® Installation Guidelines Stationary Diesel Generators Residential and Commercial 15–50 kW, 12–50 kVa 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. (000209b) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) Para español , visita: http://www.generac.com/service-support/product-support-lookup Pour le français, visiter : http://www.generac.
Use this page to record important information about this generator. Record the information found on this unit data label on this page. For location of the unit data label, see owner’s manual. Model: The unit has a label plate affixed to the inside partition, to the left of the control panel console. Serial: Always supply the complete model number and serial number of the unit when contacting an Independent Authorized Service Dealer (IASD) about parts and service.
Table of Contents Section 1: Safety Rules & General Information Introduction ..........................................................1 Read This Manual Thoroughly ....................................1 Safety Rules .........................................................1 How to Obtain Service .................................................1 General Hazards ..................................................2 Exhaust Hazards ..................................................3 Electrical Hazards .......
Section 6: Operational Checks Introduction ........................................................27 Self Test ..............................................................27 Checking Manual Transfer Switch Operation ............................................................27 Electrical Checks ...................................................... 27 D2.2L G22 Extended Tank (10000018412, page 1 of 2) ............................... 41 D2.2L G22 Extended Tank (10000018412, page 2 of 2) ................
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Safety Rules Thank you for purchasing this high performance, liquidcooled, engine-driven stationary generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. The engine and generator are factory installed in an allweather, metal enclosure intended exclusively for outdoor installation. The engine operates on ultra low sulfur diesel fuel.
Safety Rules & General Information General Hazards WARNING DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190) DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000191) WARNING Loss of life.
Safety Rules & General Information Exhaust Hazards DANGER DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) WARNING Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. (000178a) WARNING Equipment and property damage.
Safety Rules & General Information WARNING WARNING Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury. (000147) Comply with regulations the Occupational Safety and Health Administration (OSHA) has established, or with equivalent standards. Also, verify that the unit is applied, used, and maintained in accordance with the manufacturer's instructions and recommendations.
Safety Rules & General Information Standards Index WARNING Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage. (000182a) WARNING Electrocution. Refer to local codes and standards for safety equipment required when working with a live electrical system. Failure to use required safety equipment could result in death or serious injury.
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Installation Planning Section 2: Installation Planning Protector Diesel Installation Planning Checklist The local building code administrator or fire marshal has verified the generator must be located a minimum of ________ ft (________m) from a house or other structure. NOTE: Minimum distance will be based on local zoning and code requirements.
Installation Planning Safety Accessories Item Description Part Number Required Emergency stop switch G006510-0 YES NO 90% Fuel fill level alarm G006504-0 YES NO G006502-0 YES NO G006511-0 YES NO Fuel fill drop tube G006507-0 YES NO Fuel tank support risers G006505-0 (15 & 20 kW) YES NO YES NO (Domestic product only) Five gallon spill box (Domestic product only) Spill box drain back (Domestic product only) G006506-0 (30, 48, & 50 kW) Stainless steel fuel l
Installation Planning Unit Drawings Installation Drawings See Figure 2-1. Installation drawings show weights, dimensions, clearances, exhaust details, connection locations, wiring stub-ups, lifting locations, and other information. Use unit specific installation drawings when designing a site installation plan. Thoroughly read the NOTES section of each drawing for important details.
Installation Planning Receiving Receiving and Unpacking Handle shipping cartons and crates with care to avoid damage. Store and unpack cartons with the correct side up, as noted by label on shipping carton. Inspection Carefully inspect generator and all contents of cartons for any damage that may have occurred during shipment. See shipping documentation for any provisions or guidance when damage is incurred. Correct all damage or deficiencies before installing generator.
Installation Planning Generator Location DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) barriers. Do NOT face radiator discharge end of the enclosure into prevailing wind. • Consider cold weather kit options and accessories for the generator in cold weather locations. • Verify unit is securely fastened to mounting pad to prevent movement caused by vibration.
Installation Planning 1 6 2 7 3 9 4 5 12 Installation Guidelines for Protector Diesel Generators
Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) Generator must be installed outdoors in a location allowing sufficient clearance around all sides for reasons of safety, maintenance, and servicing. Placement requirements for a diesel storage tank vary by municipality.
Site Selection and Preparation Site Preparation Stub-Up Area Generator Foundation Install generator on a concrete pad or base slab able to support its weight and accessories. All applicable codes should be followed. A correct foundation is needed to resist dynamic loading and reduce transmitted noise and vibration. The exact composition of the mounting pad must follow standard engineering practices for the required loading and application.
Site Selection and Preparation Mounting Fixed Foundation Use mounting holes in base frame to fasten unit to foundation. Always use hardware of a suitable grade, size, and style. Connections All electrical connections must have flexible sections to isolate vibration if they connect to the unit base rails. Correctly support and secure all piping before installing flexible connection.
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Diesel Fuel Systems Section 4: Diesel Fuel Systems General Information Diesel Fuel Base Tank Because diesel fuels are less volatile than gasoline or gaseous fuels, they are sometimes considered safer. Due to this perception, careless installation practices can occur which may lead to serious problems with generator set performance and reliability. Periodically inspect and test the system to verify all components remain in good working order. See Figure 4-1.
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Electrical System Section 5: Electrical System General Information All wiring must be correctly sized, routed, supported, and connected. All wiring must comply with NEC and local codes. The generator uses Customer Connection Interface (CCI) panels to separate high voltage and customer control wiring connections. These two panels are clearly labeled. The wiring diagrams for each specific unit show the connection points in their corresponding sections.
Electrical System Remove Rear Panel and Stub-Up Cover Typical Load Leads and Control Wiring in Stub-Up 1. See Figure 5-1. Remove six screws with nylon washers to release rear panel (A) from enclosure. For best results, rotate left side of panel outward away from enclosure before disengaging right side. NOTE: Disconnect wire harness from switch located in the customer access assembly housing. This will allow door to be completely removed. NOTE: The illustration in Figure 5-3 is for reference only.
Electrical System 1 2 3 5 4 001758 Load Wiring Connections 1 E1 4 Ground 2 E2 5 3 Neutral Knock out plug (cold weather kit) Notes: Single-phase installation shown. See Figure 5-4 for typical control wiring connections. Figure 5-3.
Electrical System Control Wiring Connections The control wire customer connection block is where all of control wiring is connected. NOTE: All wiring must comply with NEC, state, and local AHJ requirements. Control wiring shall be installed per the requirements of NEC Articles 300.3(C) and 725.46. If installing conductors with different voltage insulation ratings, a 600V rated electrical sleeve is provided and can be found in the manual bag. See Figure 5-4.
Electrical System Figure 5-5.
Electrical System Optional Accessory Power • Accessory power for optional items (battery warmer and block heater) should come from a customer utility supply source (with appropriate sized breaker), which is also powered by emergency power during an outage. • Optional user installed GFCI receptacles provide a place to plug in optional battery warmer and block heater. NOTE: See Figure 5-1. Remove knockout plug and route accessory wiring to customer supplied weatherproof junction box.
Electrical System • When working on battery, always remove watches, rings, or other metal objects, and only use tools that have insulated handles. Do not lay tools or metal parts on top of battery. • Discharge static electricity from body before touching battery by first touching a grounded metal surface. • Wear full eye protection, protective clothing, and gloves when handling a battery. • Immediately wash down spilled electrolyte with an acid neutralizing agent.
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Operational Checks Section 6: Operational Checks Introduction Checking Manual Transfer Switch Operation CAUTION Equipment damage. Perform functional tests in the exact order they are presented in the manual. Failure to do so could result in equipment damage. (000121) NOTE: The following procedures require special tools and skills. Contact an IASD to perform these tasks. Self Test This controller goes through a system self test at startup, which checks for utility voltage on DC circuits.
Operational Checks 9. Press MANUAL key on control panel to crank and start engine. 10. Allow engine to warm up for approximately five minutes. Set MLCB switch on generator control panel up to ON (CLOSED). IMPORTANT NOTE: Generator power voltage is now supplied to transfer switch. DANGER Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury. (000129) 11.
Operational Checks Auxiliary shutdown switches are not intended to be a primary means to shut down generator under normal operating conditions. Accidental activation of an auxiliary shutdown switch will prevent generator from operating during a power outage. Checking Automatic Operation Proceed as follows to check system for correct automatic operation: 1. Verify generator is in OFF mode. Red LED above OFF on control panel illuminates to verify system is OFF. 2. Install front cover over transfer switch. 3.
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Installation Checklists Section 7: Installation Checklists Safety Checklist Foundations and Mounting Checklist NOTE: See Safety Rules & General Information for more information. NOTE: See Site Selection and Preparation for more information.
Installation Checklists Does installation appear to have necessary accessories to allow fast, reliable starting and operation in adverse weather conditions (such as engine block heaters, battery warmers, etc.)? Do these parameters meet all applicable codes and local jurisdiction? Exhaust System Checklist NOTE: See Diesel Fuel Systems for more information.
Installation Drawings Section 8: Installation Drawings D2.5L G2 Single Wall (10000022175, page 1 of 2) SERVICE ITEM 739 [29.1] CENTER OF GRAVITY RADIATOR/EXHAUST DISCHARGE AIR (BOTH SIDES) AIR INTAKE (BOTH SIDES) RADIATOR/EXHAUST DISCHARGE AIR 2" O.D. EXHAUST OUTLET 2.
Installation Drawings D2.5L G2 Single Wall (10000022175, page 2 of 2) FUEL FILL (2" NPT FEMALE) 1120 [44.1] FUEL LEVEL GAUGE/SENDER 1008 [39.7] 787 [31.0] EMERGENCY VENT (2" NPT FEMALE) 691 [27.2] 446 NORMAL VENT (2" NPT FEMALE) [17.5] FUEL TANK HIGH AND LOW VOLTAGE STUB-UP AREA 625 [24.6] TYP TOTAL CAPACITY 169 [44] USABLE CAPACITY 151 [40] CAPACITY: LITER [GALLON] DIMENSIONS: MM [INCH] 674 [26.
Installation Drawings D2.5L G2 Extended Tank (10000018189, page 1 of 2) 884 [34.8] CENTER OF GRAVITY INTERNAL DIVIDER PANEL SEPARATES FUEL TANK VENTILATION DUCT FROM THE ENGINE, ALTERNATOR AND EXHAUST SYSTEM REMOVE PANEL TO ALLOW TANK VENTS TO TERMINATE OUTSIDE OF THE GENERATOR ENCLOSURE (CHECK LOCAL AND STATE CODE FOR APPLICABILITY) 209 [8.2] EXHAUST OUTLET 580 [22.8] EXHAUST OUTLET SERVICE ITEM 2.5L OIL FILL CAP RIGHT SIDE WEIGHT DATA WITH EMPTY BASETANK (SEE NOTE 5) NOTES: 1.
Installation Drawings D2.5L G2 Extended Tank (10000018189, page 2 of 2) 1722 [67.8] 1631 [64.2] 906 [35.7] OUTER TANK LEAK DETECTOR 357 [14.0] 231 [9.1] 107 [4.2] INNER TANK NORMAL VENT (2" NPT FEMALE) CUSTOMER OPTION (2" NPT FEMALE) OUTER TANK EMERGENCY VENT (2" NPT FEMALE) FUEL TANK 674 [26.5] 624 [24.6] TYP HIGH AND LOW VOLTAGE STUB-UP AREA 574 [22.6] TYP 464 TOTAL CAPACITY 127 [33.5] USABLE CAPACITY 121 [32] CAPACITY: LITER [GALLON] DIMENSIONS: MM [INCH] 639 [25.
Installation Drawings D2.5L G2–95 Gal Tank (10000028999, page 1 of 2) 884 [34.8] CG INTERNAL DIVIDER PANEL SEPARATES FUEL TANK VENTILATION DUCT FROM THE ENGINE, ALTERNATOR AND EXHAUST SYSTEM SERVICE ITEM 2.
Installation Drawings D2.5L G2–95 Gal Tank (10000028999, page 2 of 2) 1722 [67.8] 1631 [64.2] 906 [35.7] OUTER TANK LEAK DETECTOR 357 [14.0] 231 [9.1] 107 [4.2] INNER TANK NORMAL VENT (2" NPT FEMALE) CUSTOMER OPTION (2" NPT FEMALE) OUTER TANK EMERGENCY VENT (2" NPT FEMALE) FUEL TANK 674 [26.5] 624 [24.6] TYP HIGH AND LOW VOLTAGE STUB-UP AREA 574 [22.6] TYP 464 373 [98.5] USABLE CAPACITY 360 [95] CAPACITY: LITER [GALLON] DIMENSIONS: MM [INCH] 639 [25.
Installation Drawings D2.2L G22 Single Wall (10000018294, page 1 of 2) 874 [34.4] CENTER OF GRAVITY SERVICE ITEM 2.
Installation Drawings D2.2L G22 Single Wall (10000018294, page 2 of 2) 1196 [47.1] 1045 [41.2] 926 [36.5] TYP 844 [33.2] TYP FUEL SUPPLY FUEL FILL (2" NPT FEMALE) FUEL LEVEL GAUGE/SENDER FUEL RETURN FUEL TANK 267 [10.5] TYP 230.9 [61] *NOTE: STUB-UP AREA FOR HIGH AND LOW VOLTAGE CONNECTIONS, CIRCUIT BREAKER, NEUTRAL AND CUSTOMER CONNECTION OPENING. 125 [4.9] STUB-UP AREA 621 [24.5] TYP 253.
Installation Drawings D2.2L G22 Extended Tank (10000018412, page 1 of 2) 1029 [40.5] CENTER OF GRAVITY INTERNAL DIVIDER PANEL SEPARATES FUEL TANK VENTILATION DUCT FROM THE ENGINE, ALTERNATOR AND EXHAUST SYSTEM SERVICE ITEM 2.
Installation Drawings D2.2L G22 Extended Tank (10000018412, page 2 of 2) 2089 [82.2] TYP 1386 [54.6] TYP 1314 [51.7] TYP 351 [13.8] INNER TANK NORMAL VENT (2" NPT FEMALE) 227 [9.0] FUEL RETURN INNER TANK EMERGENCY VENT (2" NPT FEMALE) 101 [4.0] OUTER TANK LEAK DETECTOR FUEL SUPPLY OUTER TANK EMERGENCY VENT (2" NPT FEMALE) FUEL TANK HIGH AND LOW VOLTAGE STUB-UP AREA 660 [26.0] TYP 620 [24.4] TYP 487 [19.2] 786 [30.
Installation Drawings D2.2L G22–132 Gal Tank (10000029492, page 1 of 2) 1029 [40.5] CENTER OF GRAVITY INTERNAL DIVIDER PANEL SEPARATES FUEL TANK VENTILATION DUCT FROM THE ENGINE, ALTERNATOR AND EXHAUST SYSTEM SERVICE ITEM 2.
Installation Drawings D2.2L G22–132 Gal Tank (10000029492, page 2 of 2) 2089 [82.2] TYP 1418 [55.8] TYP 1307 [51.5] TYP 377 [14.8] INNER TANK NORMAL VENT (2" NPT FEMALE) 247 [9.7] FUEL RETURN INNER TANK EMERGENCY VENT (2" NPT FEMALE) 117 [4.6] FUEL SUPPLY OUTER TANK LEAK DETECTOR OUTER TANK EMERGENCY VENT (2" NPT FEMALE) FUEL TANK 786 [30.9] HIGH AND LOW VOLTAGE STUB-UP AREA 658 [25.9] TYP 618 [24.3] TYP 485 [19.1] 125 [4.9] STUB-UP AREA 314 [12.
Installation Drawings D3.4L G16 Single Wall (10000042752, page 1 of 2) 892 [35.1] CENTER OF GRAVITY SEE NOTE 5 AIR INTAKE (BOTH SIDES) RADIATOR/EXHAUST DISCHARGE AIR (BOTH SIDES) SERVICE ITEM 3.
Installation Drawings D3.4L G16 Single Wall (10000042752, page 2 of 2) FUEL FILL (2" NPT FEMALE) FUEL LEVEL GAUGE/SENDER 1194.2 [47.0] NORMAL VENT (2" NPT FEMALE) 1043.6 [41.1] EMERGENCY VENT (2" NPT FEMALE) FUEL TANK HIGH AND LOW VOLTAGE STUB-UP 786 [30.9] 757.1 [29.8] TYP 267.1 [10.5] TYP 181.1 [7.1 ] TYP 230.9 [61] *NOTE: STUB-UP AREA FOR HIGH AND LOW VOLTAGE CONNECTIONS, CIRCUIT BREAKER, NEUTRAL AND CUSTOMER CONNECTION OPENING. FUEL SUPPLY FUEL RETURN 253.
Installation Drawings D3.4L G16 Extended Tank (10000042807, page 1 of 2) REMOVE PANEL TO ALLOW TANK VENTS TO TERMINATE OUTSIDE OF THE GENERATOR ENCLOSURE (CHECK LOCAL AND STATE CODE FOR APPLICABILITY) 998 [39.3] CENTER OF GRAVITY SEE NOTE 5 SERVICE ITEM 3.
Installation Drawings D3.4L G16 Extended Tank (10000042807, page 2 of 2) 350.5 [13.8] INNER TANK NORMAL VENT (2" NPT FEMALE) 313.8 [12.4] INNER TANK EMERGENCY VENT (2" NPT FEMALE) 225.5 [8.9] 100.5 [4.0] OUTER TANK LEAK DETECTOR FUEL LEVEL GAUGE/SENDER FUEL TANK OUTER TANK EMERGENCY VENT (2" NPT FEMALE) HIGH AND LOW VOLTAGE STUB-UP AREA TOTAL CAPACITY 233 [61] USABLE CAPACITY 209 [55] CAPACITY: LITER [GALLONS] DIMENSIONS: MM [INCH] 786 [30.9] 717.1 [28.
Installation Drawings D3.4L G16 – 132 Gal Tank (10000043316, page 1 of 2) 998 [39.3] CENTER OF GRAVITY SEE NOTE 5 REMOVE PANEL TO ALLOW TANK VENTS TO TERMINATE OUTSIDE OF THE GENERATOR ENCLOSURE (CHECK LOCAL AND STATE CODE FOR APPLICABILITY) AIR INTAKE (BOTH SIDES) RADIATOR/EXHAUST DISCHARGE AIR (BOTH SIDES) SERVICE ITEM 3.
Installation Drawings D3.4L G16 – 132 Gal Tank (10000043316, page 2 of 2) 376.5 [14.8] 314 [12.4] 246.5 [9.7] INNER TANK NORMAL VENT (3" NPT FEMALE) INNER TANK EMERGENCY VENT (3" NPT FEMALE) FUEL LEVEL GAUGE/SENDER 116.6 [4.6] OUTER TANK LEAK DETECTOR FUEL TANK OUTER TANK EMERGENCY VENT (3" NPT FEMALE) HIGH AND LOW VOLTAGE STUB-UP AREA 125 [4.9] *STUB-UP AREA 657.9 [25.9] TYP 484.7 [19.
Installation Drawings Alternator Wiring Diagram (1 of 2) Installation Guidelines for Protector Diesel Generators 51
Installation Drawings Alternator Wiring Diagram (2 of 2) 52 Installation Guidelines for Protector Diesel Generators
Installation Drawings Alternator AC Lead Connections The electrical wires in the unit’s AC connection (lower) panel should be installed according to number of leads and voltage/phase required for the application. The voltage and phase are described on the generator data label. The number of lead wires can be identified using the Specifications section and power output rating on the generator data label.
Installation Drawings B Three-Phase Alternators (“Delta” Configuration) E1 S1 S1 S4 S4 S6 S5 S3 E3 00 L-L A S2 S6 S5 S3 S2 E2 006480 L-N A Neutral B Internal connections Figure 8-4. Stator Power Winding Connections— 3-phase, 120/208V (6 Lead) The Stationary Emergency Generator is designed to supply three-phase electrical loads. Electric power is produced in the alternator power windings.
Part No. 10000023517 Rev. C 02/26/19 ©2019 Generac Power Systems, 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. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) www.generac.
