Generac Power Systems Magnum MGG100M Operator'S Manual Download Page 70

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Wiring Diagrams

MGG100M Operating Manual

36833 C

CAM LOCKS

CIRCUIT

BREAKER

CAM

LOCK

PANEL

GND

CAM

LOCK

PANEL

GND

ALT

NOTE: REPEAT ALT CAM LOCK FOR THIRD SET.

TO LUG

BLOCK

GROUND

TO LUG

BLOCK

GROUND

90415_S_02.19.14

Summary of Contents for Magnum MGG100M

Page 1: ...OPERATOR MANUAL Parts manuals available online at www generacmobileproducts com 36833 C 11 16 GASEOUS GENERATOR MGG100M 02104...

Page 2: ...nmental 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...

Page 3: ...Intended Use Generac Mobile Products LLC recommends a trained and licensed professional perform all electrical wiring and testing functions Any wiring should be in compliance with the National Electri...

Page 4: ...This Page Intentionally Left Blank 36833 C MGG100M Operating Manual iv...

Page 5: ...iption 14 Intended Use 14 Generator 14 Generator and Load Compatibility 14 Load Imbalance Limits 14 H 100 Control Panel 15 Components 15 Left Display 15 Right Display 15 Emergency Stop Switch 16 Commo...

Page 6: ...ng Fuel Sources 29 Pipe Diameter and Fuel Flow Rate 30 Valve and Fitting Pipe Equivalents 32 Grounding Unit 33 Connecting Loads 33 Prestart Inspection 33 Operating Unit 34 Purging Air from Fuel Line 3...

Page 7: ...ngine Oil and Filter 50 Engine Coolant 50 Checking Coolant Level 51 Adding Coolant 51 Fan Belt 51 Fuel System 51 NG Fuel Filters 51 External Drain Ports 51 Particulate Filter 52 Moisture Separator Fil...

Page 8: ...This Page Intentionally Left Blank 36833 C MGG100 Operating Manual viii...

Page 9: ...pmentwasdesignedfor specific applications DO NOT modify or use this equipment for any application other than which it was designed Equipmentoperatedimproperlyorbyuntrainedpersonnelcanbedangerous Readt...

Page 10: ...ine Keep hands feet and loose clothing away from moving parts on the generator and engine Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire Batteri...

Page 11: ...Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention Spilled electrolyte i...

Page 12: ...weight to be carried by one axle which can cause premature wear on the tires and axles resulting in potentially unsafe operating conditions The trailer is equipped with electric surge brakes Check th...

Page 13: ...ings for the symbols used on the decals No open flames Read and understand the supplied operator s manual before operating unit Belt entanglement hazard keep body parts clear of this area Fan hazard k...

Page 14: ...Safety 6 MGG100M Operating Manual 36833 C This Page Intentionally Left Blank...

Page 15: ...s 12V 1 Battery rating 720 CCA Generator Brand Marathon Model 362PSL3185 Type insulation H Type Capacities Coolant incl engine qt L 22 0 20 8 Oil incl filter qt L 8 5 8 0 Oil Reservoir qt L 62 8 59 4...

Page 16: ...glycol can be used in place of ethylene glycol but do not mix the types Coolant capacity including engine 22 qt 20 8L WARNING Risk of burns Do not open coolant system until engine has completely coole...

Page 17: ...R MODEL XXX000 GAWR PNBE TIRE PNEU RIM JANTE GONF A FROID KPA PSI LPC SGL DUAL EACH AXLE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U S FEDERAL MOTOR VEHICLE SAFETY STANDAR...

Page 18: ...Information 10 MGG100M Operating Manual 36833 C Generator Data Label The generator data label is prominently displayed on the generator behind the NG fuel filters see Figure 4 Figure 4 Generator Data...

Page 19: ...nual 11 COMPONENT LOCATIONS Left Side Figure 5 Component Locations Left Side 1 Air filter 6 Manual holder 2 Lift structure 7 Oil filter 3 Oil reservoir 8 Oil fill 4 Catalyst exhaust muffler 9 Coolant...

Page 20: ...controller 2 Coolant pressure cap 9 H 100 controller 3 Coolant drain 10 Main circuit breaker MLCB 4 Engine oil drain 11 Customer disconnect switch box 5 Dipstick 12 Connection lugs with cam locks 6 Ba...

Page 21: ...LPL solenoid valve vent 13 Moisture separator drain port 5 LPL vaporizer and regulator 14 Particulate filter drain port 6 Wellhead gas A F solenoid valve 15 LPL solenoid shut off valve 7 Wellhead gas...

Page 22: ...erators with a four pole rotor are driven at a rated speed of 1 800 rpm to supply a frequency of 60 Hertz See the generator data label for rated AC volts watts amperes and number of phases The generat...

Page 23: ...ht display The left display can be configured to display different menus Default items are current operating volts amperes kilowatts and frequency See the H 100 Control Panel Operations Manual for mor...

Page 24: ...l output function 1 COMMON ALARM activates under alarm conditions Digital output function 2 COMMON WARNING activates under warning conditions Note DTC faults do not activate the alarm horn See Unit Al...

Page 25: ...ED remains on if the alarm or warning condition is acknowledged but still active Setting the Internal Clock The H 100 control panel contains an internal clock that tracks date and time The clock is us...

Page 26: ...shutdown set at 70 kW five second delay Our testing indicates that knocking can start to occur at loads above 70 kW To operate the unit above 70 kW an adjustment must be made within the generator cont...

Page 27: ...o disconnect power to the convenience receptacles use the individual circuit breakers located near each receptacle When the MLCB is OFF O power does not flow between the generator and connection lugs...

Page 28: ...rtant to follow the maintenance specifications in the manual to ensure that the engine complies with the applicable emissions standards for the duration of the product s life FUEL SYSTEM Note The igni...

Page 29: ...ts and uses the primary fuel source provided it is available The primary fuel source is available when input pressure in the primary fuel line is at or above 30 PSI 207 kPa Note Input pressure is fuel...

Page 30: ...top beacon indicates what fuel source is currently in use See table below Low Fuel Pressure Warning The NG fuel system is equipped with a low fuel pressure warning the LPL fuel system is not If input...

Page 31: ...e unit enabling the unit to start and run The unit runs on LPL until the pumpjack delivers NG to the fuel system at or above 30 PSI 207 kPa at which point the unit switches to the NG fuel source See P...

Page 32: ...rich for at least one minute Diagnostic trouble codes do not generate audible alarms They display the Malfunction Indicator Light MIL message CHECK ENGINE on the H 100 control panel display Figure 17...

Page 33: ...rm warning or DTC first becomes active If a shutdown alarm is active and an alarm or warning is not acknowledged the displays will flash with the Alarm LED To view the alarm warnings pages 1 Press MEN...

Page 34: ...00 controller display Note The manufacturer recommends notifying a GMPASD of any alarm warning condition so qualified service personnel can examine the situation Shutdown alarms are cleared as follows...

Page 35: ...Service if you have any questions The procedures in this manual are suggestions The owner operator is responsible for ensuring these procedures are executed by licensed contractors according to all a...

Page 36: ...operation as follows On level stable ground Outdoors and in a well ventilated location A safe distance from doors windows and ventilation equipment which can draw in exhaust DANGER ASPHYXIATION RUNNIN...

Page 37: ...fuels without both sources connected the unit may shut off immediately stopping power to the output connections See Fuel System for more information Connect fuel sources as follows 1 Select pipes app...

Page 38: ...e for required flow rate Table 1 NG Flow Rate Ft3 Hr At Pipe Length Pipe Length Feet Iron Pipe Size Diameter 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 4 6 8 15 73 165 332 722 1174 2386 3704 6253 13352 37229 30...

Page 39: ...art Liquid Propane Flow Iron Pipe Size Diameter 1 4 3 8 1 2 3 4 1 1 1 4 1 1 2 Schedule Schedule Schedule Schedule Schedule Schedule Schedule GPH 40 80 40 80 40 80 40 80 40 80 40 80 40 80 10 729 416 15...

Page 40: ...4 3 0 2 8 3 8 3 7 90 Screwed Elbow 1 8 1 6 2 3 2 1 3 1 2 9 3 7 3 4 4 6 4 4 5 3 5 1 6 9 6 5 Screwed T Thru Run 1 4 1 3 1 7 1 6 2 4 2 3 2 8 2 6 3 6 3 3 4 2 4 0 5 4 5 0 Screwed T Thru Branch 4 6 4 0 5 6...

Page 41: ...m flammable or combustible material Verify no load is connected to unit Inspect engine and genset verify there are no loose wires or components Tighten if necessary Inspect generator windings for mois...

Page 42: ...See Fuel System for more information Starting Unit The intended use is MANUAL mode key switch position MAN See Equipment Description for more information MANUAL Mode 1 Turn key switch to MAN The unit...

Page 43: ...ration speed verify the voltage setting is correct and adjust if necessary WARNING Do not connect or disconnect a fuel source while the engine is running Shutting Down Unit CAUTION Equipment Damage Th...

Page 44: ...Down 1 Verify the MLCB is OFF O 2 Pull the EMERGENCY STOP switch 3 On controller acknowledge the EMERGENCY STOP shutdown alarm See Unit Alarms and Warnings for more information 4 Turn key switch to OF...

Page 45: ...tomer Convenience Receptacles The customer convenience receptacle is attached to the outside of the customer disconnect switch box Figure 20 The receptacle is a 120VAC duplex outlet rated at 20A with...

Page 46: ...installation requirements could result in death serious injury and damage to equipment or property 000155 Connections to the lugs should be made by running the power cables up through the opening in...

Page 47: ...ustomer disconnect switch box These receptacles provide connection points for attachment of external loads to the generator WARNING It is HIGHLY RECOMMENDED that only a trained and licensed electricia...

Page 48: ...er operating safety The generator neutral is bonded to ground when it is shipped from the factory The bonding plate will need to be removed when the generator is used as a standby power source INSTALL...

Page 49: ...utility lines WARNING Incorrect installation of this generator set could result in property damage injury or death Connection of the generator to its fuel source must be done by a qualified professio...

Page 50: ...solution of 1 lb 454 grams bicarbonate of soda baking soda to 1 gal 3 8L of water The bicarbonate solution is to be added until evidence of reaction foaming has ceased The resulting liquid is to be f...

Page 51: ...cations for more information 5 Check the wheel lugs Tighten or replace any that are loose or missing If a tire has been removed for axle ser vice or replaced tighten the lugs in the order shown to the...

Page 52: ...Operation 44 MGG100M Operating Manual 36833 C This Page Intentionally Left Blank...

Page 53: ...y a GMP ASD See the emissions warranty CAUTION Verify timing is set correctly to 18 BTDC Failure to do so could result in irreparable damage to the unit See Ignition and Distributor Timing for more in...

Page 54: ...erating manual or engine service maintenance manual before performing any maintenance checks or service This maintenance schedule reflects the minimum tasks that need to be accomplished to ensure that...

Page 55: ...ator replace if necessary Remove valve covers and Inspect valvetrain for excess wear or abnormalities Check valve lash adjust if necessary if adjusted replace rocker nuts Have a GMPASD replace distrib...

Page 56: ...er hoses for deterioration Engine Oil At all times the engine oil dipstick should measure between FULL and ADD See Engine Oil Recommendations for more information About the Engine Oil Replenishment Sy...

Page 57: ...3 Fully insert dipstick into dipstick tube Visually confirm dipstick is fully inserted 4 Wait 10 seconds then remove dipstick 5 Examine oil level on both sides of dipstick The lower of the two levels...

Page 58: ...contact 10 Close engine oil drain valve and reinstall plug at the skid frame drain port 11 Remove oil fill cap on engine valve cover and add fresh oil See General Information for oil capacity and oil...

Page 59: ...000154 2 Add coolant to overflow jug according to the Coolant Recommendations until coolant level is between ADD And FULL Fan Belt Every 500 hours remove the fan belt and inspect it as follows Inspec...

Page 60: ...To monitor the condition of the filter cartridge check the Differential Pressure Indicator DPI Figure 25 Figure 25 Particulate filter Replace the filter cartridge as follows 1 Twist off filter body 2...

Page 61: ...ith the engine running close the manual valve 4 When the engine runs out of fuel turn the key switch to OFF and turn the battery disconnect switch to OFF 5 Loosen the hose clamps at the inlet and outl...

Page 62: ...ry cables and connections for cleanliness and corrosion Every six months a GMPASD should inspect the battery system as follows Check battery condition Check battery charge using a battery hydrometer R...

Page 63: ...the exhaust system Ignition and Distributor Timing All distributor servicing MUST be performed by a GMPASD Removal of the tamper resistant cap by anyone other than a GMPASD constitutes a violation of...

Page 64: ...toil Figure 26 Jack Lubrication Points Trailer Wheel Bearings The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the a...

Page 65: ...t controller after an emergency stop Resolve shutdown alarm condition Verify oil pressure reading correctly Engine starts but runs poorly Fuel or ignition problem Contact Generac Mobile Products Techn...

Page 66: ...greater horsepower rating than necessary to move the mechanical load High output voltage Faulty wiring Failed AVR module Check wiring Replace AVR module Electrical shock when frame is touched Static...

Page 67: ...FORMER COMMUNICATIONS PORT CROSSOVER CONNECTOR AUTOMATIC VOLTAGE REGULATOR DC CHARGE ALTERNATOR ALARM HORN CT_ CO COM AH1 ALT AVR LEGEND OIL TEMPERATURE CONNECTOR OTC AIR FUEL SOLENOID AFS OXYGEN SENS...

Page 68: ...8B 398C 399B 399A 399C J2 10 J2 9 J2 11 N TO GENERATOR MLCB L2 L1 L3 A B C N NB COMPONENTS LOCATED IN ALTERNATOR CONNECTION BOX WHITE WHITE WHITE J2 29 J2 6 J2 7 225 224 00 227 S1 S2 226 S3 IFT J2 17...

Page 69: ...1 573V WTS 2 68R MOD 1 809 GD 12 769 RB1A 2 445 SPLICE 3 15B 1 35 13 24 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 387 COM 2 DI3 TB1 8X 601 CO 9 183 TB1 2X R1...

Page 70: ...0M Operating Manual 36833 C CAM LOCKS CIRCUIT BREAKER CAM LOCK PANEL GND L0 L1 L3 L2 L1 L3 L2 CAM LOCK PANEL GND L0 L1 L3 L2 ALT NOTE REPEAT ALT CAM LOCK FOR THIRD SET TO LUG BLOCK GROUND TO LUG BLOCK...

Page 71: ...5A 15A 14 RB3A 1 CO 2 RB3A 4 CO 8 RS485 RS485 COMM PORT SHLD 0 0 0 0 FUSED DC X Y 2 1 3 5 4 6 7 8 TB2 1 SPLICE 4 0 0 TB1 1X CO 6 ENGINE RUN GND COMPONENTS LOCATED ON LOW VOLTAGE CUSTOMER CONNECTION PA...

Page 72: ...SWC 0 1 CHASSIS ECM 229 15E 0 15A SWC 3 3 J2 5 174 SW1 J2 28 175 4 CO B 3 B1 4 4 SWC ES1 0 229 2 15A 1 2 AH1 0 10 229 7 56A 445 J1 23 J1 34 15 R15B 256 15A GD 4 14 15A 14 15A 15A SC 56 15A RB1 4 15 3...

Page 73: ...COMPONENTS LOCATED ON ENGINE BATTERY 12V OS J1 5 J1 4 804 805 TB3 8X 0 14 C A B D 804 805 0 0 0 0 505 0 TB3 7Y J2 15 14 601 2 1 4 3 3 4 1 2 0 FSP 56 CO 9 56 OTC 3 TB3 1Y GA 3 WTS 3 WLS 3 56 0 16 13 13...

Page 74: ...573V CHASSIS ECM 0 79 J1 24 J1 25 69R J1 19 69V J1 20 GND 0 573R J1 29 0 68V 68R J1 15 J1 31 0 523V J1 9 GND GND J1 30 OTC 523R 0 523V 68R 0 573R 573V 14 TB3 8X DIST BAT 4 3 2 1 6 5 523V 1 68 68A 68R...

Page 75: ...MGG100M Operating Manual 67 TRAILER LIGHTS WHT BRN BRN GRN YEL 29 94 214 94 214 40 WHT 62 WHT BLK 115 WHT RED BLK WHT WHT BLK WHT BLK RED BLK WHT WHT BLK WHT BLK BRN 62 BRN WHT WHT 115 BRN 115 WHT 11...

Page 76: ...Wiring Diagrams 68 MGG100M Operating Manual 36833 C This Page Intentionally Left Blank...

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Page 84: ...hts reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products Generac Mobile Products 215 Power Drive...

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