Generac QT02524GNSN Manual
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STANDBY GENERATOR
OWNER'S MANUAL
This manual should remain with the unit.
A new standard of reliability
Serial Number
2.4L
25kW
Models
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
— — CAUTION
Cover112 Rev. B 09/07 Part No. 0G4159
Catalog Number OMASPEA025-1
Standby Generator Sets
Table of Contents
SECTION PAGE
SAFETY RULES ................................................ 1-1
INTRODUCTION .....................................................1-3
Read this Manual Thoroughly ...................................1-3
Operation and Maintenance ......................................1-3
How to Obtain Service ..............................................1-3
IDENTIFICATION RECORD .....................................2-1
Data Label ................................................................2-1
EQUIPMENT DESCRIPTION ...................................3-1
Equipment Description ................................................3-1
Engine Oil Recommendations ......................................3-1
Coolant Recommendations...........................................3-1
ENGINE PROTECTIVE DEVICES ............................4-1
High Coolant Temperature Switch ............................4-1
Low Coolant Level Sensor .........................................4-1
Low Oil Pressure Switch ...........................................4-1
Overcrank Shutdown ................................................4-1
Overspeed Shutdown ................................................4-1
RPM Sensor Loss Shutdown .....................................4-1
DC Fuse ....................................................................4-1
FUEL SYSTEMS .....................................................5-1
Fuel Requirements ....................................................5-1
Natural Gas Fuel System ..........................................5-1
Propane Vapor Withdrawal Fuel System....................5-1
LP Fuel System .........................................................5-1
SPECIFICATIONS ...................................................6-1
Generator .................................................................6-1
Engine.......................................................................6-1
Cooling System .........................................................6-1
Fuel System ..............................................................6-1
Electrical System ......................................................6-1
Cold Weather Kit .......................................................6-2
Reconfiguring the Fuel System ..................................6-2
GENERAL INFORMATION .......................................7-1
Generator AC Lead Connections ..................................7-1
Four-lead, Single-phase Stator ..................................7-1
Alternator Power Winding Connections ........................7-1
3-phase Alternators ..................................................7-1
INSTALLATION .......................................................8-1
Installation ...................................................................8-1
Preparation Before Start-up .........................................8-1
Transfer Switch ........................................................8-1
Fuel System ..............................................................8-1
Generator Set Lubrication ........................................8-1
Prior to Initial Start-up .............................................8-1
Engine Coolant .........................................................8-1
Belt Tension ..............................................................8-1
Electrical System ......................................................8-1
Initial Inspection for QT Genset Start-up .....................8-1
Start-up Checklist ........................................................8-2
Preparation for Start-up............................................8-2
Start-up Inspection ...................................................8-2
OPERATION ...........................................................9-1
Generator Control and Operation ................................9-1
Operating Unit with Manual Transfer Switch ...............9-1
Engine Start-up and Transfer ...................................9-1
Retransfer and Shutdown .........................................9-1
Operating Unit with Automatic Transfer Switch ...........9-1
MAINTENANCE .....................................................10-1
Maintenance Performed by Authorized
Service Facilities .....................................................10-1
Every Three Months ...............................................10-1
Once Every Six Months ...........................................10-1
Once Annually .........................................................10-1
First 100 Operating Hours ......................................10-1
Every 500 Operating Hours ....................................10-1
Every 800 Operating Hours ....................................10-1
Exhaust Manifold Procedure ......................................10-1
Intake Manifold Procedure .........................................10-1
Cylinder Head Procedure ...........................................10-1
Cooling System ..........................................................10-2
Overload Protection for Engine DC
Electrical System ....................................................10-2
Checking Fluid Levels ................................................10-2
Check Engine Oil ....................................................10-2
Battery Fluid ...........................................................10-2
Engine Coolant .......................................................10-2
Maintenance Owner/Operator Can Perform ................10-3
Check Engine Oil Level ...........................................10-3
Check Battery .........................................................10-3
Exercise System ......................................................10-3
Inspect Cooling System ...........................................10-3
Check Engine Coolant Level....................................10-3
Perform Visual Inspection .......................................10-3
Inspect Exhaust System ..........................................10-3
Check Fan Belt ........................................................10-3
Inspect Engine Governor ........................................10-3
Changing Engine Oil ...............................................10-3
Changing the Engine Air Cleaner ............................10-3
Spark Plugs ............................................................10-4
Coolant Change .......................................................10-4
Miscellaneous Maintenance ........................................10-4
Cleaning the Generator ...........................................10-4
Battery ....................................................................10-4
Battery Maintenance ...............................................10-4
Battery Replacement ...............................................10-5
SERVICE SCHEDULE ...........................................11-1
TROUBLESHOOTING ...........................................12-1
Troubleshooting Guide ...............................................12-1
NOTES
EXPLODED VIEWS & PARTS LISTS
WIRING DIAGRAMS & SCHEMATICS
Content016 Rev. A 06/07
Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become
familiar with this Owner’s Manual and with the unit.
The generator can operate safely, efficiently and reli-
ably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals affixed
to the unit are, therefore, not all inclusive. If a pro-
cedure, work method or operating technique is used
that the manufacturer does not specifically recom-
mend, ensure that it is safe for others. Also make
sure the procedure, work method or operating tech-
nique utilized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by a Service Dealer or other competent,
qualified electrician or installation technician who
is familiar with applicable codes, standards and
regulations. The operator also must comply with
all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electri-
cal and building codes. Comply with regulations
the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
generator is installed, operated and serviced in
accordance with the manufacturer’s instructions
and recommendations. Following installation, do
nothing that might render the unit unsafe or in
noncompliance with the aforementioned codes,
standards, laws and regulations.
• The engine exhaust fumes contain carbon mon-
oxide gas, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. For that
reason, adequate ventilation must be provided.
This should be considered prior to installing the
generator. The unit should be positioned to direct
exhaust gasses safely away from any building
where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit
must be installed properly per the manufacturer's
instruction, and in strict compliance with appli-
cable codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical in any room or building hous-
ing the generator to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seri-
ously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation
be copied and posted in potential hazard areas. Safety should be stressed to all operators,
potential operators, and service and repair technicians for this equipment.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:
1-1
Standby Generator Sets
Important Safety Instructions
Safety004 Rev. B 08/07
IDENTIFICATION RECORD
DATA LABEL
Every generator set has a DATA LABEL that contains
important information pertinent to the generator. The
data label, which can be found attached to the gen-
erator’s lower connection box, lists the unit’s serial
number and its rated voltage, amps, wattage capacity,
phase, frequency, rpm, power factor, etc.
NOTE:
For actual information related to this particular
model, please refer to the Manual Drawing Listing
located at the end of this manual, or to the data
label affixed to the unit.
Generator Model and Serial Number
This number is the key to numerous engineering and
manufacturing details pertaining to your unit. Always
supply this number when requesting service, order-
ing parts or seeking information.
2-1
Standby Generator Sets
General Information
Identy 005 Rev. A 03/07
MANUFACTURING INFORMATION
Data Label
EQUIPMENT DESCRIPTION
This equipment is a revolving field, alternating cur-
rent generator set. It is powered by a gaseous fueled
engine operating at 1800 rpm for 4-pole direct drive
units, 3600 rpm for 2-pole direct drive units and
2300 - 3000 rpm for quiet drive gear units. See the
Specifications section for exact numbers. The unit
comes complete with a sound attenuated enclosure,
internally mounted muffler, control console, main-
line circuit breaker, battery charger, and protective
alarms as explained in the following paragraph.
All AC connections, including the power leads from
the alternator, 120 volt battery charger input and
control connections to the transfer switch are avail-
able in the main connection box.
The generator incorporates the following generator
features:
• Rotor and Stator insulation is Class F rated as
defined by NEMA MG1-32.6, NEMA MG1-1.66.
The generator is self ventilated and drip-proof con-
structed.
• The voltage waveform deviation, total harmonic
content of the AC waveform and telephone influ-
ence factor have been evaluated and are acceptable
according to NEMA MG1-32.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at
the factory. Use a high-quality detergent oil classi-
fied “For Service SJ or SH.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
NOTE:
For temperatures below 32° F, it is strongly recom-
mended to use the optional Cold Weather Start Kit
(part number listed in the Specification Section).
The oil grade for temperatures below 32° F is 5W-
30 synthetic oil.
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol
base anti-freeze and deionized water. Cooling system
capacity is listed in the specifications. Use only deion-
ized water and only low silicate anti-freeze. If desired,
add a high quality rust inhibitor to the recommended
coolant mixture. When adding coolant, always add
the recommended 50-50 mixture.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chro-
mium hydroxide (“green slime”) forms and will
cause overheating. Engines that have been oper-
ated with a chromate base rust inhibitor must
be chemically cleaned before adding ethylene
glycol base anti-freeze. Using any high silicate
anti-freeze boosters or additives will also cause
overheating. The manufacturer also recommends
that any soluble oil inhibitor is NOT used for this
equipment.
DANGER
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 30W or 15W-40
32° to 80° F (0° to 27° C) SAE 20W-20 or 15W-40
Below 32° F (0° C) See Note
3-1
Standby Generator Sets
Equipment Description
Equip002 Rev. A 08/06
FUEL SYSTEM
FUEL REQUIREMENTS
The standby generator may be equipped with one of
the following fuel systems:
• Natural gas fuel system
• Propane vapor (PV) fuel system
The Manual Drawing Listing that is affixed to the
unit includes the “Identification Code,” which may be
used to identify the type of fuel system installed on
the unit.
Recommended fuels should have a Btu content of at
least 1,000 Btu's per cubic foot for natural gas; or at
least 2,520 Btu's per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 5 inches
to 14 inches water column (0.18 to 0.5 psi); and
for liquid propane, 5 inches to 14 inches of water
column (0.18 to 0.5 psi).
NOTE:
Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below five inches
water column for natural gas or 5 inches water
column for propane vapor for all load ranges.
NOTE:
It is the responsibility of the installer to make sure
that only the correct recommended fuel is sup-
plied to the generator fuel system. Thereafter, the
owner/operator must make certain that only the
proper fuel is supplied.
NATURAL GAS FUEL SYSTEM
Natural gas is supplied in its vapor state. In most
cases, the gas distribution company provides piping
from the main gas distribution line to the standby
generator site. The following information applies to
natural gas fuel systems.
• Gas pressure in a building is usually regulated by
national, state and local codes.
• To reduce gas pressure to a safe level before
the gas enters a building, a primary regulator is
needed. The natural gas supplier may or may not
supply such a regulator.
• It is the responsibility of the gas supplier to make
sure sufficient gas pressure is available to operate
the primary regulator.
• Gas pressure at the inlet to the fuel shutoff sole-
noid should not exceed approximately 14 inches
water column (0.5 psi). Optimum pressure at the
fuel shutoff solenoid is 11 inches water column
(0.4 psi).
PROPANE VAPOR WITHDRAWAL FUEL SYSTEM
This type of system utilizes the vapors formed above
the liquid fuel in the supply tank. Approximately 10
to 20 percent of the tank capacity is needed for fuel
expansion from the liquid to the vapor state. The
vapor withdrawal system is generally best suited for
smaller engines that require less fuel. The installer
should be aware of the following:
• When ambient temperatures are low and engine
fuel consumption is high, the vapor withdrawal
system may not function efficiently.
• Ambient temperatures around the supply tank
must be high enough to sustain adequate vaporiza-
tion, or the system will not deliver the needed fuel
volume.
• In addition to the cooling effects of ambient air, the
vaporization process itself provides an additional
cooling effect.
LP LIQUID FUEL SYSTEM
LP is supplied as a liquid in pressure tanks. It is
usually made up of propane, butane, or a mixture of
the two gases. Propane tends to vaporize readily even
at temperatures as low as -20° F (-29° C). However,
butane reverts to its liquid state when temperatures
drop below 32° F (0° C).
LP in a liquid withdrawal system must be converted
to its gaseous state before it is introduced into the
engine carburetor. A vaporizer-converter is generally
used to accomplish this. In such a converter, heated
engine coolant is ported through the converter to
provide the necessary heat for conversion of the fuel
from a liquid to a gaseous state.
5-1
Standby Generator Sets
Fuel Systems
FuelSys001 Rev. A 06/08
Produkt Specifikationer
| Mærke: | Generac |
| Kategori: | Generator |
| Model: | QT02524GNSN |
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