 32 – load tranSFer; nominal for 10 consecutive seconds.; utility reStored
  • Page 33 – Part 2; Description and components
  • Page 34 – Figure 1. AC Generator Exploded View
  • Page 35 – DEscriPtioN & comPoNENts; Stator aSSemBly; Figure 4. Stator Assembly Leads
  • Page 36 – Figure 5. Typical Voltage Regulator
  • Page 37 – oPEratioNal aNalYsis; rotor reSidual maGnetiSm; Figure 2. Field Boost Circuit Schematic; Figure 1. Operating Diagram of AC Generator
  • Page 39 – trouBlEsHootiNG floWcHarts; Problem 1 - Generator Produces Zero Voltage or Residual Voltage
  • Page 41 – Problem 3 - Generator Produces Low Voltage at No-Load
  • Page 43 – DiaGNostic tEsts; Figure 1. Generator Main Circuit Breaker Test Points; teSt 2 – check ac output VoltaGe
  • Page 44 – DaNGEr: usE EXtrEmE cautioN; teSt 4 – FiXed eXcitation teSt/; Figure 2. Voltage Regulator; Set VOM to DC amperage.
  • Page 45 – ed
  • Page 46 – teSt 7 – teStinG the Stator With a Vom; LINE; LOAD; Figure 4. Test 7 Test Points
  • Page 47 – Figure 5. Stator Assembly Leads; teSt 8 – teSt BruShleSS Stator
  • Page 48 – teSt 9 – check capacitor; Danger: the capacitor may need to be dis-
  • Page 49 – Figure 7. Field Boost Test Points; teSt 10 – teSt dpe WindinG on; Warning: the capacitor may need to be; Set VOM to measure resistance.; note: isolate all main stator leads before proceeding.
  • Page 50 – teSt 11 – reSiStance check oF; teSt 12 – check BruSheS and Slip; Figure 8. Checking Brushes and Slip Rings
  • Page 51 – teSt 13 – teSt rotor aSSemBly; Figure 9. The Rotor Assembly; teSt 14 – check ac output Frequency
  • Page 52 – teSt 16 – check Stepper motor; a. Connect one meter lead to Red, connect the
  • Page 53 – Figure 11. Throttle Positions 9/10 kW Units; STEPPER MOTOR; Figure 12. Throttle Positions 9/10 kW Units; STEPPER MOTOR; Figure 13. Throttle Positions 12-20 kW Units; teSt 17 – check and adjuSt VoltaGe; Figure 15. Voltage Adjustment Potentiometer
  • Page 54 – a. Single Cylinder Units: Frequency should not; Warning: Please keep safety in mind while
  • Page 55 – DO NOT SUBSTITUTE ANY OTHER DEVICE
  • Page 56 – NotEs
  • Page 59 – tranSFer mechaniSm; Figure 2. Load Connected to Utility Power Source; tranSFer relay; Generator battery voltage (12 volts DC) is available to; a. The 12 volts DC circuit is completed through
  • Page 60 – Figure 5. Transfer Relay Schematic; neutral luG; Figure 6. Transfer Switch Terminal Block
  • Page 61 – FuSe holder; Figure 7. The Fuse Holder
  • Page 62 – operational analySiS; Figure 1 is a schematic for a typical “W/V-Type” transfer switch.
  • Page 63 – Figure 2 is a wiring diagram for a typical “W/V-Type” transfer switch.
  • Page 64 – utility Source VoltaGe aVailaBle; Figure 3. Utility Source Power Available
  • Page 65 – utility Source VoltaGe Failure
  • Page 66 – tranSFer to StandBy; Figure 5. Transfer Action to Standby Position
  • Page 69 – utility reStored, tranSFer SWitch de-enerGized
  • Page 70 – utility reStored, retranSFer Back to utility
  • Page 71 – tranSFer SWitch in utility
  • Page 72 – trouBlEsHootiNG floW cHarts
  • Page 73 – OR; Problem 9 – Blown F1 or F2 Fuse
  • Page 74 – kW: Green LED Flashes
  • Page 76 – b. Turn off all power voltage supplies to the trans-
  • Page 77 – (2) W h e n t h e g e n e ra t o r s t a r t s, a n “ e n g i n e; teSt 27 – check manual tranSFer; DaNGEr: Do Not attEmPt maNual; a. Move the transfer switch operating lever up to
  • Page 78 – connectionS; caution: after removing the fuse from the bat-
  • Page 79 – teSt 29 – teSt tranSFer relay tr; Figure 3. Transfer Relay Test Points; CONNECT VOM TEST
  • Page 80 – teSt 30 – StandBy control circuit
  • Page 81 – Figure 4. Standby Control Circuit Test Points
  • Page 82 – Figure 5. The Home Page, Debug and Output Screens; Figure 6. Transfer Relay Test Points; teSt 32 – utility control circuit
  • Page 83 – Figure 7. Utility Control Circuit Test Points
  • Page 85 – Figure 8. Fuse Holder and Fuses; teSt 35 – check n1 and n2 WirinG
  • Page 86 – Figure 9. Terminal Block Test Points; teSt 37 – check utility SenSinG; Figure 10. Transfer Switch Fuse Block; teSt 39 – check VoltaGe at terminal
  • Page 87 – XXXXXXXXXXXXXXXXXXXXXXXXXXX
  • Page 90 – DET
  • Page 95 – LSS; NB; LSC; C D
  • Page 98 – A. UTILITY 1 and UTILITY 2; Figure 1. Terminal Strip; circuit Board; • Delivers “field boost” current to the generator rotor; Postion; DEscriPtioN aND comPoNENts
  • Page 99 – Figure 3. Control Panel Component Identification
  • Page 101 – REMOTE WIRELESS CONNECTION; Figure 5. 10 kW Printed Circuit Board and J1 Connector
  • Page 102 – Figure 6. 12/14 kW Printed Circuit Board and J1 Connector
  • Page 103 – Figure 7. 16, 17 and 20 kW Printed Circuit Board and J1 Connector
  • Page 104 – FEMALE SIDE; Figure 8. Choke Solenoid Connector Pin Number Identification; menu SyStem naViGation
  • Page 105 – ESC; MENU SYSTEM
  • Page 107 – Figure 1. circuit condition - utility Source Voltage available
  • Page 108 – initial dropout oF utility Source VoltaGe
  • Page 109 – timer on the circuit board will turn on.
  • Page 110 – utility VoltaGe dropout and enGine crankinG
  • Page 111 – Figure 3. circuit condition - engine cranking
  • Page 112 – enGine Startup and runninG
  • Page 113 – Figure 4. circuit condition - engine Startup and running
  • Page 114 – initial tranSFer to the “StandBy” Source
  • Page 115 – Figure 5. circuit condition - initial transfer to Standby
  • Page 116 – utility VoltaGe reStored / re-tranSFer to utility
  • Page 117 – Figure 6. circuit condition - utility Voltage restored
  • Page 118 – enGine ShutdoWn; energize and close to terminate the engine fuel supply.
  • Page 119 – • Without fuel flow and without ignition, the engine will shut down.
  • Page 120 – Problem 15 – Engine Will Not Crank When Utility Power Source Fails
  • Page 121 – Problem 17 – Engine Cranks but Won’t Start
  • Page 123 – Problem 19 – Shutdown Alarm/Fault Occured
  • Page 124 – Problem 21 – Generator Will Not Exercise
  • Page 125 – AUTO; teSt 57 – try a manual Start; a. The engine should crank cyclically through it’s
  • Page 126 – Figure 2. The Home Page, Debug and Input Screens; teSt 59 – teSt auto operationS
  • Page 127 – B. p e r f o r m a l o a d t e s t o n t h e B a t t e r y :; Figure 4. Using a Battery Hydrometer; Figure 5. Reading a Battery Hydrometer
  • Page 128 – teSt 62 – check Wire 56 VoltaGe; a. Press “ESC” until the main menu is reached.; DEBUG; Figure 6. The Home Page, Debug and Output Screens; teSt 63 – teSt Starter contactor; Figure 7. The Starter Contactor Relay
  • Page 129 – teSt 64 – teSt Starter contactor; a. No voltage should be indicated initially.
  • Page 130 – teSt 65 – teSt Starter motor; a. Shor ted ar mature (wire insulation wor n and; If battery voltage is indicated on the meter but starter; PINION
  • Page 131 – With the starter motor activated (jump the terminal on the
  • Page 132 – Figure 17. Testing Starter Motor Performance; teSt 66 – check Fuel Supply and; must be available or the engine will not start.; DaNGEr: GasEous fuEls arE HiGHlY; See Figures 18, 19 or 20 for the gas pressure test point on; Figure 19 (10 kW) Gas Pressure Test point
  • Page 133 – teSt 67 – check circuit Board Wire 14; Figure 21. The Home Page, Debug and Output
  • Page 134 – Operational Check
  • Page 135 – Figure 23. Solenoid Energized, Choke Open; Figure 24. Exploded View Showing Location of Choke
  • Page 136 – teSt 70 – check For iGnition Spark; crank cycle sequence table; crank cycle 1; Seconds; crank cycle 3; Seconds; crank cycle 4; Seconds; crank cycle 5; Seconds
  • Page 137 – Figure 27. Spark Tester
  • Page 138 – Figure 29. Checking Engine Miss; teSt 71 – check Spark pluGS; NORMAL; teSt 72 – check enGine / cylinder leak
  • Page 139 – • Air escapes through the breather – check piston; teSt 73 – check ShutdoWn Wire
  • Page 140 – WIRE 18 CONNECTION; a. O n V- t w i n u n i t s, r e m ove W i r e 5 6 f r o m t h e; teSt 74 – check and adjuSt iGnition
  • Page 141 – Air Gap
  • Page 142 – Verify installation of magnetos correctly by ensuring both
  • Page 143 – teSt 75 – check oil preSSure SWitch; Navigate to the Digital inputs display screen.; Figure 41. The Home Page, Debug and Input Screens; Remove the oil pressure gauge and reinstall the oil
  • Page 144 – teSt 76 – check hiGh oil temperature; TESTING HIGH OIL TEMPERATURE SWITCH:; teSt 77 – check and adjuSt ValVeS
  • Page 145 – JAM NUT; teSt 78 – check Wire 18 continuity; Figure 45. Wire 18 Connection 8 kW Units
  • Page 146 – Figure 47. The Date and Time, and Main Menu; teSt 80 – check crankinG and runninG
  • Page 148 – teSt 81 – check to See iF loW Speed
  • Page 149 – system functional tests
  • Page 150 – DaNGEr: BE surE to turN off all; electrical checkS; Complete electrical checks as follows:; sYstEm fuNctioNal tEsts
  • Page 151 – tHE traNsfEr sWitcH is NoW ElEctri-; ProcEED WitH cautioN! GENErator; Generator teStS under load; Do Not attEmPt maNual traNsfEr; a. 7/8kW voltage should be greater than 230 volts
  • Page 152 – checkinG automatic operation; • After about fifteen seconds, the switch should; SettinG the eXerciSe timer
  • Page 153 – major Disassembly; Torque Requirements
  • Page 154 – Front enGine acceSS; a. Remove engine wiring harness at the J1 port.; maJor DisassEmBlY
  • Page 158 – major diSaSSemBly
  • Page 164 – Remove Engine: Using proper lifting equipment remove; torque requirementS
  • Page 166 – WiriNG DiaGram, 8 KW HomE staNDBY
  • Page 168 – scHEmatic, 8 KW HomE staNDBY; PAGE LEFT PLANK INTENTIONALLY
  • Page 170 – WiriNG DiaGram, 10 KW HomE staNDBY
  • Page 172 – scHEmatic, 10 KW HomE staNDBY; PAGE LEFT BLANK INTENTIONALLY
  • Page 174 – WiriNG DiaGram, 14 KW HomE staNDBY
  • Page 176 – scHEmatic, 14 KW HomE staNDBY
  • Page 178 – WiriNG DiaGram, 17 KW HomE staNDBY
  • Page 180 – scHEmatic, 17 KW HomE staNDBY
  • Page 182 – WiriNG DiaGram, 20 KW HomE staNDBY
  • Page 184 – scHEmatic, 20 KW HomE staNDBY
  • Page 186 – WiriNG DiaGram, HomE staNDBY
  • Page 188 – scHEmatic, HomE staNDBY
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a u t o m a t i c s t a n d b y g e n e r a t o r s

air-cooled Product

M O D E L S :

7 kW N G, 8 kW L P

9 kW N G, 1 0 kW L P

1 3 kW N G, 1 4 kW L P

1 6 kW N G, 1 7 kW L P

1 8 kW N G, 2 0 kW L P

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Summary

Page 2 - ElEctrical formulas

ElEctrical formulas TO FIND KNOWN VALUES 1-PHASE 3-PHASE KILOWATTS (kW) Volts, Current, Power Factor E x I 1000 E x I x 1.73 x PF 1000 KVA Volts, Current E x I 1000 E x I x 1.73 1000 AMPERES kW, Volts, Power Factor kW x 1000 E kW x 1000 E x 1.73 x PF WATTS Volts, Amps, Power Factor Volts x Amps E x ...

Page 3 - contents; Test 4 – Fixed Excitation Test/Rotor

Page 1 contents specifications .......................................................... 4 Generator ................................................................ 4 Engine ..................................................................... 5 Fuel Consumption ......................................

Page 6 - Stator WindinG reSiStance ValueS / rotor reSiStance; sPEcificatioNs

Page 4 Generator Unit 8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW Rated Max. Continuous Power Capacity (Watts*) 7,000 NG 8,000 LP 9,000 NG 10,000 LP 12,000 NG 12,000 LP 13,000 NG 14,000 LP 16,000 NG 16,000 LP 16,000 NG 17,000 LP 18,000 NG 20,000 LP Rated Voltage 120/240 Rated Voltage at No-Load (NG) 22...

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