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Owner’s Manual for MGG450

1

Introduction and Safety

Section 1 Introduction and Safety

Introduction

Thank  you  for  purchasing  a  Generac  Mobile  Products 
LLC  product.  This  unit  has  been  designed  to  provide 
high-performance,  efficient  operation,  and  years  of  use 
when maintained properly.
The  information  in  this  manual  is  accurate  based  on 
products  produced  at  the  time  of  publication.  The 
manufacturer  reserves  the  right  to  make  technical 
updates,  corrections,  and  product  revisions  at  any  time 
without notice.

Read This Manual Thoroughly

(000100a)

WARNING

Consult Manual. Read and understand manual
completely before using product. Failure to 
completely understand manual and product
could result in death or serious injury.

If any section of this manual is not understood, contact your 
nearest  Generac  Mobile Authorized  Service  Dealer  (GMP 
ASD), or contact

 

Generac Mobile Technical Service at  

1-800-926-9768 or 

www.generacmobileproducts.com

  

with any questions or concerns.

This  manual  must  be  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 
followed  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, operate, and stop 
the unit in case of emergency.

How to Obtain Service

When  the  unit  requires  servicing  or  repairs,  contact  a 
GMP  ASD  for  assistance.  Service  technicians  are 
factory-trained  and  are  capable  of  handling  all  service 
needs.  For  assistance  locating  a  dealer,  go  to 

https://

www.generacmobileproducts.com/parts-service/find-
service

.

When  contacting  a  GMP ASD  about  parts  and  service, 
always supply 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 procedure, work method, 
or  operating  technique  that  the  manufacturer  does  not 
specifically  recommend,  verify  that  it  is  safe  for  others 
and does not render the equipment unsafe.
Throughout  this  publication,  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  that  may  be 
hazardous if performed incorrectly or carelessly. Observe 
them carefully. Alert definitions are as follows:

(000001)

DANGER

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

(000002)

WARNING

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

(000003)

CAUTION

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

NOTE: 

Notes contain additional information important to 

a procedure and will be found within the regular text of 
this manual.

These  safety  alerts  cannot  eliminate  the  hazards  that 
they indicate. Common sense and strict compliance with 
the  special  instructions  while  performing  the  action  or 
service are essential to preventing accidents.
The  operator  is  responsible  for  proper  and  safe  use  of 
the  equipment. The  manufacturer  strongly  recommends 
that if the operator is also the owner, to read the owner’s 
manual and thoroughly understand all instructions before 
using  this  equipment.  The  manufacturer  also  strongly 
recommends  instructing  other  users  on  how  to  properly 
start  and  operate  the  unit.  This  prepares  them  if  they 
need to operate the equipment in an emergency.

Содержание MGG450

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

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

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

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

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

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

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

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

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

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

Страница 59: ...___________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ___________________________________________________________________...

Страница 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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