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Maintenance

Owner’s Manual for 50 Hz Air-Cooled Generator Sets

25

Section 4: Maintenance

Maintenance

Regular  maintenance  will  improve  performance  and 
extend  engine/equipment  life.  Pramac  recommends  all 
maintenance work be performed by an IASD. 

Prepare Generator Set for 

Maintenance

Generator Set Enable/Disable Procedure

NOTE: 

If  generator  set  is  running,  follow  procedure

 

Shutting Generator Set Down While Under Load Or 
During A Mains Power (Utility) Outage

.

To turn generator set OFF:

1.

Press OFF mode button on control panel.

2.

Set MLCB (generator disconnect) on generator set 
to OFF (OPEN).

3.

Turn  off  mains  power  supply  to  transfer  switch

 

using the means provided (such as a main line util-
ity breaker).

4.

Remove 7.5A fuse from the control panel.

5.

Follow maintenance procedure(s).

To turn generator set back ON:

NOTE: 

If generator set was running before maintenance 

refer  to  “To Turn The  Generator  Set  Back  On”  in 

Shut-

ting Generator Set Down While Under Load Or 
During A Mains Power (Utility) Outage

.

1.

Turn  on  mains  power  supply  to  transfer  switch 
using the means provided.

2.

Install 7.5A fuse in control panel.

3.

Press AUTO mode button on control panel.

4.

Set MLCB (generator disconnect) on generator set 
to ON (CLOSED).

5.

Close and lock lid if maintenance is complete.

The system is now in automatic mode. 

Enclosure Panel Removal

Maintenance  procedures  may  require  removal  of  front 
panel or intake side panel. The following procedures out-
line  the  removal  process.  Remove  these  panels  only  if 
directed to do so in the specific maintenance procedure

 

to be performed.

Front Access Panel Removal

See 

Figure 4-1

. Remove front access panel (A) by lifting

 

it straight up and out once lid is open.
Always lift front access panel straight up before pulling it 
away from enclosure. Do not pull panel away from enclo-
sure before lifting up (B).

Figure 4-1. Remove Front Access Panel

Only qualified service personnel may
install, operate, and maintain this
equipment.

ISO000182a

Automatic start-up. Disconnect mains
power and render the equipment
inoperable before attempting repairs
or maintenance.

ISO000191a

005628

A

B

Summary of Contents for GA20000

Page 1: ...oled Generator Sets 20 kVA Original Instructions SAVE THIS MANUAL FOR FUTURE REFERENCE Register your Pramac product at www activategen com This product is not intended to be used in a critical life support application ISO000209b ...

Page 2: ...ntenance Correct maintenance and care of the generator set 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 all maintenance for safe operation is performed promptly and to have the equipment inspected periodically by an IASD Normal maintenance service and replacement of parts are the responsibi...

Page 3: ...O 8528 1 2005 Application ratings and performance ISO 8528 5 2013 Generating sets IEC 60034 1 2010 Rotating electrical machines Part 1 Rating and performance Harmonised Standards applied for Outdoor Noise Emission Directive 2000 14 EC ISO 8528 10 1998 Measurement of airborne noise by the enveloping surface method EN ISO 3744 1995 Determination of sound power levels and sound energy levels of noise...

Page 4: ...iv Owner s Manual for 50 Hz Air Cooled Generator Sets This page intentionally left blank ...

Page 5: ... The LCD Panel 18 Menu System Navigation 19 Setting the Exercise Timer 21 Emergency Stop 21 Operating Modes 21 Manual 21 Auto 21 Exercise 22 Manual Transfer Operation 22 Transfer to Generator Set Power Source 22 Transfer to Mains Power Source 22 Automatic Transfer Operation 23 Automatic Sequence of Operation 23 Mains Utility Power Failure 23 Cranking 23 Cold Smart Start 23 Cleaning Cycle 23 Load T...

Page 6: ...he Sediment Trap 33 Attention After Submersion 33 Corrosion Protection 33 Remove From and Return To Service 33 Remove From Service 33 Return to Service 34 Decommissioning 34 Section 5 Troubleshooting Quick Reference Guide Generator Set Troubleshooting 35 Quick Reference Guide 36 Section 6 Servicing Centers ...

Page 7: ...e used in conjunction with all other supporting product documentation supplied with the product SAVE THESE INSTRUCTIONS for future reference This manual contains important instructions that must be fol lowed during placement operation and maintenance of the unit and its components Always supply this manual to any individual that will use this unit and instruct them on how to correctly start operat...

Page 8: ...ep 1 Unit set for Natural Gas NG operation Step 2 Press and rotate fuel selector 180 to change fuel type Step 3 Unit set for Liquid Propane LPG operation NOTE This decal is intended to be discarded after installation and need not be replaced if missing E Shock Hazard Read The Manual Live components carrying potentially lethal voltages may be accessible inside Render the equipment safe before attem...

Page 9: ...e manual completely before installing or operating this equipment Do not smoke near this equipment Do not allow open flames near this equipment J Read Owner s Manual Read the manual for an explanation of this device K Lifting Point Install lifting attachments to this location and only this location Do not connect lifting device directly to the lift point L Pinch Point Keep hands clear of these are...

Page 10: ...Safety Information 4 Owner s Manual for 50 Hz Air Cooled Generator Sets Figure 1 1 Safety Decals A B C E F H J K G D L E M P N Q K K 005771 ...

Page 11: ... load Do not open the generator set enclosure while the generator set is running ISO000533 Read instruction manual Read and understand manual completely before using this equipment ISO000100a Refer to local codes and standards for safety equipment required when working with a live electrical system ISO000257 Only qualified service personnel may install operate and maintain this equipment ISO000182...

Page 12: ... s instructions ISO000178a Connection of fuel source must be completed by a qualified professional technician or contractor ISO000151a The generator set must be installed and operated outdoors only ISO000525 Fuel and vapors are extremely flammable and explosive No leakage of fuel is permitted Keep fire and spark away ISO000192 Use only approved switchgear to isolate generator from the normal power...

Page 13: ...ting equipment After equipment shutdown allow sufficient time for surfaces to cool prior to contact ISO000108 Asphyxiating atmosphere Carbon monoxide a colorless odorless poisonous gas is emitted in engine exhaust while equipment is running Avoid inhalation of exhaust gases ISO000103 Pinch point Keep hands clear of these areas when installing the front panel or closing the roof ISO000526 Inspect t...

Page 14: ...in or eyes flush with water and seek immediate medical attention ISO000163a Avoid water contact with a power source ISO000104 Disconnect the negative battery cable then the positive battery cable when working on unit ISO000130 Disconnect battery ground terminal before working on battery or battery wires ISO000164 Always recycle batteries at an official recycling center in accordance with all local...

Page 15: ...shutdown procedure in Shut ting Generator Set Down While Under Load Or During A Mains Power Utility Outage before opening the enclosure This allows adequate cooling to reduce the risk of exposure to hot surfaces 006597 Figure 1 2 Hot Surfaces The enclosure provides protection against hot surfaces inside the generator set Hot surfaces may be present if the generator set has been operating under a l...

Page 16: ...Safety Information 10 Owner s Manual for 50 Hz Air Cooled Generator Sets This page intentionally left blank ...

Page 17: ...er F Oil drain K Status LED indicators O Sediment trap B Main line circuit breaker MLCB generator disconnect G Composite base L Oil filter P Fuel regulator C Airbox with air cleaner H Exhaust enclosure M Oil fill cap Q Fuel inlet D Control panel J Emergency stop N Oil dipstick R Wi Fi module E Battery compartment battery not supplied A C E B D H A L M N O P Q F J 005622 K G R ...

Page 18: ...10 Insulation Class 11 Power Factor 12 Controller Part Number 13 Country of Origin 14 Generator Duty Rating 15 Rated Ambient Temperature 16 Unbalanced Load Capacity 17 CE Conformity Marking 18 Generator Set Rated Power 19 Performance Class 20 Ambient Air Temperature 21 Degree of Protection 22 Approximate Mass Fuel Inlet Pressure Decal 1 Serial Number 2 LPG Minimum Inlet Pressure 3 LPG Maximum Inle...

Page 19: ... Sound pressure measurement uncertainty 1 dB A A Weighted sound power level LwA 94 dB A Sound power measurement uncertainty 1 dB A Normal operating range This unit is tested in accordance to ISO 8528 standards with an operating temperature of 29 C 20 F to 50 C 122 F For areas where temperatures fall below 0 C 32 F a cold weather kit is recommended There may be a decrease in engine power when opera...

Page 20: ...of these systems include Alarms High Temperature Low Oil Pressure Overcrank Overspeed Overvoltage Undervoltage Overload Underspeed RPM Sensor Loss Controller Fault Wiring Error Stepper Overcurrent Emergency Stop Warnings Charger Warning Charger Missing AC Low Battery Battery Problem Exercise Set Error USB Warning Download Failure The control panel contains a display which alerts opera tor when a f...

Page 21: ... lation manual for complete procedures and details Battery Requirements 12 volts Group 26R Wet Cell 540CCA minimum or Group 35 AGM 650CCA minimum not included with unit See Maintenance for correct battery maintenance procedures Battery Charger The battery charger is integrated into the control panel module in all models It operates as a smart charger ensuring output charging levels are safe and co...

Page 22: ...ere temperatures fall below 18 C 0 F Not necessary for use with AGM style batteries Recommended in areas where temperatures fall below 18 C 0 F Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on generator set along with oil recommendations See http www pramacparts com for more information Fascia Base Wrap The fascia base wrap snaps together around the bottom of the n...

Page 23: ...sure Generator Set Enclosure Opening the Lid See Figure 3 1 Two locks secure lid one on each side A Open protective rubber cap to access keyhole and press down on lid above side lock and unlock latch to correctly open lid Figure 3 1 Side Lock Location Repeat for other side Lid may appear stuck if pressure is not applied from top Always verify side locks are unlocked before attempting to lift lid N...

Page 24: ...see Setting the Exercise Timer Green LED on this button flashes when gener ator set is running as a result of a mains power loss MANUAL D Cranks and starts generator set Transfer to standby power will not occur unless there is a mains power failure Blue LED on this button illuminates when gen erator set is running in MANUAL mode LED flashes when generator set is running in MAN UAL mode and mains p...

Page 25: ...g Down Running Warning Warning Message Warning Message s Low Battery Exercise Set Error Service Schedule A Service Schedule B Inspect Battery Stopping FIRMWARE ERROR 9 Fuel Pressure Battery Problem Charger Warning Charger Missing AC Overload Warning SEEPROM ABUSE USB Warning Download Failure Overload Warning No WIFI Module No WIFI Router Comms No WIFI Server Comms Cranking Warning Warning Message ...

Page 26: ...e and time displayed for each occurence NOTE 3 Error code displayed for each Alarm Error Code and Alarm Message swap every 5 seconds Battery NOTE 1 Last 50 maintenance logs displayed NOTE 2 Date and time displayed for each occurence If enabled Refer to the Wi Fi manual for flow charts relating to Wi Fi If not enabled Displays SETUP WIFI Only if Wi Fi is disabled Date Time automatically updates if ...

Page 27: ...opera tions Follow appropriate procedures in this manual to correctly disable generator set during mainte nance and service operations This device is not intended to be a primary means of shutting down generator set See generator set shutdown sequence in Prepare Generator Set for Maintenance for correct shutdown procedures Proceed as follows to reset emergency stop 1 Pull out emergency stop button...

Page 28: ...ored shut down gener ator set and transfer to mains power source Proceed as follows to manually transfer to mains power and shut down generator set 1 Set main circuit breaker in distribution panel to OFF OPEN to remove all loads from generator set 2 To shut down generator set Allow generator set to run for 5 minutes at no load After 5 minutes use emergency stop button to shutdown generator set Wai...

Page 29: ...w a fixed temperature based on model upon startup in AUTO mode generator set will warm up for 30 seconds before a load is applied The generator set will start with normal warmup delay of five seconds if ambient temperature is at or above the fixed temperature A check for correct output voltage buildup is performed when generator set engine is started If some condition impedes normal voltage creati...

Page 30: ...nstall 7 5A fuse in control panel 2 Verify MLCB generator disconnect is OFF OPEN 3 Press AUTO mode button on the control panel 4 Generator set will start and run Allow generator set to run and warm up for a few minutes 5 Set MLCB generator disconnect to ON CLOSED 6 Close and lock lid 7 Set main circuit breaker in the distribution panel to ON CLOSED 8 Turn on mains power supply to transfer switch u...

Page 31: ...der Load Or During A Mains Power Utility Outage 1 Turn on mains power supply to transfer switch using the means provided 2 Install 7 5A fuse in control panel 3 Press AUTO mode button on control panel 4 Set MLCB generator disconnect on generator set to ON CLOSED 5 Close and lock lid if maintenance is complete The system is now in automatic mode Enclosure Panel Removal Maintenance procedures may req...

Page 32: ...n the Service Schedule for correct generator set operation Engine oil and oil filter must be changed and valve clear ance adjusted after first 25 hours of operation Emissions critical maintenance must be performed as scheduled in order for emissions warranty to be valid Emissions critical maintenance consists of servicing the air filter and spark plugs in accordance with the Service Schedule The c...

Page 33: ...lace spark plugs Inspect adjust valve clearance Inspect clean sediment trap See local codes and guidelines Contact nearest IASD for assistance if necessary Remove any shrubs or tall grasses which have grown within 0 91 m 3 ft of intake and discharge louvers on the sides of the enclosure Clean any debris dirt grass clippings etc which may have accumulated inside enclosure Verify all sources of pote...

Page 34: ...ner s Manual for 50 Hz Air Cooled Generator Sets Maintenance Log Battery Inspection And Charge Check Dates Performed Oil Oil Filter Air Filter And Spark Plug Replacement Dates Performed Valve Adjustment Dates Performed ...

Page 35: ...anges See Specifications NOTE Unit comes from factory filled with 5W 30 weight organic oil Changing the Oil and Oil Filter Proceed as follows to change oil and oil filter 1 Press MANUAL mode button on control panel to start engine and run it until thoroughly warmed up Press OFF mode button on control panel to shut down engine 2 Perform To turn the generator set OFF in Gener ator Set Enable Disable...

Page 36: ...aner cover 8 Perform To turn the generator set back ON in Generator Set Enable Disable Procedure Spark Plugs Proceed as follows to inspect spark plug s gap and replace spark plug s as necessary 1 Perform To turn the generator set OFF in Gener ator Set Enable Disable Procedure 2 Remove front panel 3 Clean area around base of spark plug s to keep dirt and debris out of engine 4 Remove spark plug s u...

Page 37: ...e generator set back ON in Generator Set Enable Disable Procedure Adjusting Valve Clearance Proceed as follows to adjust valve clearance 1 Perform To turn the generator set OFF in Gener ator Set Enable Disable Procedure 2 Remove front panel and intake side panel as described in Front Access Panel Removal and Intake Side Panel Removal 3 Turn off generator set fuel supply and disconnect negative bat...

Page 38: ...ables for tightness and corrosion Tighten and clean as necessary Figure 4 7 Battery Cables 4 Unsealed batteries only Completely disconnect battery Check battery fluid level and if necessary fill with distilled water only DO NOT use tap water Have an IASD or a qualified service technician check state of charge and condition 5 Connect battery cables and install intake side panel when inspection is c...

Page 39: ...duled maintenance should be conducted to perform a visual inspection of unit for corrosion Inspect all metal components of generator set including base frame brackets generator housing entire fuel system inside and outside of generator set and fastener loca tions If corrosion is found on generator set components for example regulator engine generator mounts fuel plenum etc replace parts as necessa...

Page 40: ...e button on control panel to stop unit 12 Press AUTO mode button on control panel The system is now in automatic mode NOTE If Wi Fi is not enabled exercise timer and current date and time must be reset when a battery is discharged or has been disconnected Decommissioning The generator set owner is responsible for correct de commissioning and disposal of this equipment when it has reached the end o...

Page 41: ...ure Verify fuel pressure to regulator is 2 49 2 99 kPa 10 12 in water column for LP gas and 0 87 1 74 kPa 3 5 7 0 in water column for NG Fuel selector in wrong position Set fuel conversion knob to correct position and program controller for fuel type Valve s out of adjustment Adjust valve clearance Internal engine issue Contact an IASD Unit is set to OFF but engine contin ues to run Controller wir...

Page 42: ...0 seconds LOW OIL PRESSURE RED Unit will not start in AUTO with mains power loss Check LEDs screen for alarms Check oil level and add oil as needed If oil level is correct contact an IASD RPM SENSE LOSS RED Unit will not start in AUTO with mains power loss Check LEDs screen for alarms Clear alarm Using control panel inspect battery by navigating to BATTERY MENU option from MAIN MENU If battery con...

Page 43: ...ays CHECK BATTERY replace battery BATTERY PROBLEM YELLOW Yellow LED illuminated in any state Check screen for additional information Contact an IASD CHARGER WARNING YELLOW Yellow LED illuminated in any state Check screen for additional information Contact an IASD SERVICE A YELLOW Yellow LED illuminated in any state Check screen for additional information Perform SERVICE A maintenance Press ENTER t...

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Page 45: ...Troubleshooting Quick Reference Guide Owner s Manual for 50 Hz Air Cooled Generator Sets 39 This page intentionally left blank ...

Page 46: ...Troubleshooting Quick Reference Guide 40 Owner s Manual for 50 Hz Air Cooled Generator Sets This page intentionally left blank ...

Page 47: ...apore 658079 Singapore Tel 65 6558 7888 Fax 65 6558 7878 PRAMAC CARIBE SRL Avda 27 de Febrero Esq Caonabo 664 Los Restauradores 10137 Santo Domingo Dominican Republic Tel 1 809 531 0067 Fax 1 809 531 0273 PRAMAC EUROPE SAS Place Léonard de Vinci 42190 St Nizier sous Charlieu France Tel 33 0 477 692 020 Fax 33 0 477 601 778 PRAMAC FU LEE FOSHAN No 25 Xinhui Road Wusha Daliang Shunde Foshan Guangdon...

Page 48: ... Inc All rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems Inc PR INDUSTRIAL s r l Località Il Piano snc 53031 Casole d Elsa Siena Italy Ph 39 0577 9651 ...

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