CAC / BDP 8kW Owner'S Manual Download

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Study

Guide

S e r v i c e T r a i n i n G

air-cooled Training

Summary of Contents for 8kW

Page 1: ...Study Guide S e r v i c e T r a i n i n g Air Cooled Training...

Page 2: ......

Page 3: ...17 20kW Air cooled Automatic Standby Generators DANGER DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY Not intended for use as Primary Power in place of utility or in life support applications LISTED C...

Page 4: ...ol points out important safety infor mation that if not followed could endanger personal safety and or property of others This symbol points out potential explosion haz ard This symbol points out pote...

Page 5: ...ck Transfer Switch Operation 13 2 3 Electrical Checks 13 2 4 Generator Tests Under Load 14 2 5 Checking Automatic Operation 14 2 6 Engine Governor Adjustment 15 2 7 Voltage Regulator Adjustment 15 Sec...

Page 6: ...tem or do anything that might render the system unsafe or in noncompli ance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Ne...

Page 7: ...erator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncomp...

Page 8: ...ar stuck Always verify that the side lock is unlocked before attempting to lift the roof 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with...

Page 9: ...use as a stationary engine for standby power generation Any other use may be a violation of federal and or local laws It is important that to follow the maintenance specifica tions in the Maintenance...

Page 10: ...e Base Oil Filter Battery Compartment Fuel Regulator Fuel Inlet back Air Filter Circuit Breakers GFCI Outlet All 17 20kW Control Panel Figure 1 3 12 14 16 17 and 20kW V twin GT 990 GT 999 Engine door...

Page 11: ...as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent fo...

Page 12: ...plications Once the generator is installed verify that the fuel pressure NEVER drops below four 4 inches water column for natural gas or 10 inches water column for liq uid propane Prior to installatio...

Page 13: ...ed with the LP Liquid Propane position 6 Save this tool with the Owner s Manual 7 Install the battery door and close the roof 8 Reverse the procedure to convert back to natural gas Figure 1 4 Fuel Sel...

Page 14: ...evels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing This unit must be installed in accordance with current applicable NFPA 37 and NFPA...

Page 15: ...osure The transfer switch that may have shipped with the 20kW generator is enclosed in a NEMA 3R indoor outdoor rated enclosure Install the transfer switch indoors on a firm sturdy supporting structur...

Page 16: ...e flame or spark in battery area and Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is set to the OFF...

Page 17: ...Set the generator s main circuit breaker to its OFF or OPEN position 2 Set the generator s AUTO OFF MANUAL switch to the OFF position 3 Turn OFF all breakers on the load center of the transfer box T1...

Page 18: ...an 230 volts and frequency should be greater than 58 Hz 10 12 14 16 17 and 20kW voltage should be greater than 240 volts and frequency should be 60 Hz 11 Let the generator run at full rated load for 2...

Page 19: ...NITS NOTE All V twin units DO NOT require an engine gover nor adjustment due to their design 2 6 3 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corros...

Page 20: ...on the genera tor panel and on the transfer switch Figure 3 2 10 12 14 16 17 20kW Generator Control Panel ENTER ECS 3 1 2 SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer...

Page 21: ...ystems section for details 10 to 20KW DISPLAY INTERFACE MENUS The LCD display is organized as detailed below The Home page this page is the default page which will be displayed if no keys are pressed...

Page 22: ...nto a rest cycle for seven 7 seconds then continue the rest of the crank cycle During a rest cycle the start and fuel outputs are de energized and the magneto output is shorted to ground Cranking Cond...

Page 23: ...he generator and activate the transfer switch manually proceed as follows 1 Set the generator s AUTO OFF MANUAL switch to OFF 2 Set the generator s main circuit breaker to its OFF or OPEN position 3 T...

Page 24: ...tion 3 5 3 120 VAC GFCI OUTLET 15 AMP BREAKER 17 20 KW ONLY These models are equipped with an external 15 amp 120 volt GFCI convenience outlet that is located in a compartment on the right side of gen...

Page 25: ...rank the engine If no RPM signal is detected within the first three 3 seconds of cranking the Control Board will shut the engine down and latch out on RPM sensor loss If the RPM signal is detected the...

Page 26: ...e is wired in series with the battery out put lead to the panel If this fuse element has melted open the engine will not be able to crank or start Replace this fuse using only an identical 7 5 amp rep...

Page 27: ...2 Apply a light coating of clean engine oil to the gas ket of the new filter See the Specifications section for recommended filter 3 Screw the new filter on by hand until its gasket lightly contacts...

Page 28: ...out the old air filter and discard appropri ately 4 Install the new filter open end first into the air box 5 Swing the yellow door shut and snap to close 6 Replace door and close roof securely Figure...

Page 29: ...Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate...

Page 30: ...TE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place Install spark plugs Re attach the spark plug wire to t...

Page 31: ...N THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery See Specifications for type and size 4 Clean and wipe the entire generator 5 Make sure the 7 5A fu...

Page 32: ...NG Enclosure louvers X X W BATTERY Remove corrosion ensure dryness X X M Clean and tighten battery terminals X X M Check charge state X R EVERY 6 M Electrolyte level X R EVERY 6 M ENGINE AND MOUNTING...

Page 33: ...l pressure incorrect 3 Confirm fuel pressure to regulator is 10 12 water column 0 36 0 43 psi for LP and 5 7 water column 0 18 0 25 psi for natural gas 4 Fuel selector in wrong position 4 Move selecto...

Page 34: ...to select the the desired screen refer to the Menu System diagram 6 1 1 CHANGING SETTINGS EDIT MENU To change a setting such as display contrast go to the EDIT menu and use the keys to navigate to the...

Page 35: ...or Other 60 Hz The possible Status messages of the display are as follows Switched Off Time Date Ready to Run Time Date Utility Loss Delay Pausing for X Seconds Cranking Attempt X Running in Exercise...

Page 36: ...32 32 Section 7 Notes Air cooled Generators...

Page 37: ...33 Section 8 Installation Diagrams Air cooled Generators Circuit Breakers Drawing No 0G8573 A...

Page 38: ...34 Section 8 Installation Diagrams Air cooled Generators Generator Drawing No 0G8280 D...

Page 39: ...35 Section 8 Installation Diagrams Air cooled Generators Generator Drawing No 0G8280 D...

Page 40: ...e neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Aut...

Page 41: ...ection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement poin...

Page 42: ...Part No 0G8334 Revision D 09 16 08 Printed in U S A Catalog No OMASPCA S 01...

Page 43: ...TECHNICAL MANUAL This manual should remain with the unit RTSS Load Shed Automatic Transfer Switch...

Page 44: ...fire hazard This symbol points out potential electrical shock hazard GENERAL HAZARDS Any AC generator that is used for backup power if a NORMAL UTILITY power source failure occurs must be isolated fr...

Page 45: ...e wet DANGEROUS ELECTRICAL SHOCK MAY RESULT Jewelry conducts electricity and wearing it may cause dangerous electrical shock Remove all jew elry such as rings watches bracelets etc before working on t...

Page 46: ...mes When the transfer signal is given by the engine generator controller all loads both criti cal and non essential loads are connected to the GENERATOR supply If the generator is overloaded the LSS w...

Page 47: ...switch 5 to ON Reconnection of the non essential loads will occur one time after the time set on DIP switches 1 4 If DIP switch 5 is OFF the LSC will attempt to reconnect the non essential loads afte...

Page 48: ...prior to installation 2 3 MOUNTING Mounting dimensions for the transfer switch enclo sure are in this manual Enclosures are typically wall mounted See Installation Diagram Handle transfer switches ca...

Page 49: ...eutrals Tighten all wires to the specified torque Torque val ues are given on the information decal located on the inside cover The main neutral block is connected bonded to the enclosure metal by a b...

Page 50: ...minals E1 E2 3 2 2 LSS MANUAL OPERATION A manual HANDLE is shipped with the transfer switch Manual operation must be checked BEFORE the LSS is operated electrically To check manual operation proceed a...

Page 51: ...e able contact carrier arm Return handle to storage bracket 3 2 5 RETURN TO UTILITY SOURCE SIDE Step 1 Manually actuate switch to return manual operating handle to the UP position Step 2 Remove manual...

Page 52: ...ion 3 Manually actuate the transfer switch main con tacts to their GENERATOR STANDBY position Refer to Manual Operation 4 Manually actuate the LSS main contacts to the UP position Non essential loads...

Page 53: ...ad to draw frequency down 55 56 hz This will require turning loads on that are connected to the LSS Do not severely overload the genera tor The LSS should actuate after three 3 seconds to disconnect t...

Page 54: ...10 Section 4 Installation Diagrams RTSS Type Transfer Switch Load Shed Interconnection Drawing No 0G8774 B...

Page 55: ...11 Section 4 Installation Diagrams RTSS Type Transfer Switch 200 Amp Load Shed Enclosure Drawing No 0G8775 B...

Page 56: ...12 Section 5 Electrical Data RTSS Type Transfer Switch Electrical Schematic Drawing No 0G7816 A...

Page 57: ...13 Section 5 Electrical Data RTSS Type Transfer Switch Electrical Schematic Drawing No 0G7816 A...

Page 58: ...14 Section 5 Electrical Data RTSS Type Transfer Switch Wiring Diagram Drawing No 0G7817 B...

Page 59: ...15 Section 5 Electrical Data RTSS Type Transfer Switch Wiring Diagram Drawing No 0G7817 B...

Page 60: ...16 Section 6 Exploded Views Parts Lists RTSS Type Transfer Switch Load Shed Transfer Switch Drawing No 0G8054 C Parts List on page 19...

Page 61: ...17 Section 6 Exploded Views Parts Lists RTSS Type Transfer Switch Load Shed Transfer Switch Drawing No 0G8054 C Parts List on page 19...

Page 62: ...18 Section 6 Exploded Views Parts Lists RTSS Type Transfer Switch Load Shed Transfer Switch Drawing No 0G8054 C Parts List on page 19...

Page 63: ...8213 1 DECAL GENERAC POWER SYSTEMS ITEM PART NO QTY DESCRIPTION 41 066849 2 SCREW HHTT M5 0 8 X 16 42 058000E 1 NUT TRIC 1 4 20 X 525 43 0E7213 1 THUMB SCREW 1 4 20x1 2 44 0G8783 1 BATTERY CHARGER ASS...

Page 64: ...20 Section 7 Notes...

Page 65: ...21 Section 7 Notes...

Page 66: ...Part No 0G8637 Revision D 08 27 08 Catalog No KGALT 1SI Printed in U S A...

Page 67: ...16 17 and 20kW Generators This Automatic Transfer Switch with built in Load Center includes an Express Install Kit Saves on installation time and cost in many cases up to 50 compared to traditional tr...

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Page 69: ...E INSTRUCTIONS The manufacturer suggests that these rules for safe operation be cop ied and posted near the unit s installation site Safety should be stressed to all operators and potential operators...

Page 70: ...ngth will be deter mined by the materials to be drilled and cut open end wrenches or adjustable wrenches socket wrenches or nut drivers standard and Phillips screwdrivers sledge ham mer level pencil c...

Page 71: ...ounting pad 49 L x 25 W 3 Lay black poly film to cover the area 4 Fill the area to ground level with pea gravel or crushed stone 5 Drive an eight foot grounding rod into the ground to grade Make sure...

Page 72: ...in emergency load center in close proximity to the main distribution panel The transfer switch can be located to the left or right of the main distribution panel Two 2 feet is the suggested distance s...

Page 73: ...uts are included in installation kit Trace each black hot wire connected and wire nut the white neutral wire from the same Romex cable circuit to the matching circuit number on the white neutral wire...

Page 74: ...g strap will also be installed with the generator Save this guide for reference at time of generator installation DANGER Be sure the service main circuit breaker is switched OFF at time of generator i...

Page 75: ...ing the supplied threaded flexible fuel line Use a pipe sealant suitable for gaseous fuel connections Check connections for leaks by opening manual fuel shut off valve and swab or spray connections wi...

Page 76: ...8 Residential Transfer Switch Installation Guide Installation Drawing 0H0258 A...

Page 77: ...9 Residential Transfer Switch Installation Guide Installation Drawing 0H0258 A...

Page 78: ...Residential Transfer Switch Installation Guide Installation Drawing 0G8573 A 10 10...

Page 79: ...11 Residential Transfer Switch Installation Guide Electrical Schematic Drawing 0G7959 A...

Page 80: ...12 Residential Transfer Switch Installation Guide Wiring Diagram Drawing 0G7958 A...

Page 81: ...13 Residential Transfer Switch Installation Guide Wiring Diagram Drawing 0G7958 A...

Page 82: ...14 Residential Transfer Switch Installation Guide Load Center Exploded View Drawing 0G8786 C...

Page 83: ...1 HARN GTS MAIN PNL 8CIR W NEUT 0G8139 1 HARN GTS MAIN PNL 10CIR W NEUT 0G8140 1 HARN GTS MAIN PNL 12CIR W NEUT 0G7955 1 HARN GTS MAIN PNL 14CIR W NEUT 0G8141 1 HARN GTS MAIN PNL 16CIR W NEUT ITEM PA...

Page 84: ...16 Residential Transfer Switch Installation Guide Notes...

Page 85: ...17 Residential Transfer Switch Installation Guide Notes...

Page 86: ...Part No 0G8571 Revision D 07 31 08 Catalog No KGATX100 1SI Printed in U S A...

Page 87: ...ny questions or need assistance contact a qualified electrical contractor This device should be installed in accor dance with all local electrical codes and or the latest edition of the National Elect...

Page 88: ...ering switch on stabs install interlock bar under the exist ing switch handle and the new switch handle as shown b Push both switches into the bus stabs STEP 5 a Position operator under the hold down...

Page 89: ...own STEP 8 Install generator control wiring must be installed in conduit Install 5A fuse if required to the terminal strip in genera tor and connect the control wire from the generator Refer to the wi...

Page 90: ...oad center as shown STEP 10 Place the front cover on the panel board Install the six 6 screws to hold the front cover on STEP 11 Apply decal 0G4742A on the left side and decal 0G4732B on right side of...

Page 91: ...5 REFERENCE Items supplied in the EZ Transfer operator kit...

Page 92: ...6...

Page 93: ...7...

Page 94: ...The National Electrical Code is a registered trademark of the National Fire Protection Association Part Number 0G6419 Revision D 04 17 08 Printed in U S A...

Page 95: ...Air cooled Generator Battery Charger Installation Guidelines...

Page 96: ...r starting battery inside the generator enclosure The charger will not replenish a fully discharged bat tery It is intended to be connected to a 120VAC gen erator backed up circuit only If it is not c...

Page 97: ...eds to be used with certain transfer switch configu rations Some transfer switch configurations already have the battery charger installed in the transfer switch Before proceeding it is necessary to s...

Page 98: ...Transfer Switch Connections Charger 2 1 2 WIRING AND CONNECTIONS AT THE GENERATOR 1 Crimp spade lugs onto all three low voltage wires 15B 0 and 23 Purchased or supplied separate ly 2 Connect the low v...

Page 99: ...iagrams section for connections Option 2 Protected Load Provided in the RTS Fuse Block Installation NOTE This section is only appropriate for 2008 RTSN or RTSE transfer switches 1 Mount the optional 5...

Page 100: ...ontroller in the gen erator 2 The battery charger can be located anywhere within the controls area on the generator It is convenient to mount the charger on the verti cal surface on right hand side of...

Page 101: ...ad attaches to the terminal labeled 15B Note that there will be two wires attached to the 15B terminal when the full installation is completed One for the battery charger and one for the common connec...

Page 102: ...ery cables Positive cable first followed by the negative cable Figure 3 12 Measurement of Charger Output with Battery Disconnected 4 1 GENREADY INSTALLATION NOTE See the GenReady Installation Wiring D...

Page 103: ...4 4 Figure 4 4 Removal of Adhesive Covering on Hook and Loop for Mounting 4 1 3 WIRING AND CONNECTIONS AT THE GENERATOR 1 Identify the DC output wires on the battery char ger and crimp spade lugs ont...

Page 104: ...the generator Remove the negative cable first fol lowed by the positive cable Take care not to short the cables together 2 Ensure power is applied to the battery charger input 3 Connect a volt meter...

Page 105: ...9 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines RTSS Diagram Drawing No 0G8774 B...

Page 106: ...10 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines RTSN Diagram Option 1 Drawing No 0G8832 A...

Page 107: ...11 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines RTSN Diagram Option 2 Drawing No 0G8832 A...

Page 108: ...12 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines RTSE Diagram Option 1 Drawing No 0G8829 A...

Page 109: ...13 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines RTSE Diagram Option 2 Drawing No 0G8829 A...

Page 110: ...14 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines GenReady Diagram Drawing No 0G4744 D...

Page 111: ...15 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines GenReady Diagram Drawing No 0G4744 D...

Page 112: ...16 Section 5 Interconnection Diagrams Battery Charger Installation Guidelines GenReady Diagram Drawing No 0G4744 D...

Page 113: ...17 Section 6 Notes Battery Charger Installation Guidelines...

Page 114: ...Part No 0G7956 Revision B 11 14 08 Printed in U S A...

Page 115: ......

Page 116: ...CAC BDP 7310 W Morris Street Indianapolis IN 46231 Specifications are subject to change without notice Catalog No ASPDS Y 1SG Printed in USA 01 09...

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