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Generac Power Systems 005210-0

Generac Power Systems 005210-0
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STANDBY GENERATOR
OWNER'S MANUAL
This manual should remain with the unit.
A new standard of reliability
Serial Number
QT
1.5L
20kW
Model: 005210-0
CAUTION
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
Not intended for use in critical life support applications.
Cover014 Rev. A 10/05 Part No. 0F7921

Table of Contents

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Generac Power Systems 005210-0 Specifications

General IconGeneral
Model Number005210-0
CategoryInverter
Rated AC Power1600W
Maximum AC Power2000W
Power Output1600W
Peak Power Output2000W
Rated Voltage120V
Voltage120V
Rated Frequency60Hz
Frequency60Hz
Engine Displacement79 cc
Fuel TypeGasoline
Fuel Tank Capacity1.06 gallons
Starting MethodRecoil
Weight46.3 lbs
Engine TypeOHV 4-Stroke
Dimensions19.7 x 11.4 x 17.9 inches
Noise Level60 dBA

Summary

Safety Rules

General Hazards

Manufacturer recommends installation, service, and repair by authorized personnel. Adhere to codes and regulations.

Electrical Hazards

Generators produce dangerous voltages and can cause fatal electrical shock. Avoid contact with bare wires and ensure covers are in place.

Fire Hazards

Keep a fire extinguisher nearby. Do not use carbon tetrachloride type. Ensure proper ventilation.

Explosion Hazards

Ensure proper ventilation to prevent explosive gas buildup. Do not smoke near the generator. Keep the area clean.

Introduction

Read This Manual Thoroughly

Understand all instructions before operating. Contact dealer if any part is not understood.

Operation and Maintenance

Operator is responsible for safety checks and prompt maintenance. Proper maintenance ensures fewer problems.

How to Obtain Service

Contact an Authorized Service Dealer for servicing or repairs. Supply model and serial numbers.

Identification Record

Data Label

Contains important information like serial number, voltage, amps, wattage, phase, frequency, RPM, and power factor.

Generator Model and Serial Number

Key to engineering and manufacturing details. Always supply when requesting service or parts.

Equipment Description

Engine Oil Recommendations

Use high-quality detergent oil classified "For Service CC, SD, SE, SF." Use recommended SAE viscosity based on ambient temperature.

Coolant Recommendations

Use a mixture of half low silicate ethylene glycol base anti-freeze and deionized water. Add rust inhibitor if desired.

Engine Protective Devices

High Coolant Temperature Switch

Shuts down the engine if coolant temperature exceeds 140°C (284°F).

Low Coolant Level Sensor

Shuts down the engine if coolant level drops below a critical point to prevent overheating.

Low Oil Pressure Switch

Shuts down the engine if oil pressure drops below 8 psi.

Overcrank Shutdown

Stops cranking if the engine fails to start after a preset duration.

Overspeed Shutdown

Shuts down the engine if it exceeds a safe, preset speed value.

RPM Sensor Loss Shutdown

Shuts down the engine if the speed signal to the control panel is lost.

DC Fuse

Protects the control panel wiring and components from overload. Located inside the control panel.

Fuel Systems

Fuel Requirements

Generator may be equipped with Natural Gas, Propane Vapor (PV), or LP Fuel System. Check Btu content and required fuel pressure.

Natural Gas Fuel System

Natural gas is supplied in vapor state. Requires proper pressure regulation and piping.

Propane Vapor Withdrawal Fuel System

Utilizes vapors above liquid fuel in the supply tank. Best suited for smaller engines. Ambient temperatures affect efficiency.

LP Fuel System

LP is supplied as liquid and must be converted to gaseous state. Vaporizers are often used.

Specifications

Generator

Details on type, rotor/stator insulation, harmonic distortion, TIF, output leads, bearings, coupling, load capacity, and excitation system.

Engine

Specifications for make, model, cylinders, displacement, bore, stroke, compression ratio, air intake, valve seats, and lifter type.

Engine Lubrication System

Details on oil pump type, oil filter, and crankcase oil capacity.

Cooling System

Specifications for water pump, fan speed, fan diameter, air flow, coolant capacity, heat rejection, and maximum operating temperatures.

Fuel System

Details on fuel type, carburetor, secondary fuel regulator, fuel shut-off solenoid, and operating fuel pressure.

Electrical System

Specifications for battery charge alternator, static battery charger, recommended battery, and system voltage.

Power Adjustment for Ambient Conditions

Information on temperature and altitude deration adjustments.

Cold Weather Kit

Optional kit for cold climates, including battery warmer, junction box, and oil.

Reconfiguring the Fuel System

Steps to reconfigure the fuel system from Natural Gas to LP vapor.

General Information

Generator AC Lead Connections

Explains how AC connections are made based on voltage codes and stator assembly. Refers to wiring diagrams.

Four-Lead, Single-Phase Stator

Describes generators designed for 240V, 1-phase, 60 Hz loads, with factory connections.

Alternator Power Winding Connections

Explains generator power winding connections, including 3-phase alternators and their voltage ratings.

3-Phase Alternators

Details the design for 3-phase loads, winding connections, and rated voltages.

Installation

Preparation Before Start-up

Instructions assume proper installation by a qualified contractor. Read safety rules.

Transfer Switch

NEC requires a transfer switch to prevent backfeed between electrical systems. Proper location and mounting are critical.

Fuel System

Ensure fuel supply delivers correct fuel at correct pressure, is purged, and leak tested. No fuel leakage permitted.

Generator Set Lubrication

Check engine crankcase oil level before operating. Engine shipped with "break-in" oil. Check gearbox oil if equipped.

Prior to Initial Start-up

Generator must be properly prepared. Using incorrect fluids may result in engine failure.

Engine Coolant

Ensure cooling system is properly filled with recommended coolant mixture. Check for leaks.

Belt Tension

Check engine fan belt tension and condition. Proper tension deflects belt about 3/8 to 5/8 inch.

Electrical System

Ensure generator is properly connected to earth ground. Ensure battery is charged and properly installed. Check electrical connections.

Initial Inspection for QT Genset Startup

Check for freight damage, manuals, fluid levels, fuel piping, muffler installation, airflow, clearances, wiring, grounding, battery charger, control panel connections, and unit security.

Start-up Checklist

Preparation for Start-up

Open battery charger breaker, remove control panel fuse, connect battery cables, close battery charger breaker, measure battery voltage.

Start-up Inspection

Details a standard form completion and distribution for start-up inspections by authorized dealers.

Operation

Generator Control and Operation

Refer to the appropriate control panel operator's manual for unit control details.

Operating Unit with Manual Transfer Switch

Procedure for manual transfer switches that do not provide automatic start-up.

Engine Start-up and Transfer

Steps for starting the engine and transferring load using a manual transfer switch. Includes safety warnings.

Retransfer and Shutdown

Steps to transfer load back to utility power and shut down the generator.

Operating Unit with Automatic Transfer Switch

Details operation with automatic transfer switches like RTS, HTS, or GTS-type. Engine starts/stops automatically or manually.

Maintenance

Maintenance Performed by Authorized Service Facilities

Safety precautions before performing maintenance, including disconnecting power and removing fuses.

Every Three Months

Check battery condition, test fuel system, check transfer switch, inspect exhaust, check ignition, and check fan belts.

Once Every Six Months

Test engine safety devices like low oil pressure, low coolant level, and high coolant temperature.

Once Annually

Test engine governor, clean and inspect generator, and flush cooling system.

First 30 Operating Hours

Change engine "break-in" oil and filter.

First 100 Operating Hours

Change engine oil and filter, retorque cylinder head, and retorque intake/exhaust manifold.

Every 500 Operating Hours

Service air cleaner, check starter, and check engine DC alternator.

Every 800 Operating Hours

Retorque cylinder head, retorque intake/exhaust manifold, check engine compression, and check valve clearance.

Cooling System

Ensure air intake and outlet openings are unobstructed for proper operation. Overheating occurs without sufficient cooling air.

Overload Protection for Engine DC Electrical System

Engine controller is protected by a 15 amp fuse. Overcurrent protection devices will open if overloaded.

Checking Fluid Levels

Check engine crankcase oil level, battery fluid level, and engine coolant level.

Exercise System

Start the generator engine once every seven days and run for at least 20 minutes.

Inspect Cooling System

Inspect hoses for damage, deterioration, leaks, and check hose clamps for tightness.

Perform Visual Inspection

Visually inspect the entire engine-generator monthly for damage, loose fasteners, or leaks.

Inspect Exhaust System

Inspect exhaust system pipes, mufflers, clamps for condition, tightness, and leaks.

Check Fan Belt

Inspect fan belts every three months. Replace damaged or worn belts. Check belt tension.

Inspect Engine Governor

Visually inspect the electronic governor. Do not attempt to adjust the governor.

Changing Engine Oil

Procedure for draining oil and replacing the oil filter. Ensure proper oil level and check for leaks.

Changing the Engine Air Cleaner

Procedure for replacing the engine air cleaner filter.

Spark Plugs

Procedure for checking and adjusting spark plug gap or replacing spark plugs.

Coolant Change

Annually have the cooling system drained, flushed, and refilled by an authorized service facility.

Miscellaneous Maintenance

General maintenance tasks including cleaning the generator and inspecting insulation resistance.

Cleaning the Generator

Keep generator clean and dry. Periodically clean exterior surfaces and internal windings.

Battery

Precautions for handling batteries, including not using jumper cables and dangers of hydrogen gas.

Battery Maintenance

Inspect battery posts, cables, and fluid levels. Check state of charge and condition.

Battery Replacement

Guidelines for replacing batteries, specifying the BCI Group No. and CCA rating.

Service Schedule

1 An early inspection of the generator set...

Monthly inspection to ensure readiness and identify problem areas. Requires safety steps before maintenance.

2 A break-in service inspection of the generator set...

One-time inspection after three months or 30 hours. Requires special tools and knowledge.

3 An operational inspection of the generator set...

Semi-annual inspection for readiness and problem identification. Requires special tools and knowledge.

4 A mid-level inspection of the generator set...

Annual inspection for readiness and problem identification. Requires special tools and knowledge.

Troubleshooting Guide

Engine wont crank.

Lists common causes for an engine not cranking, such as blown fuses, battery issues, or defective starter components.

Engine cranks but wont start

Identifies causes like out of fuel, defective solenoid, open wires, or bad spark plugs for an engine that cranks but won't start.

Engine starts hard, runs rough.

Potential issues include plugged air cleaner, fuel line, defective spark plugs, or incorrect fuel pressure.

Engine starts then shuts down.

Common causes include low oil level, overheating, defective low oil pressure or coolant switches, or control module failure.

AUTOOFFMANUAL Switch at OFF, engine continues to run

Troubleshooting for the AUTO/OFF/MANUAL switch and associated wiring or control module issues.

No AC output from generator.

Checks for main breaker, circuit breaker/fuses, transfer switch position, generator failure, or thermal breaker.

Warranty

Generac Power Systems Standard Limited Warranty for Home StandbyLight Commercial Product 45 kW and Below

Details the limited warranty for Generac standby/light commercial products, covering parts and labor for defects.

Warranty Schedule

Outlines warranty coverage for components, parts, and labor for the first two years. Requires start-up and registration.

This Warranty Shall Not Apply to the Following:

Lists exclusions from warranty coverage, such as normal maintenance, misuse, environmental damage, and unauthorized modifications.

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