OWNER/OPERATOR S MANUAL

Transcription

1 OWNER/OPERATOR S MANUAL MAGNUM POWER 12KW / 18KW / 23KW NATURAL GAS / LP GAS GENERATOR Proposition 65 The engine exhaust and some of its constituents are known by the state of California, USA to cause cancer, birth defects and other reproductive harm. Revision: B Date: 4/05/01 Part #: MAGNUM PRODUCTS, INC. 918 Knopf Road Berlin, Wisconsin Ph: (920) Fax: (920)

2 table of contents MGL12 Specifications... 3 Safety... 4 Preface... 6 Controller Features... 7 Display and Automatic Fault Shutdowns... 7 Warning Light... 8 Resetting The Periodic Maintenance Timer... 8 Installation... 9 Electrical Wiring Procedure Typical Installation of Generator and Utility Power Components Generator and Utility Power to Transfer Switch Diagram Voltage Connection Diagram Fuel Supply to Engine Information Installing The Gas Fuel System Fuel-To-Engine Application Natural Gas Application L.P. (Propane) Gas Application Operation Prestart Checks Start Functions Controller Resetting Procedure Manual Start and Transfer Manual Retransfer and Shutdown Automatic Operation Automatic Operating Sequence Battery Storage Instructions Cooling Troubleshooting Service Schedule Wiring Diagrams Exploded View of Control Box and Parts List Exploded View of Generator Set and Parts List Warranty Engine Serial # Engine Model # 2

3 1 specifications Generator MGL12 MGL18 MGL23 L P Gas Rated Maximum Power Capacity (Watts) Standby / Continuous 11,800 / 10,500 16,900 / ,900 / 20,500 Natural Gas Rated Maximum Power Capacity (Watts) Standby / Continuous 9,400 / 8,300 13,000 / 11,500 20,500 / 18,000 Rated Voltage (1 phase) 120/240 V 120/240 V 120/240 V Rated Maximum Load 120/240 V 100/50 A 150/75 A 200/100 A Rotor and Stator insulation Class F Class F Class F Rated AC Frequency RPM 1800 RPM 1800 RPM Transfer Switch Amperage Rating 100 or 200 A, 100 or 200 A, 100 or 200 A, 240 V 240 V 240 V Engine Make Nissan Nissan Nissan Model CG 13 H 20 H 25 Type of Engine 4-Cycle, 4-Cycle, 4-Cycle, Liquid Cooled Liquid Cooled Liquid Cooled Number of Cylinders Displacement 1.3 Liter 2.0 Liter 2.5 Liter Valve Arrangement 4-Valve DOHC Overhead Valve Overhead Valve Ignition System Solid State Solid State Solid State Starter 12 V DC 12 V DC 12 V DC Air Cleaner Paper Type Paper Type Paper Type Oil Filter Full Flow Full Flow Full Flow Spin-on Spin-on Spin-on Crankcase Oil Capacity 3.9 U.S. Quarts 4.0 U.S. Quarts 4.0 U.S. Quarts (Consult engine operators manual for oil recommendations) Thermostat Temperature Temperature Temperature Activated Activated Activated Generator Dimensions (All Models) Minimum Battery Recommendations* (All Models) Length Inches (156.2 cm) Voltage - 12 Cold Cranking Amps (CCA) Width - 32 Inches (81.3 cm) Group - 56 Amp-Hour Capacity - 65 Height - 38 Inches (96.5 cm) * Use a 750 CCA battery when operating in temperatures below 32 F (0 C). 3

4 2 safety The following symbols are used throughout this manual. Follow listed instructions to ensure your safety. Read this manual carefully. Know your equipment. Consider applications limitations and potential hazards specific to your unit. This equipment is designed for specific applications. Do not modify or use for any application other than which it was designed. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. The following Safety precautions apply whenever using, storing or servicing Magnum Generators or their engines to reduce the possibility of personal injury. Overlooking or ignoring these precautions can lead to personal injury or product damage. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury or product damage. Indicates operation or maintenance information which is helpful to improve performance or operation. ELECTROCUTION FLASH HAZARD 1. Turn off utility power and turn off the generator to prevent electrocution before servicing. 2. Ensure that the unit is properly grounded. 3. Move the generator main circuit breaker to the OFF position when servicing or troubleshooting the unit. 4. The output voltage of the generator can cause a fatal electric shock. Avoid contact with any alternating current wiring. 5. Use extreme caution when servicing this equipment in damp or wet conditions. 6. Do not remove control box cover when the engine is running. Exposed live electrical terminals can cause electrical shock. 7. This unit is a single-phase stand-by electrical source. Check your electrical requirements before installing. 8. Use a ground fault circuit interruptor (GFCI) in damp or highly conductive areas and construction sites to prevent electrical shock. Magnum Products Inc. recommends that a trained and licensed professional perform all electrical wiring and testing functions and all fuel connections. Installation should be in compliance with the United States Na-tional Electric Code (NEC), state and local codes and Occupational Safety and Health Association (OSHA). CARBON MONOXIDE HAZARD 1. Engine exhaust contains carbon monoxide, a deadly, odorless, invisible gas, which, if inhaled, causes nausea, fainting or death. 2. Never allow snow, leaves, or other debris to block air or exhaust openings to generator. 4

5 3. Operate only in well-ventilated areas. 4. Never operate indoors without exhaust system to the outside. 5. Ensure that exhaust cannot seep into enclosed rooms. 1. Improper installation can damage your electrical system and cause property damage, serious injury or death. 2. A potential for fire or explosion always exists when using natural gas or L.P. (Propane) gas. 3. Ensure that all connections, hoses, and clamps are secure and free of leaks. 4. Turn fuel shut-off valves to the OFF position when the unit is serviced or if there is a strong odor of fuel, call fuel supplier from a remote location. 5. Never smoke or use open flames near the unit, fuel storage tank or battery. 6. Follow all codes pertaining to installation and operation of fuel storage tanks. 7. Keep a fire extinguisher close by. Consult your fire department for best type of extinguisher to use. 8. Batteries contain sulfuric acid, which can cause severe injury or death. Sulfuric acid can cause permanent eye damage, burn flesh, and eat holes in clothing. Protective eye wear and clothing are necessary when working on or around the battery. If acid splashes in or around the eyes, flush with water for 15 minutes. Seek immediate medical attention. BURN HAZARD EXPLOSION FIRE HAZARD After operating, allow unit to cool before touching components. Your generator must never be operated under the following conditions: a. Noticeable change in engine speed b. Loss of electrical output c. Equipment connected to the generator overheats d. Sparking occurs e. Engine misfires f. Excessive generator vibration g. Operating on a combustible surface Don t wear loose clothing, jewelry, etc. that may be caught in rotating parts. Don t insert objects through the venting slots, even if the generator is not operating. Follow all Safety Instructions. Never operate without protective covers or housings or with broken or missing parts. Contact Magnum Products Inc. for replacements. Never operate generator when ambient temperature is over 110 F (43 C). Prolonged exposure to sound levels in excess of 85DBA can cause permanent hearing loss. Wear hearing protection when near an operating generator. Do not operate without a functional exhaust system. Keep the generator clean and free of oil, mud, and other foreign matter. Make sure the engine and generator reach operating speed before connecting any electrical load. ACCIDENTAL STARTING Turn the main circuit breaker to the OFF position and remove the battery cables from the battery (negative first) before performing any service work. When finished, reconnect the battery cables (positive first), then turn the main circuit breaker to the ON position. Cabinet should be locked at all times. 5

6 3 preface We all depend on electric power in our daily lives. It makes our lives easier and more enjoyable and is normally so readily available that we take it for granted. Whether we are at home, work, shopping or out for entertainment, we rely on electrical power to allow us to do the things we want. At times, though, certain circumstances occur to disrupt this flow of electricity. Any number of problems can cause this type of disruption and it is at this time that you need the reliable power of Magnum Power Generators. Your home or business will be safe-guarded from damage or loss due to a sudden and/or prolonged power loss. Your Magnum Power Generator will sense the loss of utility supplied electrical power and automatically provide your premises with the power you need. When utility power returns, the generator will transfer back to that supply and await the next time it is needed. The peace of mind and feeling of security provided is apparent whether you are there or not. YOU CAN REST ASSURED WITH MAGNUM POWER GENERATORS! The generator sets referred to in this manual are very high quality, electric power sources. They are engine driven, emergency systems intended to supply temporary electric power to lights, appliances, power tools, and other industrial, commercial and home products. Thoroughly study the safety and operating instructions to ensure you are acquainted with the generator set. Proper preparation, operation and maintenance will result in safe operation, best performance and generator set longevity. Refer to the Service Schedule chart for maintenance times and to the Troubleshooting chart in this manual for diagnosing problems. These generator sets are constantly upgraded. Specifications described in this manual are subject to change without prior notice. Before using, determine the suitability of the product for its intended use. Magnum is not responsible for the misuse of the generator. Refer to the separate engine manufacturer s manual for recommended engine oil, filters, spark plugs, etc. These generator sets are powered by liquid cooled engines. This liquid cooling works in conjunction with air drawn into the enclosure, across the engine and exhausted to keep both generator and engine at the proper operating temperature. In climates where the temperature drops below 40 F (4 C), a block heater must be installed on the engine. Contact dealer for details. Failure to do so can result in poor performance or component failure. 6

7 4 controller features Any tampering or adjustments to the controller can cause serious injury or death. DISPLAY AND AUTOMATIC FAULT SHUTDOWNS The generator controller has four essential features: 1. A start control switch [A] that enables automatic (stand-by) starting UP position, manual starting DOWN position, or OFF ("O") middle position. 2. A line circuit breaker [B] has been sized for generator output in the event of an overload or a short circuit. If the generator set circuit breaker trips, reduce the load, and switch the breaker back to the ON position. The generator set will continue to run even if the circuit breaker is in the OFF position, but there will be no output voltage. 3. A monitoring system that incorporates a display (C) to constantly indicate various generator and engine functions. Also, holding the switch (D) below the display in the UP position will show engine running hours, engine sender condition, periodic maintenance time, and engine fault set points. Holding the switch DOWN will "lock in" a specific display. 4. A fault shutdown condition that will cause the engine to stop running because of a sensed problem. There is also a warning light [E] that illuminates as a prealarm for a potential fault condition. If the generator set fails to start after five attempts, the overcrank shutdown will be activated. If the generator is in an overspeed or underspeed mode, the shutdown will be activated. If there is a current overload, the shutdown will be activated. The engine is also equipped with an oil pressure sender that will activate the low oil pressure shutdown if the oil pressure drops too low, and a water temperature sender that will activate a high temperature shutdown if the engine temperature exceeds safe level. These errors are indicated on the display. Generator information is shown on the top line of the display and engine information is shown on the bottom line of the display. Both are scrolled continuously while the generator is operating. 7

8 The generator features are: Volts Displays the AC output voltage being produced by the generator. Phase Indicates which phase is currently being displayed. Amps Displays the AC output amperage produced by the generator. If the generator is operating at noload, output amperage will display "0". Hertz Displays output frequency. The reading should be approximately 60 Hz under a no-load condition. An underspeed fault shutdown will occur after 15 seconds at 50 Hz (1500 RPM). An overspeed fault shutdown will occur at 75 Hz (2250 RPM). The engine features are: Oil Pressure Displays engine oil pressure. The gauge registers oil pressure between PSI. Normal operating pressure is between PSI. If oil pressure drops below 15 PSI for more than five seconds, a fault shutdown will occur. Fuel Fuel level will not be indicated. Temperature Displays the temperature of the engine coolant. If the temperature goes above 240 F for more than five seconds, a fault shutdown will occur. Battery This display monitors engine battery voltage. Normal voltage is between 13.5V-14.5V. The display will show coolant sender and oil pressure sender fault. It will also show "Time to Service" information. A shut down will not occur under these conditions. After a fault shutdown, the generator operating system must be reset. Place the engine start switch in the OFF ("0") position, then go back to the AUTO or MANUAL mode. WARNING LIGHT The amber warning light will turn on prior to a fault condition occurring. This calls attention to a potential fault condition. When the warning light illuminates, the LCD will start blinking to indicate which function is approaching its fault value. The pre-alarm set points are: High Temperature 235 F. Low Temperature 70 F. Low Oil Pressure 20 PSI. Fuel Level N/A. Time to Service 0 hours. Sender Failure Engine coolant and oil pressure senders. A fault shutdown will occur if an overcrank condition arises. This will be after the fifth 10-second crank/rest cycle. Current load is also monitored. The values are internally programmed at the factory and are different for each generator model. A fault shutdown will occur when an overload condition is sensed. Determine and eliminate the cause by checking all loads at the generator to make sure they do not exceed the generator power rating. RESETTING THE PERIODIC MAINTENANCE TIMER After maintenance has been performed on the generator set, it is necessary to reset the timer. If the timer is at "0", hold the switch below the LCD to the UP position until the "Time to Service" resets to 250 hours. If the service time is greater than "0", (maintenance was performed prior to the timer running out) hold the switch up for 30 seconds to reset the timer to 250 hours. 8

9 5 installation This generator set may have been transported by common carrier truck to dealer destinations. It is possible that hardware and/or electrical connections may have become loosened. As part of original installation, always include the following: 1. Check all outside and inside hardware for tightness. Tighten as necessary. 2. Check the termination points of all wiring in generator control panel, engine wiring, and transfer switch. Tighten or repair as necessary. 3. Normally, loose wires can be found by manually pulling wires to the left and right of the connection point. The Magnum Power 12KW, 18KW and 23KW standby generators were not designed as a do-it-yourself installation project. 2. Mount the generator on a solid foundation. A 3 in. cement slab is recommended along with anchoring the unit to the foundation with bolts. Allow 3 ft of clearance around the entire generator for maintenance, service, and exhaust gases. 3. The location must provide adequate airflow for engine and generator cooling. To prevent damage to the generator set caused by overheating, ensure that all air inlets and outlets are free from obstruction at all times. In climates of extreme cold temperatrures, a coolant heater must be installed on the engine. Failure to do so can result in poor performance or component failure. Contact dealer for details. It is equally important to carefully plan the installation in conjunction with qualified installation professionals. Take into consideration: 1. Location of the generator indoor or outdoor. (Proper exhaust ventilation is necessary. Place in an area that is not prone to flooding.) 4. The transfer switch must be sized to handle the ampere rating. 5. The generator s voltage and phase ratings must be in accordance with the utility supply and load circuit voltage and phase rating. 6. Never install the generator on combustible material. If the installation location is made of combustible material, the qualified installation professional must take the necessary measures to insulate the generator. 7. Decide what the critical loads are, and choose the proper isolation method. 8. Choose which fuel type/source to use for the generator. Locate the generator as close as possible to that type and source. (Check all fuel lines for leaks). 9

10 ELECTRICAL WIRING PROCEDURE Typical Installation of Generator and Utility Power Components (A) Ground stake and ground wire for separately derived systems where there is no direct generator neutral connection to the utility company neutral. Furnished by the installer. For a system that does not have utility power (separately derived), the generator neutral must be bonded to the ground at the generator set. (B) Normal utility power meter and power input to normal distribution panel. (C) Original electric distribution panel. This supplies power for all non-emergency loads plus the emergency loads connected to the utility side of the transfer switch. (D) Separate smaller distribution panel for the emergency loads that were taken from the original distribution panel. Furnished by the installer. (E) Transfer switch with UL 1008 listing, either 100 amp or optional 200 amp size, with remote start stop function. (F) Generator set output wires in conduit. (G) Control wires in conduit. Do not turn on utility power until all electrical wiring has been completed and the battery has been properly installed and the battery cables have been connected (positive first, then negative). Use a ground fault circuit interrupter (GFCI) in damp or highly conductive areas and construction sites to prevent electrical shock. Electrical wiring should be in compliance with the United States National Electrical Code (NEC), state and local codes and Occupational Safety and Health Association (OSHA). Do not install the 12VDC battery until all the other wiring procedures have been completed. 10

11 Generator and Utility Power to Transfer Switch Diagram (A) Generator power (B) Utility power (Service entrance) (C) Electrical load (D) Transfer switch (E) Utility power to switch hook-up and test point (U1) (F) Utility power to switch hook-up and test point (U2) (G) Neutral (Ground) (H) Generator power to switch hook-up and test point (E1) (I) Generator power to switch hook-up and test point (E2) (J) Remote start (K) Remote annunciator (L) Power wires for trickle charger and block heater Voltage Connection Diagram Refer to transfer switch manual for specific installation. Line Side To Get Load side - Use Hz L1-L Hz L2-L Hz L1-L2 Never connect leads L1 and L2 together on the line side. 11

12 FUEL SUPPLY TO ENGINE INFORMATION Fuel line diameter depends on the amount of fuel needed to run an engine-generator at full load and the distance the fuel must be moved. Refer to specification Table A for fuel consumption. Table B shows pipe size for L. P. (Propane) gas. Table C shows pipe size for natural gas. Table A: Fuel Consumption Use horsepower (H. P.) to find fuel consumption. Then, match that figure up with the length of fuel pipe. Example: An MGL18 generator with natural gas fuel which is located 100 feet from fuel source. Locate fuel consumption in Table A for match MGL18 (= 217 cu. ft.). Find closest fuel consumption in Table C that is greater than 217 cu. ft. in 100 foot column (= 400 cu. ft.). Find the pipe diameter for this amount of fuel on left side of Table C (= 1-1/4 in.). Table B: L. P. (Propane) Gas Pipe Sizing Maximum pipe capacity in thousands of BTU per hour for a gas pressure drop of 0.5 inches of water column (14-16 inches water column gas pressure at engine inlet). Table C: Natural Gas Pipe Sizing Maximum pipe capacity in cubic feet of gas per hour for 0.5 psi or less, and a pressure drop of 0.5 inches of water column based on a 0.60 specific gravity gas (14-16 inches water column gas pressure at engine inlet). INSTALLING THE GAS FUEL SYSTEM In no way should the following information be understood to conflict with existing local, state, or national fuel gas codes which may differ from the information in this manual. Contact your local fuel supplier for specific sizing information. Cast iron pipe fittings such as main fuel feed lines, elbows, tees, couplings, etc. shall be used. Aluminum tubing shall not be used in exterior locations or where it is in contact with masonry, plaster walls or insulation. TABLE A: FUEL CONSUMPTION THOUSANDS OF BTU PER HOUR / CUBIC FEET PER HOUR Unit MGL12 MGL18 MGL23 L. P. (Propane) gas Natural gas TABLE B: L. P. (PROPANE) GAS PIPE SIZING IN THOUSANDS OF BTU PER HOUR Length (FT.) DIA (Nominal iron pipe sizes) 1/2" /4" " /4" /2" " TABLE C: NATURAL GAS PIPE SIZING IN CUBIC FEET PER HOUR Length (FT.) DIA (Nominal iron pipe sizes) 1/2" /4" " /4" /2" /4" "

13 Fuel-to-Engine Application A specific assembly of components for either natural or LP (Propane) gas is required for the generator set. Certain parts and their positioning must change to adapt to the difference in fuels. For application, refer to the drawings on pages 13 and 14. Natural Gas Application H E G C F A A B D A (A) Inlet nipple (in. NPT x in.) operating range; inches water column gas pressure (B) Elbow 90 (in. NPT) (C) Fuel solenoid valve (D) Fuel Assy Bracket (E) U Bolt (1/4 in. x 2.0 in.) (F) Regulator *Install with valve upward ** Engine side port to pull 5 inches water column gas pressure (G) Elbow 90 (3/4 in. NPT) (H) Hose fitting (3/4 in. NPT x 1 in.)

14 L.P. (Propane) Gas Application H F E G A C A B D A (A) Inlet nipple (in. NPT x in.) operating range; inches water column gas pressure (B) Elbow 90 (in. NPT) (C) Fuel solenoid valve (D) Fuel Assy Bracket (E) U Bolt (1/4 in. x 2.0 in.) (F) Regulator *Install with valve downward and the spring removed **Engine side port to pull 1 (negative) inch water column gas pressure (slight vacuum) (G) Elbow 90 (3/4 in. NPT) (H) Hose fitting (3/4 in NPT x 1 in.)

15 6 operation PRESTART CHECKS CONTROLLER RESETTING PROCEDURE The following procedure must be used to reset the controller after a fault condition. Never operate generator when ambient temperature is over 110 F (43 C). Before starting the generator, perform the following procedures to ensure peak performance: 1. Check engine oil level. It should be at or near the full mark. 2. Visually inspect engine, generator, and exhaust system to ensure they are free from any obstructions or debris that may block air flow or possibly ignite from contact with hot engine components. The engine compartment should be free of any objects foreign to its design. 3. Inspect the battery cables to ensure they are tightly connected and free of corrosion. 4. Maintain a clean air filter to prevent contaminants from entering the engine. START FUNCTIONS AUTO/OFF-RESET/MANUAL SWITCH: Set the toggle switch to the "AUTO" position for automatic operation. Set toggle switch to the "MANUAL" position to crank and start the generator engine. Set switch to "OFF" position ("O") to shut down an operating engine. Automatic operation will not be possible when "OFF" or "MANUAL" are selected. 1. Place the toggle switch in the "OFF/RESET" position. 2. Switch the circuit breaker to the "OFF" position, and disconnect the load. 3. Correct the fault condition. 4. Place the toggle switch in the "MANUAL" or "AUTO" position for startup. MANUAL START AND TRANSFER Place the AUTO/OFF-RESET/MANUAL switch in the "MANUAL" position. The engine controller will begin the starting procedure detailed above. If the generator does not start, return the switch to the OFF-RESET position for the duration of 10 seconds and return the switch to the "MANUAL" position. If the generator completes a second starting cycle without successfully starting, refer to the troubleshooting section of this manual. To start the engine manually and transfer load circuits to the EMERGENCY (standby) power source manually, proceed as follows: 1. Shut off utility power by putting the main line circuit breaker in the "OFF" position. With this switch set to "AUTO", the engine can crank and start suddenly without warning. Such automatic start up normally occurs when utility source voltage drops below a preset level. To prevent possible injury that might be caused by such sudden starts, set switch to "OFF" ("O") before working on or around the unit. Fault display: Use this readout to help troubleshoot. The display will function with the generator placed in the AUTO position. Do not try MANUAL operation of the transfer switch until all power supplied to the switch has been positively turned "OFF". Failure to turn OFF the supplied power may result in an extremely dangerous and potentially lethal electrical shock. 2. Check for proper manual operation of the automatic transfer switch using a transfer switch handle. See Generator and Utility Power to Transfer Switch Diagram for voltage tests points. 15

16 3. After verification that transfer switch operates manually, actuate the transfer switch main contacts to the UTILITY position, i.e., LOAD terminals connected to the utility power supply. 4. Turn ON the utility power supply to the transfer switch with whatever means provided (normally the utility main line circuit breaker). Use an AC voltmeter to verify that correct load voltage is available at transfer switch main contact, terminal lugs U1 (E) and U2 (F) and ground at neutral post (G). Voltage for 120 V output should be V. Voltage for 240 V output should be V. 5. Set the AUTO/OFF-RESET/MANUAL switch to the "OFF" position on the generator control panel. 6. Turn OFF the utility power supply to the transfer switch. 7. Set the generator s main circuit breaker to the "OFF" position. 8. Turn off all electrical loads. Initial testing and adjustment should be conducted with the generator at no load. 9. Set the AUTO/OFF-RESET/MANUAL switch to the "MANUAL" position to start the generator engine manually. Let the unit stabilize and warm up for a few minutes. 10. Set the main circuit breaker on the generator to the "ON" position. 11. Using an accurate AC voltmeter, verify that correct rated voltage and frequency are being supplied to transfer switch terminals E1 (H), E2 (I), and neutral ground (G). a. Do not proceed until generator output frequency and voltage are correct. b. If AC frequency is not within Hz at noload, contact authorized service technician. DO NOT attempt to adjust the governor. Only qualified service facilities should adjust the governor. Excessively HIGH operating speeds are dangerous and increase the risk of personal injury. LOW speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and AC voltage are supplied only at the proper governed speed. Incorrect AC frequency and/or voltage may damage some connected electrical load devices. ONLY QUALIFIED SERVICE TECHNICIANS SHOULD ADJUST THE ENGINE GOVERNOR. On units connected for 240 volts, 1 phase output, line-toline voltage at 60 Hz should be 240 volts ±10%. Take these initial readings with the generator running at noload. DO NOT PROCEED UNTIL NO LOAD FREQUENCY AND VOLTAGE ARE CORRECT. 12. Verify that all utility power has been turned "OFF" to the transfer switch. Then, manually actuate the transfer switch main contacts to the "STANDBY" position, i.e., LOAD connected to the GENERA- TOR. 13. Turn ON electrical loads that almost equal the generator s wattage amperage capacity. With an AC frequency meter, check frequency at transfer switch terminals E1 (H) and E2 (I). With generator under load, frequency should not drop below 58 Hz. 14. Let the generator run under load for at least minutes. Check for unusual vibration, noise, high temperature, and other indications of abnormal operation. MANUAL RETRANSFER AND SHUT DOWN Electrical loads may be retransferred back to the utility power and the generator can be shutdown as follows: 1. Verify that utility power supply to the transfer switch has been positively turned "OFF". 2. Set the generator s main circuit breaker to its "OFF" position. 3. Let the generator engine run at no-load for several minutes to stabilize internal unit temperatures. 4. On the generator control panel, set the AUTO/OFF- RESET/MANUAL switch to "OFF". Wait for engine to come to a complete stop. 5. With the manual transfer handle, move the switch s main contact back to the utility power position. This reconnects the utility power supply. 6. Turn ON the utility power supply to the Transfer Switch. The utility power source now powers the loads. 16

17 AUTOMATIC OPERATION To set the system for fully automatic operation: 1. Check that load circuits are connected to the utility power supply. 2. Set the AUTO/OFF-RESET/MANUAL switch to the "AUTO" position. 3. Set the generator main circuit breaker to its "ON" position. When the controller receives the start command from the transfer switch, the starting procedure will begin. If the generator fails to start, the transfer switch will stay connected to utility power. Refer to the troubleshooting section of this manual for more information. The controller will start the engine if either: The control switch is in the MANUAL position. The control switch is in the "AUTO" position and the remote start contacts are closed. If the engine is already running, the start attempt will be cancelled. The controller will attempt to start the engine by engaging the fuel solenoid and the starter relay. The speed input is monitored to determine if the engine starts. When running speed is detected, the starter relay is disengaged and normal monitoring is begun after the startup delay period of 10 seconds. This delay allows oil pressure to be established and allows the engine speed to stabilize. Cranking will continue for 15 seconds if the engine does not start. After this time, the fuel solenoid and the starter relay are disengaged for a rest period of 10 seconds. After the rest period, another crank attempt is performed. AUTOMATIC OPERATING SEQUENCE The sequence of automatic operation is briefly described as follows: 1. If the utility source drops below a preset level a delay timer starts. 2. After the delay time, the transfer switch sends a signal to the engine remote contacts to start. The delay timer is provided to override momentary outages and prevent nuisance starting of the generator. 3. The transfer switch senses the voltage of the emergency source. When the emergency source reaches a preset level, transfer delay timing begins. When this time is completed, the load circuits are transfered to the emergency source. 4. If the utility source voltage is restored, above the preset level, the transfer switch monitors the voltage for a period of time. After this time the switch retransfers load circuits back to the utility power source. 5. After load circuits are retransfered, the engine will go through its cool down procedure before shutting down. BATTERY Use a 12-volt battery with a minimum of 450 cold cranking amps for the generator. The climate will be a major factor in deciding the appropriate battery. If the temperature dips below 0 F for extended lengths of time, a more powerful battery may be necessary. Consult your local dealer/distributor for assistance. After five unsuccessful attempts, the controller will issue an OVERCRANK shutdown fault. If this occurs follow the guidelines in the troubleshooting section of this manual. If the generator set is not run on a regular basis, use an external battery charger to sustain full charge. Follow the safety precautions in the beginning of this manual when servicing the battery. Battery gases can cause an explosion, which can cause severe injury or death. Take extreme care when removing and replacing battery terminals. Reversed connections can cause severe damage to the generator controller. 17

18 7 storage instructions Storage procedure for the engine: 1. Run the engine to warm up the oil. 2. Drain oil from the crankcase. 3. Refill with fresh oil of recommended grade. 4. Remove spark plugs and pour 1oz of engine oil into cylinders. 5. Replace spark plugs and crank slowly to distribute oil. 6. Clean dirt and chaff from cylinders, cylinder head fins, blower housing, rotating screen and muffler. 7. Start generator, shut off fuel supply, and let the engine stop from lack of fuel. 8. Disconnect fuel source and cap fuel inlet. Enclosure and Generator preparation: Allow the generator to be completely cooled. Disconnect battery cables (negative first), clean, and wrap with non-absorbent adhesive tape. Remove dirt and dust from outside and inside of cabinet. Remove any foreign objects. Store in a clean and dry area, but NOT near anything which uses a pilot light or any device that can create a spark. Place a tarp over the entire unit to prevent dust and dirt build-up. 18

19 8 cooling These generator sets are powered by liquid cooled engines. The system is thermostatically controlled which allows liquid flow through the engine when the temperature reaches F (74-80 C). It is imperative for proper operation and longevity that the cooling system be maintained according to the engine manufacturer s manual and the maintenance chart in this manual. The engine draws in air from the generator side, and draws the air across the engine, exhaust, generator end, and out the radiator end of the enclosure. The enclosure for the genset was designed to take in and blow out a specific amount of air. Any obstructions to the airflow can cause severe engine and generator damage from overheating. In climates of extreme cold temperatrures, a coolant heater must be installed on the engine. Failure to do so can result in poor performance or component failure. Contact dealer for details. 19

20 9 troubleshooting When problems arise with the generator set, don t overlook the obvious solutions. More times than not, a simple solution will fix the problem. If you are unable to correct the problem call your local dealer/distributor for assistance. Problem Possible Cause Source/Solution Generator does not Poor battery connections or Inspect cable connections for corrosion and turn over. cables are reversed. correct placement. Controller fuse is blown. AUTO/OFF-RESET/MANUAL Switch is off. Defective AUTO/OFF-RESET/ MANUAL Switch. Inspect fuse and replace if necessary. Place switch in desired position. Perform a function test. Generator turns Fuel source. Inspect fuel lines to ensure the generator over, but does not set is receiving the appropriate level of fuel start, or starts pressure. Check to ensure that the difficulties. correct fuel source has been supplied. Primary and Secondary Regulators. Weak Battery. Low oil pressure shut down. (LCD will display) Fouled spark plugs or loose connection. Engine timing off. Perform a function test. Check voltage and recharge or replace. Check oil level and pressure. If both are within the recommended levels, check controller for function. Inspect spark plugs, and replace if necessary. Check for tight connection to spark plug wire. Service engine. No AC output from Main Breaker in "OFF" position. Place breaker in the "ON" position. generator. Main Breaker tripping from overload. Reduce the load on the generator. Main Breaker tripping from a short circuit. Voltage Regulator Generator problem. Find the short in the system and correct. Check fuse in voltage regulator. Check voltage regulator. Contact your local dealer or distributor for assistance. 20

21 Problem Possible Cause Source/Solution High output Faulty Voltage Regulator Replace voltage regulator. (Frequency) Generator problem. Governor Setting Contact your local dealer or distributor for assistance. Contact your local dealer or distributor for assistance. Low output Overloading generator. Reduce the load on the generator. (Frequency) Faulty Voltage Regulator Replace voltage regulator. Generator problem. Governor Setting Contact your local dealer or distributor for assistance. Contact your local dealer or distributor for assistance. Generator stops No Fuel. Check fuel source. suddenly. Low oil pressure shutdown. Check oil level and pressure. (LED will be steady Red) Over temp. shutdown Blown Controller Fuse. Overspeed shutdown. (LED will be steady Red) Engine Problems. Check coolant level and thermostat. Replace fuse. If it blows again, inspect controller for faults. Place the controller in the "OFF" position for 30 seconds and return to desired position. If the shut down occurs again, check the governor, mag pick-up, fuel supply and controller. Service engine. DUSTY OR DIRTY OPERATING CONDITIONS Under these conditions, use dry compressed air to blow out the generator. With the generator set running, direct air through the slots at the engine end of the generator set. ENGINE SERVICE Perform routine maintenance at specified intervals as documented in the supplied engine manufacturer s manual. TUNE-UPS Have the generator set tuned-up by an authorized distributor. Tune-ups will improve performance and maintain reliability. 21

22 10 service schedule Perform recommended service at every scheduled interval to ensure satisfactory operation. If rough operation, lack of power, or excessive oil use is apparent, have an authorized distributor service the generator set. Immediate action can prevent serious problems. SERVICE SCHEDULE Component Fuel Inspect flexible lines and connections Check solenoid valve operation Cooling Air cleaner Louvers Exhaust System Inspect Insulation Check Muffler bracket Inspect Muffler box for fire hazards Engine (See manufacturer s manual) Check oil level Change oil * Change oil filter * Change air cleaning cartridge Clean cooling system** Replace or clean spark plugs Electrical System Inspect battery and battery tray (Not supplied with unit.) Clean and tighten battery terminals 5 Hours or Daily Frequency 50 Hours 250 Hours Weekly Every or or 2 Years Annually Annually Change oil every 125 hours when operating under heavy load or in high temperatures. Clean more often under dusty conditions or when airborne debris is present. Replace air cleaner parts if excessively dirty. ** Flush cooling system every 2 years. * Change oil after first 8 hours, then after every 250 hours or annually. 22

23 11 wiring diagrams MAIN WIRING DIAGRAM MGL12 23

24 MAIN WIRING DIAGRAM MGL18 AND 23 24

25 EXPLODED VIEW OF CONTROL BOX AND PARTS LIST OF CONTROL BOX Item Part No. Part Description Qty Control Box Assembly (MGL12) Control Box Assembly (MGL18) Control Box Assembly (MGL23) Hinge, Face Plate Solenoid Terminal, Remote Start Switch, Toggle Housing, Controller Face Plate Flange, Mounting Controller, LCD (MGL12) Controller, LCD (MGL18) Controller, LCD (MGL23) Breaker, Circuit-50 Amp (MGL12) Breaker, Circuit-70 Amp (MGL18) Breaker, Circuit-100 Amp (MGL23) Controller, Govenor Retainer, Screw Screw, Mounting Strip, Main Terminal 1 14* Resistor 1 * MGL12 model only 25

26 EXPLODED VIEW OF GENERATOR SET 26

27 PARTS LIST OF GENERATOR SET Item Part No. Part Description Qty * Complete Unit (MGL 12) 1 * Complete Unit (MGL 18) 1 * Complete Unit (MGL 23) B Skid, Weldment Battery 1 * Engine Assembly (MGL 12) 1 * Engine Assembly (MGL 18) 1 * Engine Assembly (MGL 23) Engine (MGL 12) Engine (MGL 18) Engine (MGL 23) Bracket, Engine Spacer, Engine Mount, Engine Engine Support Adapter Block (MGL12) Adapter Block (MGL18 and 23) 1 * Mag Pickup Governor Gas Mixer Air Cleaner Generator (MGL 12) Generator (MGL 18) Generator (MGL 23) Panel, Front (MGL 12) Panel, Front (MGL 18 & 23) 1 * Valve Assembly, Fuel Solenoid Valve Bracket, Valve 1 * Radiator Assembly (MGL 12) 1 * Radiator Assembly (MGL 18 & 23) Radiator (MGL 12) Radiator (MGL 18 & 23) Shroud, Radiator (MGL 12) Shroud, Radiator (MGL 18 & 23) 1 * Guard, Fan (MGL 12) 1 * Guard, Fan (MGL 18 & 23) Bracket, Radiator (MGL 12) Bracket, Radiator (MGL 18 & 23) 4 * Bottle Assembly, Coolant Panel, Rear Cover, Radiator Door, Panel Handle, Door Exhaust Pipe Panel, Top Cover Electrical Muffler Bracket, Muffler Bracket, Muffler 1 * DC Harness, Engine Wire (MGL 12) 1 * DC Harness, Engine Wire (MGL 18 & 23) 1 * AC Harness, Generator Wire (MGL 12, 18 & 23) Pipe, Exhaust 90 Elbow Panel, Front Duct Panel, Duct Cover 1 * Exhaust Pipe Rain Cap 1 * Not Shown 27

28 ONE YEAR OR ONE THOUSAND (1000)-HOUR LIMITED WARRANTY Your Magnum Power Standby Generator was manufactured, assembled, tested, and inspected by experienced craftsmen. Magnum Products, Inc. warrants the generator set for a period of one year or 1000 hours, which ever occurs first. The following conditions must be met: * You must be the original consumer. * Installation and start-up procedures were performed by an authorized professional in accordance with the guidelines published in the operations manual. * Maintenance schedules and operation procedures detailed in the operations manual were followed. * Malfunctions or damages were not a result of misuse, unreasonable use, acts of nature or repair and service work performed by an unauthorized person. * Warranty form completed and returned to Magnum. ITEMS NOT COVERED BY WARRANTY: * Maintenance items i.e. spark plugs, air filter, fuses, adjustments, LCD, etc. * Any rental of the standby generator will void warranty. * Any engine fluids that are necessary for normal operation of the generator set. * Any charges related to the starting battery or the installation of the starting battery. * The initial installation and start-up charges. * Damages caused from the following list will not be covered under warranty: * Failure to exercise the generator under load. * Use of unauthorized service parts, incorrect fluid type, or inappropriate fluid level. * Failure to keep air intake and cabinet free of obstructions and debris. * Failure to properly maintain a clean air filter. * Failure to maintain the maintenance schedule detailed in the operations manual. At the point of purchase, a warranty card must be filled out and returned within 45 days to Magnum Products, Inc. If the card is not filled out and returned, the ship date from the factory will be used as the start date for the warranty period. Magnum Products, Inc. will not be liable for any incidental or consequential damages of any kind without prior authorization from the warranty department. This warranty is exclusive to Magnum Products, Inc. and no one is authorized to extend the warranty in any way. * Engine is warranted by the manufacturer. See engine manual for full details. For warranty service, please call your local servicing dealer. 28