Liquid-Cooled Instruction Sheet

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Engine Shutdown Add-On Kit 1

INSTRUCTION SHEET

2017 NEC Required Engine

Shutdown Add-On Kit

(445.18(B))

Liquid-Cooled Products 15kW–60kW

Introduction

New specifications in Article 445.18(B) of the 2017

National Electrical Code (NEC) require generators to be

equipped with an independent means of shutting down

the prime mover (engine). The shutdown mechanism,

when activated, requires a mechanical reset. Generators

15 kW and larger require two engine shutdown switches.

This kit includes all components needed to install

required engine stop switches on Generac liquid-cooled

Protector™ Series gaseous and diesel generators

equipped with Evolution™ controllers.

NOTE: Some Authorities Having Jurisdiction (AHJs) and

local codes require Protector diesel generators to be

equipped with an optional Emergency Stop Switch (E-

stop) as shown on the pre-installation checklist. The E-

stop is offered separately from this kit as model

G0065100.

IMPORTANT NOTE:

If installing this kit on a Protector

diesel unit equipped with or requiring an E-stop, turn to

page 6

and proceed with

INSTRUCTIONS—Protector

Diesel (with E-stop)

If installing this kit on a Protector diesel unit that does not

require an E-stop, proceed with the instructions

beginning on this page.

INSTRUCTIONS—Protector

Gaseous / Protector Diesel

(no E-stop)

Required Tools

The installer must be equipped with common installation

tools including:

• power drill

• drill bits

• center punch

• wire cutters

• wire stripper

• crimper

• pencil or marker

• electrical tape

• Step drill capable of boring a 13/16 inch (21 mm)

diameter hole

• Clear silicone sealant

Prepare for Installation

Before installing this kit, prevent the generator from

accidental startup:

1. Open viewing window.

2. Press OFF key on control panel keypad. Red LED

above key illuminates to confirm system is OFF.

3. Move main circuit breaker switch to OFF (Open).

4. Remove 7.5 A fuse.

DANGER

Accidental start-up. Disconnect power and render

unit inoperable before performing service work.

Failure to do so will result in death or serious injury.

(000344)

(000182)

WARNING

Only qualified service personnel may install, operate,

and maintain this equipment. Failure to follow proper

installation requirements could result in death, serious

injury, and damage to equipment or property.

(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.

CAUTION

(000246)

Equipment Damage. The emergency stop switch is

not to be used to power down the unit under normal

operating circumstances. Doing so will result in

equipment damage.

Summary of content (9 pages)

PAGE 1
INSTRUCTION SHEET 2017 NEC Required Engine Shutdown Add-On Kit (445.18(B)) Liquid-Cooled Products 15kW–60kW DANGER Accidental start-up. Disconnect power and render unit inoperable before performing service work. Failure to do so will result in death or serious injury. (000344) WARNING Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and damage to equipment or property.
PAGE 2
5. See Figure 1. Remove side access panel using viseaction latch key. Wire Preparation 1. See Figure 3. Cut black wire (A) at center of loop. 004888 004890 Figure 1 - Remove Side Access Panel 6. 7. Loosen nut on negative battery terminal and disconnect from post. Verify negative connector is isolated away from battery. Remove six screws with nylon washers to release rear panel. A NOTE: To simplify removal, rotate left side of panel outward away from enclosure before disengaging right side. 8.
PAGE 3
2. Use a step drill to bore a 13/16 in. (21 mm) diameter hole in the roof panel. IMPORTANT NOTE: Do NOT drill hole larger than 13/16 in. (21 mm)! An oversize hole will prevent rocker switch installation and cannot be repaired in the field. The entire roof panel must be replaced. 3. Thoroughly clean area of any metal shavings. IMPORTANT NOTE: Do NOT drill hole larger than 13/16 in. (21 mm)! An oversize hole will prevent rocker switch installation and cannot be repaired in the field.
PAGE 4
5. See Figure 8. Connect one crimped end of 24 in. (61 cm) wire (E) and 36 in. (91 cm) wire (C) to rocker switch terminals on outboard side of controller access cover. Verify there is enough insulation removed to properly connect and disconnect wires. 9. 10. E 11. 12. C 13. 004896 Figure 8 - Crimped Rocker Switch Wires 6. 7. Position rear enclosure panel close to rear of generator. Wires connected to switch in rear panel will be routed and wired to inside of generator control panel. See Figure 9.
PAGE 5
Firmware Update (if required) Test Switch Operation The generator controller may require a firmware update. Firmware version 1.19 or later is required. Verify controller firmware version. If an update is required, install latest version before testing engine shutdown switches. 1. Connect negative battery terminal and tighten nut. 2. Install 7.5 A fuse and configure install wizard. 3. With generator controller OFF, enter Edit menu. 4. Scroll through the options and select “Update Firmware.” Press Enter. 5.
PAGE 6
INSTRUCTIONS—Protector Diesel (with E-stop) NOTE: To simplify removal, rotate left side of panel outward away from enclosure before disengaging right side. Only one rocker switch is required on Protector diesel units with an E-stop. The rocker switch will be mounted inside the customer access cover. Dispose of the second rocker switch. Required Tools The installer must be equipped with common installation tools including: • power drill 8.
PAGE 7
IMPORTANT NOTE: Do NOT drill hole larger than 13/16 in. (21 mm)! An oversize hole will prevent rocker switch installation and cannot be repaired in the field. The entire customer access cover must be replaced. 3. Thoroughly clean area of any plastic shavings. 4. Install customer access cover in rear enclosure panel, securing with four screws. 5. 004890 6. Cut away one square inch (6.5 cm2) of insulating foam on inside of rear panel directly aligned with rocker switch hole. See Figure 17.
PAGE 8
See Figure 18. Connect crimped ends of 36 in. (91 cm) wire (C) and black wire from E-stop harness (D) to rocker switch terminals at customer access cover. Verify there is enough insulation removed to properly connect and disconnect wires. 4. 7. See Figure 20. Crimp an insulated barrel splice connector (E—supplied) to stripped end of 36 in. (91 cm) wire (C). Crimp open end of barrel splice connector to the stripped black wire on pin side of Deutsch connector.
PAGE 9
Activate Engine Shutdown Functionality The controller must detect the installed E-stop and rocker switch to activate emergency stop functionality. 1. Install 7.5A fuse. 2. Connect negative battery terminal and tighten nut. Verify controller is powered and generator is OFF 3. Disengage E-stop and turn rocker switch ON. 4. Push E-stop knob. Controller should detect that the E-stop has been engaged and will display “Emergency Stop Alarm.