Generac Power Systems PWRgenerator 9 kW, Owner'S Manual

Page 1: ...R FUTURE REFERENCE Register your Generac product at WWW GENERAC COM 1 888 GENERAC 888 436 3722 000209b WARNING Loss of life This product is not intended to be used in a critical life support application Failure to adhere to this warning could result in death or serious injury ...

Page 2: ...is the operator s responsibility to perform all safety inspections 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 responsibility of the owner operator and are not considered defects in materials or workmanship within the terms of the warranty Individual operat...

Page 3: ... Operating Modes 16 Interface Menu Displays 16 LCD Panel 16 Menu System Navigation 17 Setting the Exercise Timer 19 Battery Charger 19 Automatic Sequence of Operation 19 Cranking 19 Cleaning Cycle 19 Shutting Generator Down While Under Load or During a Utility Outage 19 PWRcell System 21 Communication 21 Inverter Control Module 21 Auto Start Stop State of Charge SoC Setpoints 21 PWRgenerator Start...

Page 4: ...Table of Contents iv Owner s Manual for PWRgenerator Air Cooled Generators This page intentionally left blank ...

Page 5: ...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 Safety Rules The manufacturer cannot anticipate every possible cir cumstance 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 tha...

Page 6: ...irs or maintenance Failure to do so could result in death or serious injury 000155a WARNING Electric shock Only a trained and licensed electrician should perform wiring and connections to unit Failure to follow proper installation requirements could result in death serious injury and equipment or property damage 000115 Moving Parts Do not wear jewelry when starting or operating this product Wearin...

Page 7: ...DANGER Electrical backfeed Use only approved switchgear to isolate generator from the normal power source Failure to do so will result in death serious injury 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 000188 DANGER Electrocution Do not wear jewelry while working on thi...

Page 8: ...ssional technician or contractor Incorrect installation of this unit will result in death serious injury and property and equipment damage 000174 DANGER Risk of fire Allow fuel spills to completely dry before starting engine Failure to do so will result in death or serious injury 000110 WARNING Risk of Fire Hot surfaces could ignite combustibles resulting in fire Fire could result in death or seri...

Page 9: ...ling facility to obtain information on local recycling processes For more information on battery recycling visit the Battery Council International website at http batterycouncil org WARNING 000228 Environmental 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 inju...

Page 10: ...Safety Information 6 Owner s Manual for PWRgenerator Air Cooled Generators This page intentionally left blank ...

Page 11: ...ock with cover E Battery compartment battery not supplied J Oil fill cap dipstick N Fuel inlet B Main line circuit breaker generator disconnect F Exhaust enclosure K Oil filter O Data decal location C Airbox with air cleaner G Status LED indicators L Composite base P Auxiliary shutdown switch D Control panel H Oil drain hose M Sediment trap Q ECM 012454 C B G F E D A A L K J H N M Q O P ...

Page 12: ...t including Model number Serial number Production date Voltage Amps Country of origin Rated ambient temperature The model data decal also displays certifica tion symbols by Intertek cETLus and the Southwest Research Institute SwRI Fuel Inlet Pressure Displays unit serial number along with mini mum and maximum inlet pressures for natural gas NG and liquid propane LP supply Space is provided for ins...

Page 13: ... decrease in engine power See Engine These generators are rated in accordance with UL 2200 Safety Standard for Stationary Engine Generator Assem blies and CSA C22 2 No 100 04 Standard for Motors and Generators NG ratings will depend on specific fuel joules BTU content Model 9 kW Engine type G Force 800 Series Number of cylinders 2 Displacement 816 cc Cylinder block Aluminum with cast iron sleeve R...

Page 14: ...M Engine Modifi cation The Emission Control System on this generator consists of the following Fuel Requirements The engine has been fitted with a dual fuel electronic fuel injection control EFIC system The unit will run on NG or LP gas but has been factory configured to run on NG The fuel system will be configured for the available fuel source during installation Recommended fuels should have a B...

Page 15: ...occurs Scheduled Maintenance Kit Includes all items necessary to perform complete routine maintenance on the generator along with oil recommendations oil not included Fascia Base Wrap The fascia base wrap snaps together around the bottom of the new air cooled generators This offers a sleek contoured appearance as well as protection from rodents and insects by covering the lifting holes located in ...

Page 16: ...General Information 12 Owner s Manual for PWRgenerator Air Cooled Generators This page intentionally left blank ...

Page 17: ...ay from unit Generator Enclosure Enclosure lid is locked prior to shipment A set of keys is attached to cardboard on top of generator An additional set of keys is attached to pallet bracket on the front intake end of generator NOTE Keys provided with this unit are intended for ser vice personnel use only Opening the Lid 1 Use keys to open generator lid 2 See Figure 3 1 Two locks A secure lid one o...

Page 18: ...d in OFF OPEN for security Use an appropriately sized padlock not included with a shackle long enough to pass through both lock tabs B Figure 3 4 Main Line Circuit Breaker MLCB NOTE DO NOT leave generator MLCB generator dis connect locked in OFF OPEN during normal generator operation Leaving MLCB generator disconnect in OFF OPEN will prevent generator from powering structure during a power outage ...

Page 19: ... fuse is located beneath rubber cover B to the right of the control panel Verify both left and right side locks are securely out of the way before closing unit All appropriate panels must be in place during any opera tion of the generator This includes operation by a servic ing technician while conducting troubleshooting pro cedures Using the AUTO OFF MANUAL Interface NOTE Damage caused by mis wir...

Page 20: ...o supply both PWRcell Battery and PWRcell Inverter which generates AC power Unit will stop when any of the following condi tions are met Generator output power is below AutoStop Power default 500w for a duration greater than AutoStopTime default 2 minutes The SoC of all battery modules is greater than AutoStopSoC default 95 The PWRcell ESS is not in Island Mode A stop command has been received fro...

Page 21: ...ng in Exercise Hours of Protection 0 H Running Cooling 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 SEEPROM ABUSE USB Warning Download Failure Pwr Cnvrtr Brd Wrn CRC Mismatch Wrn Cranking Warning Warning Message Alarm Message s High ...

Page 22: ...ime displayed for each occurence NOTE 3 Error code displayed for each Alarm Error Code and Alarm Message swap every 5 seconds Maint NOTE 1 Last 50 maintenance logs displayed NOTE 2 Date and time displayed for each occurence Firmware Update Å YES Æ Current V 1 01 USB V 1 05 Are You Sure Yes or No Update from Å USB or Wi Fi Æ Select YES then press ENTER to continue or ESCAPE to cancel update During ...

Page 23: ...ows 10 sec onds cranking seven seconds resting followed by four additional cycles of 10 seconds cranking fol lowed by seven seconds resting NOTE An alarm will be triggered if generator does not start after these five attempts Cleaning Cycle If some condition impedes normal voltage creation such as frost crystals or dust dirt preventing a good electrical connection start sequence will be interrupte...

Page 24: ...se in controller 2 Complete Install Wizard 3 Verify generator MLCB generator disconnect and PWRcell Inverter DC disconnect circuit breaker are OFF OPEN 4 Set generator to AUTO mode at the controller 5 Set PWRcell Inverter DC disconnect circuit breaker to ON CLOSED 6 Set generator MLCB generator disconnect to ON CLOSED The system now operates in automatic mode DO NOT leave generator MLCB generator ...

Page 25: ...hen the PWRgenerator will automatically be prompted to start and stop while in AUTO mode Auto StrtSoC and AutoStopSoC These setpoints can be adjusted through the Mod Settings menu on the PWR generator device page on the ICM PWRgenerator Start Stop Commands PWRgenerator can be manually commanded to start or stop from the PWRgenerator device menu The following criteria must be met for the commands t...

Page 26: ...n to select Adjusting PWRgenerator Setpoints PWRgenerator setpoints are adjusting using the inverter control panel See PWRcell Inverter owner s manual for further information Proceed as follows to adjust PWRgenerator setpoints 1 Press left and right arrow keys to access PWRgen erator device page Press center button to enter PWRgenerator menu 2 Press up and down arrow keys to highlight Mod Settings...

Page 27: ...rform maintenance as specified in the Service Schedule for correct generator operation Engine oil and oil filter must be changed 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 plug s in accordance with Service Schedule Controller...

Page 28: ...eplace engine oil and oil filter Replace engine air filter Clean inspect spark plug gap replace if necessary Inspect clean sediment trap See local codes and guidelines Replace alternator brushes Contact the nearest IASD for assistance if necessary Remove any shrubs or tall grasses which have grown within 3 ft 0 91 m of intake and discharge louvers on enclosure sides Clean any debris dirt grass cli...

Page 29: ... Petroleum Institute API Service Class SJ SL or better Do not use special additives Synthetic SAE 5W 20 GEO Gaseous Engine Oil for all temperature ranges See Engine Changing the Oil and Oil Filter Proceed as follows to change oil and oil filter 1 Lift lid and press MANUAL button on control panel to start engine and run until it is thoroughly warm ed up Press OFF button on control panel to shut dow...

Page 30: ...d engine cool lift lid and remove front panel 2 Clean area around base of spark plug s to keep dirt and debris out of engine 3 Remove spark plug s and inspect Install new plug s if existing plug s is worn or if reuse is ques tionable 4 Clean plug s by scraping or washing with a wire brush and commercial solvent Do not blast plug s to clean NOTE Clean spark plug in emergency situations only Otherwi...

Page 31: ...ows to inspect battery 1 Press OFF button to shut down generator then lift lid and remove front panel 2 Set generator MLCB generator disconnect to OFF OPEN 3 Remove 7 5A fuse from control panel 4 Remove intake side panel See Intake Side Panel Removal 5 See Figure 4 4 Inspect battery posts and cables for tightness and corrosion Tighten and clean as necessary Figure 4 4 Battery Cables 6 Unsealed bat...

Page 32: ...ess AUTO button on control panel 7 Set generator MLCB generator disconnect to ON CLOSED The system is now in AUTO NOTE If correct PWRcell Battery SoC is present at this time generator will perform its usual shutdown process Performing Fuel System Leak Test All products are factory tested before shipping to verify the performance and integrity of the fuel system How ever it is important to perform ...

Page 33: ...gine Oil Requirements 7 Attach a tag to engine indicating viscosity and clas sification of the new oil in the crankcase 8 Remove spark plug s and spray a fogging agent into spark plug s threaded openings Install and tighten spark plug s to specification 9 Remove battery and store in a cool dry place 10 Clean and wipe down generator enclosure Return to Service Proceed as follows to return unit to s...

Page 34: ...Maintenance 30 Owner s Manual for PWRgenerator Air Cooled Generators This page intentionally left blank ...

Page 35: ...tact an IASD for assistance Faulty spark plug s Clean inspect spark plug gap replace spark plug s if necessary Engine starts hard and runs rough Air cleaner plugged or damaged Inspect and clean air cleaner Faulty spark plug s Clean inspect spark plug gap replace spark plug s if necessary Incorrect fuel pressure Verify fuel pressure to regulator is 10 12 in water column 2 49 2 99 kPa for LP and 3 5...

Page 36: ...ect level Faulty engine breather Contact an IASD for assistance Incorrect type or viscosity of oil See Engine Oil Requirements Damaged gasket seal or hose Inspect for oil leaks Restricted air filter Replace air filter Power converter faults PWRcell battery limitations Contact an IASD for assistance PLM communication error Disconnected breakers Problem Cause Correction ...

Page 37: ... Inverter control panel for PV production and export from PWRcell Batteries Batteries and or solar are providing power NONE GREEN Unit will not start in AUTO with utility loss Check screen for start delay countdown If startup delay is greater than expected contact an IASD to adjust from 2 to 1500 seconds LOW OIL PRESSURE RED Unit will not start in AUTO with utility loss Check LEDs screen for alarm...

Page 38: ...nformation Contact an IASD CHARGER WARNING YELLOW Yellow LED illuminated in any state Check screen for additional information Contact an IASD LOW REBUS VOLTAGE WARNING YELLOW Yellow LED illuminated in any state Check screen for additional information Contact an IASD LOW REBUS VOLTAGE WARNING YELLOW Yellow LED illuminated in any state Check screen for additional information Set generator MLCB gener...

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Page 40: ... rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems Inc Generac Power Systems Inc S45 W29290 Hwy 59 Waukesha WI 53189 1 888 GENERAC 1 888 436 3722 www generac com ...