Generac Power Systems RD015 Bedienungsanleitung

Owner’s Manual

For

Stationary Diesel Generators

Residential and Commercial

Protector™Series

This manual should remain with the unit.

This manual must be used in conjunction

with the appropriate installation manual.

*NOT INTENDED FOR USE IN CRITICAL

LIFE SUPPORT APPLICATIONS.

*ONLY QUALIFIED ELECTRICIANS OR

CONTRACTORS SHOULD ATTEMPT

INSTALLATION!

*DEADLY EXHAUST FUMES! OUTDOOR

INSTALLATION ONLY!

Model

RD015 - 15 kW 60 Hz

RD020 - 20 kW 60 Hz

RD030 - 30 kW 60 Hz

RD048 - 48 kW 60 Hz (Single Phase Only)

RD050 - 50 kW 60 Hz (Three Phase Only)

0066781 - 30 kW 60 Hz

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 onto the sample

label printed here. The Unit Identification Label is

located at the rear of the alternator on 15/20 kW (2.3L)

units, and on the front engine mount on 30 kW (2.4L)

and 50 kW (3.4L) models. The label provides the follow-

ing information:

•Model Number

•Serial Number

•Rated KW

•Voltage Rating

•Maximum Current Rating (AMPS)

When contacting an Authorized Service Dealer 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 per-

formed promptly, and to have the equipment checked

periodically by an Authorized Service Dealer.

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, con-

tact an Authorized Service Dealer for assistance. Autho-

rized service technicians are factory-trained and are

capable of handling all service needs.

AUTHORIZED

SERVICE DEALER LOCATION

To locate the nearest

AUTHORIZED SERVICE DEALER,

please call this number:

1-800-333-1322

or visit the dealer locator at:

www.generac.com/Service/DealerLocator/

SAMPLE LABEL

Table of Contents

Owner’s Manual for Stationary Diesel Generators iii

Section 1 Safety

1.1 Introduction .......................................................................................................................... 1

1.2 Safety Information ................................................................................................................ 2

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

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

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

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

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

Section 2 Specifications

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

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

2.2 Specifications ....................................................................................................................... 6

2.2.1 Engine ...........................................................................................................................................6

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

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

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

2.5.1 Fuel Maintenance .........................................................................................................................8

2.5.2 Fuel Maintenance .........................................................................................................................8

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

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

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

2.8 Accessories .......................................................................................................................... 8

Section 3 Activation and Startup

3.1 Orientation .......................................................................................................................... 11

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

3.3 Prime Fuel System ............................................................................................................. 12

3.4 Install Battery ..................................................................................................................... 12

3.5 Open Viewing Window ....................................................................................................... 13

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

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

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

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

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

Table of Contents

iv Owner’s Manual for Stationary Diesel Generators

3.8.3 Electrical Checks ........................................................................................................................ 16

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

3.8.5 Check Automatic Operation ........................................................................................................ 17

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

Section 4 Operation

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

4.2 Auto/Manual/Off ..................................................................................................................19

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

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

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

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

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

4.6.1.1 Exercise Time ..................................................................................................................... 22

4.6.2 User Programmable ................................................................................................................... 23

4.6.2.1 Start-Up Delay Timer .......................................................................................................... 23

4.6.2.2 Warm-Up Delay Timer ........................................................................................................ 23

4.7 USB Port for Firmware Updates ........................................................................................23

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

4.9 Transfer Switch Automatic Operation ..............................................................................23

4.9.1 Automatic Sequence of Operation .............................................................................................. 24

4.9.1.1 Utility Failure ....................................................................................................................... 24

4.9.1.2 Cranking.............................................................................................................................. 24

4.9.1.3 Load Transfer...................................................................................................................... 24

4.10 Transfer Switch Manual Operation .................................................................................24

4.10.1 Transfer to Generator Power .................................................................................................... 25

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

Section 5 Maintenance

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

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

5.2.1 Removal ..................................................................................................................................... 29

5.2.2 Installation .................................................................................................................................. 29

5.3 Service Maintenance Intervals ..........................................................................................30

5.4 Remove From Service ........................................................................................................31

5.5 30 Hour Break-In .................................................................................................................31

Table of Contents

Owner’s Manual for Stationary Diesel Generators v

5.6 Daily Maintenance (If Running Continuously) ................................................................. 31

5.7 Schedule A Maintenance ................................................................................................... 32

5.7.1 Preliminary Instructions ..............................................................................................................32

5.7.2 Check Fuel Level and Fill ...........................................................................................................32

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

5.7.4 Check Coolant Level and Hoses ................................................................................................33

5.7.5 Check Radiator for Clogging .......................................................................................................34

5.7.6 Check Lubricating Oil Level ........................................................................................................34

5.7.7 Check Battery Condition/Fluid Level ...........................................................................................35

5.7.7.1 Check Condition and Clean ................................................................................................ 35

5.7.7.2 Check Fluid Level ............................................................................................................... 35

5.7.7.3 Check State of Charge........................................................................................................ 35

5.7.7.4 Battery Replacement .......................................................................................................... 35

5.7.8 Check and Adjust V-Belt .............................................................................................................37

5.7.8.1 Check.................................................................................................................................. 37

5.7.8.2 Adjust .................................................................................................................................. 38

5.7.9 Replace Air Filter Element ..........................................................................................................38

5.7.10 Drain Breather Canister and Replace Filter ..............................................................................38

5.7.11 Lubricate Governor Rod Linkage ..............................................................................................39

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

5.8 Schedule B Maintenance ................................................................................................... 40

5.8.1 Replace Lubricating Oil and Oil Filter .........................................................................................40

5.8.2 Replace Fuel Filter ......................................................................................................................41

5.8.2.1 Prime Fuel System.............................................................................................................. 41

5.8.3 Drain/Flush Coolant System .......................................................................................................41

5.8.4 Final Instructions .........................................................................................................................42

5.9 Schedule C Maintenance ................................................................................................... 43

5.10 Return To Service ............................................................................................................ 43

Section 6 Troubleshooting

6.1 Engine Troubleshooting .................................................................................................... 45

6.2 Controller Troubleshooting ............................................................................................... 46

6.3 Removal From Service During Utility Outages ............................................................... 47

6.4 Storage ................................................................................................................................ 47

6.4.1 Prepare For Storage ...................................................................................................................47

6.4.2 Return From Storage ..................................................................................................................48

6.5 Attention After Submersion .............................................................................................. 49

6.6 Attention After Fuel Spillage ............................................................................................. 49

6.7 Contaminated Fuel Disposal ............................................................................................. 49

Table of Contents

vi Owner’s Manual for Stationary Diesel Generators

(000005)

WARNING

California Proposition 65. This product contains or

emits chemicals known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

(000004)

WARNING

California Proposition 65. Engine exhaust and some of

its constituents are known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

Owner’s Manual for Stationary Diesel Generators 1

Section 1 Safety

1.1 — 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, mon-

itors, televisions, etc.), lighting, microwaves, and other residential and business loads.

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 Authorized Service Dealer for assistance.

SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rules for safe operation be cop-

ied and posted near the generator installation site. Safety should be stressed to all operators and potential operators of

this equipment.

SAFETY: 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:

INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS

INJURY.

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

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

NOTE: Notes contain additional information important to an operation or procedure.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of informa-

tion each indicates is as follows:

This symbol points out important Safety Information that, if not followed, could endanger personal safety and/or

property of others.

This symbol points out a potential Explosion Hazard.

This symbol points out a potential Fire Hazard.

This symbol points out a potential Electrical Shock Hazard.

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

2Owner’s Manual for Stationary Diesel Generators

1.2 — Safety Information

Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Man-

ual 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.

Despite the safe design of this generator, operating this equipment imprudently, neglecting its mainte-

nance or being careless can cause possible injury or death. Permit only responsible and capable per-

sons to install, operate and maintain this equipment.

Potentially lethal voltages are generated by these machines. Ensure steps are taken to make the

machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near a running generator.

The installation of this generator must always comply with applicable codes, standards, laws and regu-

lations.

A running generator gives off DEADLY carbon monoxide, an odorless, colorless, poisonous gas.

Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, head-

ache, vomiting, weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even

death.

The control panel for this unit is intended to be operated by qualified service personnel only.

1.3 — General Hazards

•For safety reasons, this equipment should only be installed, serviced and repaired by a Service Dealer or other

competent, qualified electrician or installation technician who is familiar with applicable codes, standards, regula-

tions and product Installation Manual guidelines. The operator also must comply with all such codes, standards,

regulations and product Installation Manual guidelines.

•The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in

sufficient concentrations, can cause unconsciousness or even death. DO NOT alter or add to the exhaust system

or do anything that might render the system unsafe or in noncompliance with applicable codes and standards.

•Install a carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.

•Adequate, unobstructed flow of cooling and ventilating air is critical for correct generator operation. Do not alter

the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation

of the generator. The generator MUST be installed and operated outdoors only.

•Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving or hot parts. Never remove any

drive belt or fan guard while the unit is operating.

•When working on this equipment, remain alert at all times. Never work on the equipment when physically or men-

tally fatigued.

•Inspect the generator regularly, and contact the nearest Dealer for parts needing repair or replacement.

•Before performing any maintenance on the generator, remove the control panel fuse and disconnect the Nega-

tive (-) battery cable to prevent accidental startup. When disconnecting battery cables always remove the NEGA-

TIVE (-) cable first. When reconnecting the cables, connect the POSITIVE (+) cable first.

•Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may

result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

Safety

Owner’s Manual for Stationary Diesel Generators 3

1.4 — Exhaust Hazards

•Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing

carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting,

weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even death. If any carbon monoxide

poisoning symptom is experienced, move into fresh air and immediately seek medical attention.

•This generator is designed for OUTDOOR installation ONLY. Never operate the generator inside any garage or

other enclosed space.

1.5 — Electrical Hazards

•All generators covered by this manual produce dangerous electrical voltages that can cause fatal electrical

shock. Utility power delivers extremely high and dangerous voltages to the transfer switch, as does the standby

generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc. while the unit is run-

ning. Ensure all appropriate covers, guards and barriers are in place, secured and/or locked before operating the

generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential

shock hazard.

•Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

•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 battery negative cable (black) from the battery neg-

ative (-) terminal.

•In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not

possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use

a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is

unconscious, apply first aid and get immediate medical help.

•Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,

or may get caught in moving parts resulting in injury.

1.6 — Fire Hazards

•For fire safety, the generator must be installed and maintained properly. Installation MUST always comply with

applicable codes, standards, laws, regulations and product Installation Manual guidelines. Adhere strictly to

local, state, and national electrical and building codes. 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.

•Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National Fire Protection

Association are appropriate for use on the standby generator. Keep the extinguisher properly charged and be

familiar with its use. Consult the local fire department with any questions pertaining to fire extinguishers.

1.7 — Explosion Hazards

•Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible mate-

rials are left in the generator compartment, or on or near the generator as FIRE or EXPLOSION may result. Keep

the area surrounding the generator clean and free from debris.

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 elec-

trical system from the utility distribution system when the generator is operating (NEC 702). Failure to

isolate an electrical 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.

Safety

4Owner’s Manual for Stationary Diesel Generators

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