Generac Power Systems Protector Series Bedienungsanleitung

Owner’s Manual

Stationary Diesel Generators

Residential and Commercial

15–30 kW, 12–24 kVA

Protector™Series

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SAVE THIS MANUAL FOR FUTURE REFERENCE

(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.

ii Owner’s Manual for Stationary Diesel Generators

Use this page to record important information about the

generator set.

For quick and easy reference, copy the information

printed on the Unit Identification Label into the table

provided below. The Unit Identification Label is located

on the left engine mount on 15/20 kW (2.5L) units, and on

the left side of the radiator shroud on 30 kW (2.2L)

models. The label provides the following information:

When contacting an Independent Authorized Service

Dealer (IASD) about parts and/or service, always provide

the complete model number and serial number.

Operation and Maintenance: Proper maintenance and

care of the generator ensures safe operation and longer

service life while also keeping operating expenses to a

minimum. It is the operator’s responsibility to perform all

safety checks, to make sure that all maintenance is

performed promptly, and to have the equipment checked

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, contact

an IASD for assistance. IASDs are factory-trained and

are capable of handling all service needs.

Model Number

Serial Number

Rated KW or kVA

Voltage Rating

Maximum Current

Rating (AMPS)

INDEPENDENT AUTHORIZED

SERVICE DEALER LOCATION

To locate the nearest

INDEPENDENT AUTHORIZED

SERVICE DEALER,

please call this number:

1-800-333-1322

or visit the dealer locator at:

www.generac.com/Service/DealerLocator/

SAMPLE LABEL

006366

(000393)

WARNING

Operating, servicing and maintaining this

equipment can expose you to chemicals

including engine exhaust, carbon monoxide,

phthalates, and lead, which are known to the

State of California to cause cancer and birth

defects or other reproductive harm. To

minimize exposure, avoid breathing exhaust,

do not idle the engine except as necessary,

service your equipment in a well-ventilated

area and wear gloves or wash your hands

frequently when servicing your equipment.

For more information go to

www.P65Warnings.ca.gov.

(000394)

WARNING

Breathing diesel engine exhaust exposes you

to chemicals known to the State of California

to cause cancer and birth defects or other

reproductive harm.

• Always start and operate the engine in a

well-ventilated area.

• If in an enclosed area, vent the exhaust to

the outside.

• Do not modify or tamper with the exhaust

system.

• Do not idle the engine except as necessary.

For more information go to

www.P65Warnings.ca.gov/diesel.

Owner’s Manual for Stationary Generators iii

Section 1: Safety

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

Read this Manual Thoroughly .....................................1

Safety Alerts .........................................................1

Safety Information ...............................................1

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

Exhaust Hazards ..................................................2

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

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

Explosion Hazards ...............................................3

Section 2: Specifications

Emission Information ..........................................5

Emissions Data Plate ..................................................5

Specifications ......................................................6

Engine .........................................................................6

Engine Oil Recommendations ............................7

Coolant Water Treatment ....................................7

Fuel Requirements ..............................................7

Fuel Maintenance ........................................................7

Battery Requirements .........................................8

Battery Charger ...........................................................8

Battery Disposal ..................................................8

Corrosion Protection ...........................................8

Accessories ..........................................................8

Section 3: Activation and Startup

Orientation ..........................................................11

Remove Side Access Panels ............................11

Prime Fuel System .............................................11

2.5L Models ...............................................................12

Open Viewing Window ......................................12

Start and Run Engine ........................................13

Test Engine Shutdown Switch Operation .......13

Activate Unit ......................................................14

Operational Checks ........................................... 15

Self Test ....................................................................15

Check Manual Transfer Switch Operation .................15

Electrical Checks .......................................................15

Test Generator Under Load ......................................16

Check Automatic Operation ......................................16

Final Instructions .............................................. 17

Shutting Generator Down While Under Load

Or During A Utility Outage ................................ 17

Section 4: Operation

Control Panel ..................................................... 19

Auto/Manual/Off ................................................. 20

Menu Navigation ................................................ 20

Alarm/Warning Conditions ............................... 22

Change Time and Date ...................................... 22

Programmable Timers ...................................... 22

Dealer Programmable ...............................................22

User Programmable ..................................................22

USB Port for Firmware Updates ....................... 22

Battery Charger ................................................. 23

Transfer Switch Automatic

Operation ........................................................... 23

Automatic Sequence of Operation ............................23

Transfer Switch Manual

Operation ........................................................... 24

Transfer to Generator Power .....................................24

Transfer Back to Utility Power ...................................25

Table of Contents

iv Owner’s Manual for Stationary Generators

Section 5: Maintenance

Component Locations .......................................27

Access Panels ....................................................29

Removal .................................................................... 29

Installation ................................................................. 29

Service Maintenance Intervals .........................29

Remove From Service .......................................30

30 Hour Break-In ................................................31

Daily Maintenance (If Running Continuously)

....31

Schedule A Maintenance ..................................31

Preliminary Instructions ............................................. 31

Check Fuel Level and Fill .......................................... 31

Drain Fuel Filter and Check Fuel Lines/Hoses ......... 32

Check Coolant Level and Hoses ............................... 32

Check Radiator for Clogging ..................................... 32

Check Lubricating Oil Level ...................................... 33

Check Battery Condition/Fluid Level ......................... 33

Battery Replacement ................................................ 34

Check and Adjust V-Belt ........................................... 34

Adjust V-Belt Tension ............................................... 35

Replace Air Filter Element—2.5L Engine ........36

Replace Air Filter Element—2.2L Engine ........36

Lubricate Governor Rod Linkage

(2.5L Engine) ......................................................37

Final Instructions ....................................................... 37

Schedule B Maintenance ..................................37

Replace Lubricating Oil and Oil Filter ....................... 37

Drain Fuel Filter and Check Fuel Lines/Hoses ......... 38

Prime Fuel System .................................................... 38

Drain/Flush Coolant System ..................................... 38

Final Instructions ....................................................... 39

Schedule C Maintenance ..................................40

Return To Service ..............................................40

Section 6: Troubleshooting

Engine Troubleshooting ................................... 41

Controller Troubleshooting .............................. 42

Removal From Service During

Utility Outages.................................................... 43

Storage ............................................................... 43

Prepare For Storage ................................................. 43

Return From Storage ................................................ 44

Attention After Submersion ............................. 45

Attention After Fuel Spillage ............................ 45

Contaminated Fuel Disposal ............................ 45

Owner’s Manual for Stationary Diesel Generators 1

Safety

Section 1: Safety

Introduction

Thank you for purchasing this stationary automatic

standby generator set. Every effort was made to ensure

that the information in this manual was both accurate and

complete at the time it was released. However, the

manufacturer reserves the right to change, alter or

otherwise improve this product at any time without prior

notice.

This generator is designed to automatically supply

electrical power to operate critical loads during a utility

power failure. The unit is factory installed in an all-

weather metal enclosure and is intended exclusively

for outdoor installation using only diesel fuel.

When properly sized, the generator is suitable for

supplying typical residential/commercial loads, such as

induction motors (sump pumps, refrigerators, freezers,

air conditioners, furnaces, etc.), electronic components

(computers, monitors, televisions, etc.), lighting,

microwaves, and other residential and business loads.

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.

Read this Manual Thoroughly

The operator is responsible for proper and safe use of

this equipment. Read and thoroughly understand the

contents of this manual before attempting to use the

equipment. If any portion of this manual is not fully

understood, contact the nearest Independent Authorized

Service Dealer (IASD) for assistance.

SAVE THESE INSTRUCTIONS: The manufacturer

suggests that this manual and the rules for safe operation

be copied and posted near the generator installation site.

Safety should be stressed to all operators and potential

operators of this equipment.

Safety Alerts

Throughout this manual, 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, function or service that may

be hazardous if performed incorrectly or carelessly.

Observe them carefully. Their definitions are as follows:

NOTE: Notes contain additional information important to

an operation or procedure.

These “Safety Alerts” cannot eliminate the hazards that

they signal. Strict compliance with these special

instructions, plus common sense, are major accident

prevention measures.

Safety Information

Study these safety rules carefully before operating or

servicing this equipment. Become familiar with this

Owner’s Manual and with the unit. The generator can

operate safely, efficiently and reliably only if it is properly

installed, operated and maintained. Many accidents are

caused by failing to follow simple rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warnings

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 the manufacturer does not

specifically recommend, ensure that it is safe for

personnel. Also make sure the procedure, work method

or operating technique used does not render the

generator unsafe.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

(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

2Owner’s Manual for Stationary Diesel Generators

General Hazards

•Inspect the generator regularly, and contact the

nearest Independent Authorized Service Dealer for

parts needing repair or replacement.

Exhaust Hazards

•The generator must be installed and operated

outdoors only.

(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.

(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.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and

appendages away from moving parts. Failure

to do so could result in death or serious injury.

(000115)

WARNING

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

Risk of injury. Do not operate or service this machine

if not fully alert. Fatigue can impair the ability to service

this equipment and could result in death or serious

injury. (000215)

(000130)

WARNING

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

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. (000216)

WARNING

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. (000247a)

(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.

Asphyxiation. Running engines produce

carbon monoxide, a colorless, odorless,

poisonous gas. Carbon monoxide, if not

avoided, will result in death or serious injury.

(000103)

DANGER

(000178a)

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.

WARNING

(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.

Safety

Owner’s Manual for Stationary Diesel Generators 3

Electrical Hazards

•The generator may crank and start at any time

when utility power is lost. When this occurs, load

circuits are transferred to the STANDBY

(generator) power source. Before working on the

generator, always move the Main Circuit Breaker

switch on the control panel down to the OFF

(Open) position, press the OFF key on the control

panel keypad, remove the 7.5 amp fuse, and

disconnect the negative battery cable (black) from

the negative (-) battery terminal.

Fire Hazards

•Comply with regulations of the Occupational Safety

and Health Administration (OSHA). Also, ensure

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.

Explosion Hazards

IMPORTANT NOTE: If this generator is used to power

electrical load circuits normally powered by a utility power

source, it is required by code to install a transfer switch.

The transfer switch must effectively isolate the electrical

system from the utility distribution system when the gen-

erator is operating (NEC 702). Failure to isolate an elec-

trical system by such means will result in damage to the

generator and also may result in injury or death to utility

power workers due to backfeed of electrical energy.

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running 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.

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so 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.

(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.

WARNING

Fire and explosion. Installation must comply

with all local, state, and national electrical

(000218)

building codes. Noncompliance could result in unsafe

operation, equipment damage, death or serious injury.

WARNING

Fire hazard. Use only fully-charged fire

(000219)

extinguishers rated “ABC” by the NFPA. Discharged or

improperly rated fire extinguishers will not extinguish

electrical fires in automatic standby generators.

(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.

Safety

4Owner’s Manual for Stationary Diesel Generators

This page intentionally left blank.

Owner’s Manual for Stationary Diesel Generators 5

Specifications

Section 2: Specifications

Emission Information

The U.S. Environmental Protection Agency (EPA)

requires that the generator comply with exhaust emission

standards. The generator is certified to meet the

applicable EPA emission levels, and is certified for use as

a stationary engine for standby power generation. Any

other use may be a violation of federal and/or local laws.

To ensure that the engine complies with the applicable

emission standards for the duration of the engine’s life, it

is important to follow the maintenance specifications in

Section 5. This generator is certified to operate on Ultra-

Low Sulfur Diesel Fuel No. 2 (KSM2610).

Emissions Data Plate

A data plate is riveted to the cylinder head cover to verify

compliance with EPA emissions regulations.

Figure 2-1. Emissions Data Plate on Cylinder Head Cover (Sample)

006367

Specifications

6Owner’s Manual for Stationary Diesel Generators

Specifications

Engine

A complete specification sheet is included in the documentation provided with the unit at the time of purchase. For

additional copies, consult your local Independent Authorized Service Dealer (IASD).

General 2.5L Engine 2.2L Engine

Engine System

Type 4 cylinder, in-line, 4 cycle 4 cylinder, in-line, 4 cycle

Fuel Type Ultra Low Sulfur Diesel Ultra Low Sulfur Diesel

Fuel Filtering 6 Microns 25 Microns (maximum)

Bore and Stroke 3.30 in x 3.90 in (84 mm x 100 mm) 3.30 in x 3.90 in (84 mm x 100 mm)

Displacement 152.86 cubic inches (2.505 liter) 135.2 cubic inches (2.216 liter)

Firing Order 1-3-4-2 1-3-4-2

Direction or Rotation CCW - As Viewed From Flywheel CCW - As Viewed From Flywheel

Dimensions L x W x H 615 mm x 492 mm x 623 mm

(24.21 in x 19.37 in x 24.53 in)

662 mm x 489 mm x 698 mm

(26.1 in x 19.3 in x 27.5 in)

Dry Weight 375 lb (170 kg) 507.1 lb (230 kg)

Compression Ratio 22: 1 21.3 : 1

Cooling System

Water Pump Pre-Lubed, Self-Sealing Pre-Lubed, Self-Sealing

Drive Belt Belt

Thermostat Full Open Temperature:

170 F (76.5° C)

Full Open Temperature:

180° F (82° C)

System Coolant Capacity 3.0 gal (11.44 liter) 2.5 gal (9.5 liter)

Coolant Flow Rate 17 gal (65 liter)/min at 1800 RPM 14.8 gal (56.2 liter)/min at 1800 RPM

Lubricating System

Oil Pump Type Gear Gear

Oil Filter Type Full Flow Spin-On Canister Full Flow Spin-On Canister

Oil Cooler Not Applicable Installed

Crankcase Capacity 6.87 qt. (6.5 liter) 11.2 qt. (10.6 liter)

Lubricating Oil 15W-40 15W-40

Oil Fill Location Filler Cap on Valve Cover and/or Front Engine Cover Filler Cap on Valve Cover and/or Front Engine Cover

Oil Drain Location Oil Pan, Bottom Side Oil Pan, Bottom Side

Intake and Exhaust System

Intake Air System Naturally Aspirated Turbocharged / Aftercooled

Maximum Allowable

Intake Restriction 7.87 in. of Water (1.96 kPa) 20 in. of Water (5.0 kPa)

Maximum Allowable

Exhaust Back Pressure 26.8 in. of Water (6.67 kPa) 41 in. of Water (10.2 kPa)

Breather Closed Crankcase System Open Crankcase System

Other Specifications

Operating Temperature Range -20° F to 120° F (-29° C to 49° C) -20° F to 120° F (-29° C to 49° C)

POWER ADJUSTMENT FOR AMBIENT CONDITIONS

Temperature Deration3% for every 5 °C above 25 °C or 1.7% for every 5 °F above 77 °F

Altitude Deration (15 & 30 kW)1% for every 100 m above 915 m or 3% for every 1000 ft above 3000 ft

Altitude Deration (20 kW) 1% for every 100 m above 305 m or 3% for every 1000 ft above 1000 ft

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