Generac Mobile MGG450 Owner'S Manual Download

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Owner’s Manual for MGG450

Troubleshooting

Digital Controller Alarm Abbreviations

Abbreviation

Definition

Analog Input

Analog Output

ATS

Automatic Transfer Switch (switches load to supplied bus (by mains or generators)

AVR

Automatic Voltage Regulator

Binary Input

Binary Output

BOC

Breaker Open & Cool-down - protection type (see application manual for details)

BTB

Bus-Tie Breaker

CAN1

CAN bus for ComAp extension modules (e.g. IGS-PTM) and engine ECU connection

CAN2

CAN bus for communication between ComAp controllers and communication modules
connection (e.g. I-LB+)

COX

Application for Complex Systems where actions are taken by a PLC and controller
only follows orders => needs an external driver (cox)

Current Transformer

ECU

Engine Electronic Control Unit

ESF

Engine Specific File

Forward Synchronization

Synchronization of unloaded generator to mains (GCB closing process)

FMI

Failure Mode Identifier

Graphical Characters - option for additional support of one "graphical" language

GCB

Generator Circuit Breaker

CHP

Combined Heat & Power - co-generation application, usually with Nm engine

I-AOUT8

Extension module with 8 AO

I-CB

Communication Bridge - interfaces IS, IG/IS-NT, ID controllers and non-standard
engine ECU

IG-AVRi

IG Automatic Voltage Regulator interface

IG-EE

InteliGen for Electronic Engines (HW optimized for connection to an engine equipped
with ECU)

IG-EEC

InteliGen EE controller with extended communication possibi switchable sens-
ing ranges of AC voltages and currents

IG-IB

IG-Internet Bridge - for internet/ethernet communication

IGL-RA15

Indication panel with LEDs signalizing state of 15 BO

IG-NT

InteliGen New Technology gen-set controller

IG-NTC

InteliGen NT controller with extended communication possibi switchable sens-
ing ranges of AC voltages and currents

IGS-NT-LSM+PMS

Dongle for IG-XX and IS-NT to enable Load Sharing and VAr sharing control loops and
PMS

IGS-PTM

Extension module with 8 BI/BO, 4 AI and 1 AO

I-LB

Local Bridge – for direct and modem monitoring and control of multiple gen-sets

IM-NT

InteliMains New Technology - Mains supervision controller; the same controller with a
different SW configuration can work as a bus-tie synchronizer

I-RB

Relay Board

IS-AIN8

Extension module with 8 AI

IS-BIN8/16

Extension module with 8 BO and 16 BI

IS-NT

InteliSys New technology gen-set controller

IS-NT-BB

InteliSys New Technology Basic Box (without display)

KWP2000

Key Word Protocol of Scania S6 unit (for engine diagnostics)

LAI

Logical Analog Inputs (card in GenConfig which is used to assign source signal to con-
troller Logical Analog Input functions, e.g. Oil press)

Summary of Contents for MGG450

Page 1: ...SAVE THIS MANUAL FOR FUTURE REFERENCE Owner s Manual For Gaseous Generator MGG450 For technical assistance contact www generacmobileproducts com Technical Support 1 800 926 9768 ...

Page 2: ...upply the complete model number and serial number of the unit Operation and Maintenance Proper maintenance and care of the generator ensures a minimum number of problems and keeps operating expenses at a minimum It is the operator s responsibility to perform all safety checks to verify that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a...

Page 3: ...ns 15 Prestart Checklist 15 Starting the Generator 16 Automatic Fuel Switching 16 Natural Gas Only Operation 16 Non Commercial Well Gas Only Operation 16 LP Liquid Only Operation 17 Gaseous and LP Liquid Automatic mode Oper ation 17 50 Hz Operation 17 Operation Checks 17 Overcrank Shutdown 18 Emergency Stop Switch 18 Engine Oil Replenishment System 18 Generator Output Connections 18 Customer Conve...

Page 4: ... Digital Controller Alarm Abbreviations 33 Digital Controller List of Alarms 35 Wiring Diagrams and Service Log DC Controls Page 1 of 6 43 DC Controls Page 2 of 6 44 DC Controls Page 3 of 6 45 DC Controls Page 4 of 6 46 DC Controls Page 5 of 6 47 DC Controls Page 6 of 6 48 Relay Connections 49 AC Connections 50 Control Panel Layout 51 Control Faceplate 52 CAN Wiring 53 Receptacle 54 Service Log 55...

Page 5: ...y the complete model and serial number of the unit as given on the data decal located on the unit Record the model and serial numbers in the spaces provided on the front cover of this manual 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 pro...

Page 6: ...CAUTION 000229 Equipment or property damage Do not block air intake or restrict proper air flow Doing so could result in unsafe operation or damage to unit Explosion and Fire Hazards 000105 DANGER Explosion and Fire Fuel and vapors are extremely flammable and explosive Add fuel in a well ventilated area Keep fire and spark away Failure to do so will result in death or serious injury 000147 WARNING...

Page 7: ...ry Hazards 000188 DANGER Electrocution Do not wear jewelry while working on this equipment Doing so will result in death or serious injury 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 000162 WARNING Explosion Do not dispose of batteries in a ...

Page 8: ...4 Owner s Manual for MGG450 Introduction and Safety This page intentionally left blank ...

Page 9: ...2 K Engine oil filter 2 B Oil reservoir L Load center C Scrubbing unit M Black start power in D Scrubbing unit drain N Generator output connections E Oil leveler O Emergency stop button F Forklift pockets P Main circuit breaker G Battery 2 Q Control panel H Catalyst 2 R Fuel inlets 3 8 in LP fuel inlet and 2 in gaseous fuel inlet I Lifting eyes S Manual holder J Oil makeup filter Generator Compone...

Page 10: ... in m 253 x 102 x 131 6 43 x 2 59 x 3 33 Capacities gal L 92 87 gal L 38 144 Trailer 3 in lunette ring psi kPA 105 724 Specifications are subject to change without notice Refer to the product specification sheet for complete list Rated Engine Power Output Continuous Rated Engine Power Output Prime Operating Speed Displacement Fuel Consumption NG 100 Prime Fuel Consumption NG 100 Continuous Fuel Co...

Page 11: ...ult condition occurs the engine can shut down automatically and the display screen will show the fault that caused the shut down The fault condition must be resolved to resume unit operation This controller records a history of unit performance which may be viewed at any time and will not be lost when the controller is powered down E 001434 H A B C D F G Figure 2 3 Digital Controller Features A Al...

Page 12: ...TE It is the customer s responsibility to select the proper operating fuel using the site certification gas anal ysis data A B C E F G H I J K D L M 001435 Figure 2 5 Fuel Selection Screen A Indicates commercial natural gas fuel operation has been selected B Indicates low energy lower heating value or BTU ft3 non commercial fuel has been selected C Indicates high energy higher heating value or BTU...

Page 13: ...the cylinder associated with the knocking values D Engine knock monitor status Level 0 indicates engine has no knock Level 1 ON indicates current knock status only while unit is operating E Sensor failure indicator Level 0 indicates all knock sensors are functional Level 1 indicates knock sensor has failed Only applies to currently operating unit Ignition Secondary Voltage Display Screen A B 00143...

Page 14: ...mand regulator B 2 in NG fuel inlet shut off valve K NG pressure sensor C NG solenoids 2 L LPL lock off valve D LP vaporizers 2 M Service shut off valve E Primary pressure regulator N Main pressure gauge F Secondary pressure regulator O Overpressure lock out device G Cyclonic separator P Secondary pressure gauge H Coalescing filter Q Overpressure relief vent I Mixer Fuel System Components ...

Page 15: ...ge phase rotation and frequency of the connected electrical loads The generator connected electrical devices or both can be damaged if voltage phase and frequency are not compatible Engine Generator Protective Devices This unit has numerous sensors to provide the control system with the information it needs to protect both the engine and generator The control panel is designed to shut down the eng...

Page 16: ...n death serious injury or property damage 000349 WARNING Personal Injury Do not use lifting hook other than as directed Failure to do so could result in death serious injury or property damage 000350 The unit has three hoist rings located on top of the unit The center hoist ring is the main attachment point and the forward and aft are for redundancy Only lift the unit with a crane rated to lift th...

Page 17: ... test must be performed For more information contact Generac Mobile Products Technical Service Natural Gas Connections NOTE The unit can operate on 5 50 psig or 40 300 psig fuel supply pressure NOTE Using the utility supply requires remove of main pressure gauge and shut off of the 2 in ball valve directly upstream NOTE Installer must verify that all fuel connections comply with all building codes...

Page 18: ... 227 20 in 51 cm 11 in 28 cm 92 in 234 cm 58 in 147 cm 331 in 841 cm 224 in 569 cm 80 303 11 in 28 cm 6 in 15 cm 51 in 130 cm 32 in 81 cm 187 in 475 cm 127 in 323 cm 735 in 1867 cm 537 in 1364 cm 100 379 7 in 18 cm 4 in 10 cm 33 in 84 cm 21 in 53 cm 119 in 302 cm 81 in 206 470 in 1194 cm 343 in 871 cm 120 454 23 in 58 cm 15 in 38 cm 83 in 211 cm 56 in 142 cm 326 in 828 cm 238 in 605 cm 140 530 15 ...

Page 19: ...ion of this unit will result in death serious injury and property 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 Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit It is the responsibility of the owner to arrange for these pro...

Page 20: ...quid shut off valve filter screen is not plugged Natural Gas Only Operation Table 3 2 Gas Pressure Utility without scrubbing system not recommended for well gas use 5 psi 34 5 kPa minimum 50 psi 345 kPa maximum Well Gas with scrubbing system 40 psi 276 kPa minimum 300 psi 2068 kPa maximum Requires that everything upstream from the 2 in ball valve has been removed or bypassed If there is sufficient...

Page 21: ...de label select MANUAL mode and press ENTER 7 Push START If engine fails to start see General Troubleshooting Guide 50 Hz Operation The MGG450 is capable of operating at either 60 Hz or 50 Hz This is achievable by changing the basic settings of the generator the AVR configuration and the ignition mode The basic settings and ignition mode can be changed by pressing the 50 Hz ON soft button at the b...

Page 22: ...the crankcase When the engine oil level is low the float will trigger the reservoir tank to send fresh oil to the crankcase The regulator delivers only that amount of oil required to maintain a constant oil level in the crankcase A fine mesh screen in the regulator provides protection against damage by contaminants and abrasive foreign matter The regulator is pre set to the correct level at the fa...

Page 23: ...on on the controller will switch the main circuit breaker CLOSE IMPORTANT NOTE Do not use the buttons on the main circuit breaker to open or close the breaker Only use the buttons on the controller If the circuit breaker buttons are pressed the unit will shutdown immediately It is especially important to only use the controller when operating in a parallel configuration as the controller will dete...

Page 24: ... each genset is dependent on Nomin Power setting Parallel MGG450 to Other Gensets The MGG450 can be operated in parallel to other non Generac gensets The real portion kW of total electrical load will be divided among all gensets connected The reactive kVAr power can be shared by activating the droop CT in the alternator AVR The controller can communicate with other controllers via an analog signal...

Page 25: ...ture and Fuel Quality 60 Hz units Ambient Temperature Methane Number 77 F 25 C 86 F 30 C 95 F 35 C 104 F 40 C 113 F 45 C 122 F 50 C 35 250 232 221 211 186 156 40 250 248 237 226 201 171 45 266 263 253 242 217 187 50 281 279 268 258 233 203 55 297 295 284 273 248 218 60 300 295 288 283 264 234 65 300 295 288 283 275 249 70 300 295 288 283 275 265 75 300 295 288 283 275 270 80 300 295 288 283 275 27...

Page 26: ... or replaced tighten lugs in the order shown in Figure 3 5 1 6 4 7 2 5 3 8 001441 Figure 3 5 Lug Tightening Sequence 6 Start all lug nuts by hand First pass tighten to 20 25 ft lbs 27 33 Nm Second pass tighten to 50 60 ft lbs 67 81 Nm Third pass tighten to 90 120 ft lbs 122 162 Nm NOTE After the first road use re tighten the lug nuts in sequence Maximum recommended speed for highway towing is 45 m...

Page 27: ... been verified as correct close the Main Circuit Breaker MCB 7 Make a final visual inspection of the generator to verify proper operation Maintenance Regular maintenance will improve performance and extend engine equipment life Generac Mobile Products LLC recommends that all maintenance work be performed by a Generac Mobile Products Authorized Service Dealer GMP ASD Regular maintenance replacement...

Page 28: ... for conditions that could hinder performance or safety such as but not limited to oil coolant fuel leakage blocked vents loose or missing hardware and electrical connections Check for foreign matter blocking the vents and on top of unit When unit is not running Visually check belts for damage Coolant should be checked daily Coolant should be visible in the sight glass located near the top of the ...

Page 29: ...isk of burns Allow engine to cool before draining oil or coolant Failure to do so could result in death or serious injury Potential of cancer Prolonged or repeated contact with used motor oil has been shown to cause cancer in laboratory animals Thoroughly wash exposed areas with soap and water 000127a WARNING 000135 CAUTION Engine damage Verify proper type and quantity of engine oil prior to start...

Page 30: ... Electrolyte solution can cause burns and blindness If electrolyte contacts skin or eyes flush with water and seek immediate medical attention 000163a WARNING 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 000228 Environmental...

Page 31: ...tteries in series to give 1100 Amps at 24 volts connected in parallel to provide 2200 CCA at 24 volts Contact your local GMP ASD for correct battery size A new battery must be filled with the proper electrolyte and be fully charged before install Battery cables are connected to the generator at the factory Connect cables to battery posts as follows 000167a CAUTION Equipment damage Do not make batt...

Page 32: ...commended that experienced pipe assembly personnel pipe fitters perform all service on the pipes If pipe assemblies must be replaced Use proper sized fittings for the pressures relative to the high and low pressure sides of the regulator Use an appropriate thread sealant for the environment temp ranges fuel mix type detergents fuel oils etc Call Generac Mobile Products for a recommended sealant an...

Page 33: ...ve must have a minimum of 15 psi 103 4 kPa for the auto discharge to operate The drain hose at the bottom of the filter assembly will expel fluids collected through an outlet located at the left frame rail near the rear of the unit Collect and dispose of the fluids per local state and federal regulations NOTE Drains must be inspected occasionally and cleaned based on how dirty the fuel being scrub...

Page 34: ...ld temperatures will force the fan back into forward flow operation If the blockage is cleared the fan will return to reverse flow operation once the coolant and intake manifold temperatures return to normal If the blockage is not cleared with the change to forward flow the unit may shutdown due to high coolant temperature and or intake manifold temperature Battery Warmer Throttle Intake Manifold ...

Page 35: ...e load Remove one or more electrical loads Debris or dirt buildup on engine radiator Remove debris and clean engine surfaces to allow cooling No Output Voltage Circuit breaker tripped or failed Reset or replace circuit breaker Internal failure of alternator Check electrical connections High Output Voltage Excessive speed Verify engine RPM Check AVR adjustment Low Output Voltage Incorrect speed Ele...

Page 36: ...roller if failed Wiring incorrect Check wiring Voltage or Current Metering is Incorrect Controller programmed values are wrong Verify the controller programmed values are correct for the voltage sensing PT ratio and or current sensing CT ratio Ground is missing Verify that the battery supply DC negative conductor is properly grounded to the engine block i e to a common ground point Voltage sensing...

Page 37: ...dard engine ECU IG AVRi IG Automatic Voltage Regulator interface IG EE InteliGen for Electronic Engines HW optimized for connection to an engine equipped with ECU IG EEC InteliGen EE controller with extended communication possibilities switchable sens ing ranges of AC voltages and currents IG IB IG Internet Bridge for internet ethernet communication IGL RA15 Indication panel with LEDs signalizing ...

Page 38: ...ensures optimization of running gen sets on sites with multiple gen sets based on kW kVA spinning reserve or on relative load no mas ter system ensures high reliability Reverse synchronisation Synchronisation of loaded generator to mains MCB closing process RTC Real Time Clock SG Speed Governor SHAIN SHared virtual Analog INput module SHAOUT SHared virtual Analog OUTput module SHBIN SHared virtual...

Page 39: ... controller internal value See GenCon fig manual Protections Batt volt Indication of battery voltage protection activity This protection is based on Analog protect Batt V Batt V and Batt volt del setpoints Check if engine alternator or independent battery charger works properly EarthFaultCurr Indication of Earth fault current protection activity This protection is based on Gener protect EarthFault...

Page 40: ...me group18 ChrgAlternFail Charger fail detection This alarm means that voltage on the D terminal is lower than 80 of controller power supply voltage and it means that bat tery is no longer charged Check function of engine alternator or independent battery charger Sd Stop fail Engine stop fail indication Stop fail means that engine does not reach still engine state within Engine params Stop time St...

Page 41: ...2 Warning protection on AI Cylinder temperature 1 32 is active Check cor responding setpoints in the Engine protect group Wrn MCB fail MCB failure was detected Refer to Circuit breakers operation sequence GCB MCB fail detection chapter in IGSNT x y Reference Guide Stp GCB fail GCB failure was detected Refer to Circuit breakers operation sequence GCB MCB fail detection chapter in IGSNT x y Referenc...

Page 42: ...otSel is set to PHASE NEUTRAL BOC L1 L2 or L3 over Generator L1 L2 or L3 voltage was over the Gen V BOC limit for Gen V del time Overvoltage protections are based on Gener protect Gen V BOC and Gen V del setpoints This alarm is issued if voltage protections are based on phase to neutral voltages It means that Basic settings Fix VoltProtSel is set to PHASE NEUTRAL Sd L1 L2 or L3 over Generator L1 L...

Page 43: ...he Mains V MP limit for Mains V del time Overvoltage protections are based on Mains protect Mains V MP and Mains V del setpoints This alarm is issued if voltage protections are based on phase to phase voltages It means that Basic settings Fix VoltProtSel is set to PHASE PHASE Mains Avg x V If the value of 10 min average mains voltage of any phase Mains Avg V1 Mains Avg V2 Mains Avg V3 exceed value...

Page 44: ...ect Ishort level for Ishort del time BOC Overload Indicates overload IDMT protection activation Overload IDMT protection is inverse definite minimum time protection which is based on the genera tor power Protection reaction time depends on generator power value High generator overload means short reaction time whereas low generator overload means longer reaction time Protection is based on setpoin...

Page 45: ...cted in a wrong way or one of the voltage control related regulation loops is set in wrong way Warning is blocked if binary output functions AVR up or AVR down are configured Refer also to Volt PF control adjust ment chapter in an IGS NT x y Reference Guide G L neg8 Generator phase is inverted Check generator phases connection one of generator phases is connected the other way round swap generator...

Page 46: ...rs in the history of the con troller when the invalid password is used Fuel Not Ready Fuel mixer has not completed its 30 second reference run immediately after controller has been powered on OR No fuel has been selected but unit start has been attempted Clear alarm select fuel and restart unit MAPControlFLS Indicates an error with the closed loop control manifold air pressure of the air fuel feeb...

Page 47: ...Owner s Manual for Generator 43 Wiring Diagrams and Service Log Section 6 Wiring Diagrams and Service Log DC Controls Page 1 of 6 ...

Page 48: ...44 Owner s Manual for Generator Wiring Diagrams and Service Log DC Controls Page 2 of 6 ...

Page 49: ...Owner s Manual for Generator 45 Wiring Diagrams and Service Log DC Controls Page 3 of 6 ...

Page 50: ...46 Owner s Manual for Generator Wiring Diagrams and Service Log DC Controls Page 4 of 6 ...

Page 51: ...Owner s Manual for Generator 47 Wiring Diagrams and Service Log DC Controls Page 5 of 6 ...

Page 52: ...48 Owner s Manual for Generator Wiring Diagrams and Service Log DC Controls Page 6 of 6 ...

Page 53: ...Owner s Manual for Generator 49 Wiring Diagrams and Service Log Relay Connections ...

Page 54: ...50 Owner s Manual for Generator Wiring Diagrams and Service Log AC Connections ...

Page 55: ...Owner s Manual for Generator 51 Wiring Diagrams and Service Log Control Panel Layout ...

Page 56: ...52 Owner s Manual for Generator Wiring Diagrams and Service Log Control Faceplate ...

Page 57: ...Owner s Manual for Generator 53 Wiring Diagrams and Service Log CAN Wiring ...

Page 58: ...54 Owner s Manual for Generator Wiring Diagrams and Service Log Receptacle ...

Page 59: ...___________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ___________________________________________________________________...

Page 60: ...ts reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products LLC Generac Mobile Products LLC 215 Power Drive Berlin WI 54923 GeneracMobileProducts com 800 926 9768 920 361 4442 ...

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