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OPERATION MANUAL

1. XP 6515 4 09 A CAUTION N j Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to
2. 2 AC power cord 3 Fuse 4 Battery leads 12 VDC Figure 2 5 6 Amp Float Equalize Battery Charger 2 7 1 Battery Charger Operation Figure 2 6 illustrates the three stage charging method Red and green LEDs indicate charger operation The chart in Figure 2 7 describes the LED indicator operation during each stage of the charging process Float Green Output Voltage To Battery VDC Figure 2 6 Charging Method XP 6515 4 09 Display Operating Condition When the red LED is on it indicates the battery is discharged and the battery charger is recharging at the BULK rate stage 1 This charging rate is 6 amps While the red LED is on the voltage measured with the battery charger on will be 11 8 14 volts If the red LED stays on for more than 24 hours refer to Section 5 4 in this manual Red ON When both the green and the red LEDs are Green ON on the battery charger is charging at an ABSORPTION rate of between 1 5 and 5 amps stage 2 This mode of charging gradually tops off your battery and reduces harmful sulfating While both LEDs are on the voltage measured with the battery charger on should be approximately 14 0 14 5 VDC If both LEDs stay on longer than 24 hours refer to Section 5 4 in this manual Red OFF When the green LED is on the battery Green ON charger is charging at a FLOAT or MAINTENANCE rate of less than 1 5 amps stage 3 Your battery is now 90 charged and rea
3. LENNOX 2009 Lennox Industries Inc Dallas Texas 75379 9900 This manual provides operation and maintenance instructions for models RGEN12 and RGEN17 18 generator sets Generator sets are approved for use in stationary standby applications in locations served by a reliable utility power source Have a Lennox dealer who is approved to sell and install Lennox generator sets hereinafter referred to as a Lennox dealer install the generator set Refer to XP 6514 Installation Instructions for installation instructions Information in this publication represents data available at the time of print The manufacturer reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Obtain service from a Lennox dealer to keep equipment in top condition RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Shipping and Packing List 1 Generator Set Check equipment for shipping damage If you find any damage immediately contact
4. Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda toa container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry t
5. Move the generator set master switch to OFF RESET Reconnect the generator set to the load using the line circuit breaker or ATS Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Note The controllers LED display remains off until an engine start command is received Section 2 Operation 15 Auxiliary fault input shutdown Description Not used High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This function becomes active after the engine reaches the crank disconnect speed Check for blocked air inlets and exhaust outlets Low oil pressure shutdown Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This function becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest Locked rotor The generator set also shuts down on OC if no engine rotation is sensed during cranking Shut
6. See Section 4 2 Service Schedule for oil change and oil filter replacement intervals See Section 1 5 for the oil drain oil check oil fill and oil filter locations 4 3 1 Low Oil Pressure Shutdown The low oil pressure LOP shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction Note The LOP shutdown feature does not protect against damage caused by operating when the oil level is low it is not a low oil level shutdown Check the oil level regularly and add oil as needed 4 3 2 Oil Check The generator set is shipped with oil Before operating the generator set check the engine oil in the crankcase See Figure 4 1 for the dipstick location Maintain the oil level at or near not over the full mark on the dipstick Add 5W 30 synthetic oil when the oil level is low See Section 4 3 3 Engine Oil Recommendation Check the oil level before each use For extended operation check the oil level every 8 hours Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil Oil Check Figure 4 1 28 Section 4 Scheduled Maintenance RGEN17 18 4 3 3 Engine Oil Recommendation Use 5W 30 API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine i
7. To prevent corrosion maintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease 4 9 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery Figure 4 8 illustrates the battery charger The charger s DC leads are factory wired Periodically tighten all connections 4 ee en D VA i 4 h E nie Sd DNI 1 LED indicators 2 Mounting flanges 3 AC power cord 4 Fuse 5 Battery leads 12 VDC Figure 4 8 6 Amp Float Equalize Battery Charger 32 Section 4 Scheduled Maintenance RGEN17 18 4 10 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 5 Troubleshooting for possible causes 4 10 1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Figure
8. service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area XP 6515 4 09 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can
9. 6515 4 09 Switch functions as the generator set operation and controller reset switch The buttons on the controller keypad are also used for system configuration and adjustment The system configuration is factory set and should not require changes under normal operating conditions Contact a Lennox dealer or service technician if adjustments are required 2 3 3 Generator Set Master Switch The generator set master switch is located on the junction box below the user interface The master switch positions are RUN OFF RESET and AUTO See Section 2 5 for operation instructions 2 4 Controller Power The controller is powered by the generator set engine starting battery Note The generator sets are equipped with factory installed battery chargers to prevent battery discharge The battery charger must be connected to utility power 2 4 1 Standby Mode When the generator set master switch is in the AUTO position and the engine is not running the controller is in standby mode Engine runtime hours are shown on the display A remote start signal contact closure will start and run the generator set The controller can be set to go into sleep mode if there is no start signal for 48 hours Section 2 Operation 13 2 4 2 Sleep Mode Controllers with application code version 1 13 or higher are shipped with the sleep mode disabled and J1939 communication enabled The controller will remain in standby mode whenever the master
10. Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and u
11. Generator set stops suddenly Low oil pressure shutdown Check the oil level Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact a Lennox dealer Controller fuse F3 blown Replace the fuse If the fuse blows again contact the a Lennox dealer Overspeed shutdown Reset the controller If the overspeed fault occurs again contact a Lennox dealer Generator set master switch in the OFF RESET position Move the switch to the correct position RUN or AUTO Remote stop command received from a remote switch or ATS Check the remote switch position Engine malfunction Contact a Lennox dealer Auxiliary winding fuse F1 blown Figure 5 2 General Troubleshooting Chart XP 6515 4 09 Replace the fuse Contact a Lennox dealer for service if fuse blows repeatedly Section 5 Troubleshooting 35 5 4 Battery Charger Troubleshooting Use the battery charger s LED indicators and the table in Figure 5 3 to troubleshoot battery charger operation problems Problem Red LED stays on for more than 24 hours One or more inoperative or damaged cells Solution Load test the battery and replace if necessary Battery charger has reduced its output voltage below the normal level due to a DC overload or a DC short Remove the source of the overload or short Disconnect the battery charger s black
12. Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts 6 Safety Precautions and Instructions Notice NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 XP 6515 4 09 Nameplate The following illustration shows a typical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual See Figure 1 1 or Figure 1 2 for the nameplate location LENNOX MODEL SERIAL SPEC SERVICE DUTY HZ RPM GEN MODEL BATT V INSULATION NEMA CLASS KW VARIES WITH BTU CONTENT OF FUEL XP 6515 4 09 Introduction Emission Compliance RGEN12 All model RGEN12 generator sets with multi fuel systems are emission certified An engine or generator set with the following identification label is certified to meet Small Off Road Engine emission sta
13. Membrane keypad for configuration and adjustment e Password protected user access to menus e Voltage gain and speed adjustment e System configuration system voltage frequency settings and generator set model e Remote two wire start stop capability e Digital isochronous governor to maintain steady state speed at all loads e Digital voltage regulation 1 5 RMS no load to full load e Automatic start for programmed cranking cycle e Master control switch mounted on the junction box Run Off Reset Auto e Upgradeable application software Section 1 Features 9 1 5 Generator Set Components Muffler Oil check Oil fill Air cleaner Fuses RS 232 connector for application program updates Controller user interface see Figure 2 1 Generator set master switch RUN OFF RESET AUTO Load circuit breaker Field connection terminal block location Spark plug locations both sides Oil drain hose OMNOTARWN Figure 1 1 Generator Set Components RGEN12 10 Section 1 Features 17 19 ADV 7466 Oil drain valve Oil filter Exhaust Equipment ground Battery charger DSAI lead location Fuel block Gas regulator assembly Fuel solenoid valve Fuel inlet Air intake Engine starting battery location battery purchased separately XP 6515 4 09 Control detai
14. bent or damaged Also check the element cover for damage and fit Replace all damaged air cleaner components Remove any loose dirt or debris from the air cleaner base Wipe the base carefully so that no dirt drops into the intake throat Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary 9 Reinstall the paper element precleaner element cover element cover nut and the air cleaner cover Secure the cover with the cover retaining knob 10 Reconnect the power to the battery charger 11 Reconnect the generator set engine starting battery negative lead last 3 6 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery The alternator fan draws cooling air through openings on the side walls of the enclosure The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet See Figure 3 5 To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times Note Do not block the generator set cooling air inlets or mount other equipment above them Overheating and severe generator damage may occur 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake Figure 3 5 Cooling Air Intake and Exhaust XP 6515 4 09 3 7 Exhaust System Remove all combustible material
15. dealer for service if problem continues High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for more than 30 seconds when the engine is running Not operative during the engine crank cycle this fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Low battery voltage warning 16 Section 2 Operation Fault code is displayed if the engine starting battery voltage falls below 11 VDC for more than 30 seconds when the engine is not running Not operative during the engine crank cycle this fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to an acceptable level Figure 2 4 Controller Fault Codes Check the battery rating and condition Check the battery charger operation Charge or replace the battery XP 6515 4 09 2 7 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery The charger s power cord must be connected to a 120 VAC power source Figure 2 5 illustrates the battery charger The battery charger uses an AGS 10 inline fuse The fuse is located in the battery lead See Figure 2 5 1 LED indicators
16. must be kept free of debris See Figure 4 2 for the oil cooler location The oil cooler is located under the No 2 cylinder shroud Remove the top mounting screw and loosen the two side screws then lift off the cylinder shroud Figure 4 4 Adjusting the Spark Plug Gap 1 Oil cooler Figure 4 2 Oil Cooler Location XP 6515 4 09 Section 4 Scheduled Maintenance RGEN17 18 29 4 5 Air Cleaner Service The engine is equipped with a replaceable high density paper air cleaner element See Figure 4 5 1 Knobs qty 2 2 Cover 3 Paper element 4 Air filter latch Figure 4 5 Air Cleaner Components Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Paper Element Service Replace the paper element at the intervals indicated in the service schedule See Section 4 2 for the service schedule See Figure 4 5 for the air cleaner components 1 Loosen the two cover retaining knobs and remove the cover 2 Rotate the air filter latch counterclockwise to unlock then remove the paper element 3 Do not wash the paper element or use pressurized air as this will damage the ele
17. positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines A WARNING 4 Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Safety Precautions and Instructions 5 Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system
18. switch is in AUTO and the engine is not running Note The battery charger must be connected to utility power to prevent battery discharge Communication parameter Cn can be changed to disable communication and enable the sleep mode if remote communication is not required See Installation Manual XP 6514 for instructions to set parameter Cn Sleep Mode If the controller communication is disabled and the generator set master switch is in the AUTO position the controller powers down automatically after 48 hours of inactivity The controller display is dark and battery draw is minimized A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 reactivates the controller Moving the generator set master switch to the RUN position also activates the controller 2 5 Generator Set Operation 2 5 1 Starting Generator Set Local Starting Move the generator set master switch to the RUN position to immediately start the generator set Auto Automatic Starting Move the generator set master switch to the AUTO position to allow startup by an automatic transfer switch ATS or remote start stop switch if equipped Close a contact across engine start leads 3 and 4 to signal the controller to start the generator set Crank Cycle The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off See Figure 2 2 for display infor
19. the spark plug gap or replace the plugs with new plugs as necessary 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine 2 Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable Cover knob i Air cleaner cover 3 Check the spark plug gap using a wire feeler Element cover nut gauge Adjust the gap to 0 76 mm 0 030 in by Element cover carefully bending the ground electrode See Foam precleaner Air cleaner element Figure 3 2 and Figure 3 3 l Air cleaner base Figure 3 4 Air Cleaner Components Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Figure 3 3 Adjusting the Spark Plug Gap XP 6515 4 09 Section 3 Scheduled Maintenance RGEN12 21 3 5 1 Precleaner Service Use the following procedure to wash and reoil the precleaner as indicated in the service schedule Wash and reoil the precleaner more often under extremely dusty or dirty conditions 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger 3 Disconnect the battery negative lead first 4 Loosen the cover retaining knob and remove the cover Remove the precleaner from the pap
20. 1 2 The circuit breaker rating is shown in Figure 4 9 If the circuit breaker trips reduce the load and switch the breaker back to the ON position With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load Model sd Circuit Breaker Rating Amp RGEN17 70 RGEN18 80 Figure 4 9 Line Circuit Breaker Rating 4 10 2 Fuses Three panel mounted fuses protect the alternator and electrical controls See Section 1 5 for fuse locations Another 10 amp fuse protects the battery charger See Figure 4 8 for the battery charger fuse location See Figure 4 10 for fuse part numbers Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 5 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts Rating Amp Part Number Auxiliary winding Relay interface board Controller Battery charger Figure 4 10 Fuses XP 6515 4 09 4 11 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer Follow the engine manufacturer s recommendations for storage if available Note Run the generator set monthly whenever possible 4 11 1 Lubricating System 1 Operate the generator set until it reaches operating temperature or about 15 minutes 2 Stop the generator set 3 W
21. 3 3 Engine Oil Recommendation Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil level 3 3 3 Engine Oil Recommendation Use API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner Select the viscosity based on the air temperature at the time of operation See Figure 3 1 10W 30 5W 20 5W 30 F 20 0 20 3240 60 80 100 C 30 20 10 0 10 20 30 40 Temperature Range Expected Before Next Oil Change Figure 3 1 Engine Oil Selection 20 Section 3 Scheduled Maintenance RGEN12 3 3 4 Oil Change Procedure Drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position b Disconnect the power to the battery charger c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container f Open the oil drain valve on the engine g Allow time for the engine oil to drain completely h Close the oil drain valve i Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip 2 Replace the oil
22. IS ENGINE MEETS EMISSION REGS FOR U S EPA PH 2 SMALL OFF ROAD ENGINES AND CA2006 AND LATER LSI ENGINES FAMILY DISPL CC MODEL NO SPEC NO SERIAL NO BUILD DATE OEM PROD NO EMISSION COMPLIANCE PERIOD EPA CERTIFIED ON REFER TO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA Figure 3 Engine Identification Label RGEN17 18 8 Introduction The Emission Compliance Period referred to on the engine identification label indicates the number of operating hours for which the engine has been shown to meet EPA emission requirements The engine compliance period in hours associated with the Category A descriptor found on the certification label is 1000 hours Refer to the certification label for engine displacement The exhaust emission control system for the CH980 engine is EM XP 6515 4 09 1 1 Specifications The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator set service manual engine operation manual and engine service manual for additional specifications Obtain copies of the latest spec sheets manuals diagrams and drawings from a Lennox dealer 1 2 Generator The generator uses a unique voltage regulation system which provides instant response to load changes This unique voltage reg
23. NEGATIVE ring terminal from the battery Reapply AC power and the green LED only should now light Onboard DC systems are drawing more current than the battery charger can replace Turn off all DC equipment while charging Red and green LEDs stay on for more than 24 hours Onboard DC systems are drawing between 1 5 and 5 amps Turn off all DC equipment while charging One or more inoperative or damaged cells Load test the battery and replace if necessary Extremely low AC voltage at the battery charger Apply a higher AC voltage source or reduce the length of the extension cord Green LED stays on when the battery is known to be low Open DC output fuse Replace AGS 10 fuse Faulty or contaminated terminal connections Clean and tighten or repair all terminal connections One or more inoperative or damaged cells Load test the battery and replace if necessary Neither of the LEDs turn on when the AC power is applied No AC power available at the battery charger Connect AC power or reset the AC breaker on the main panel Component failure Figure 5 3 Battery Charger Troubleshooting 36 Section 5 Troubleshooting Replace battery charger XP 6515 4 09
24. Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set 4 1 Routine Maintenance Refer to the following service schedule and the runtime hours displayed on the controller display to schedule routine maintenance Intervals are shown in hours of operation and or time intervals i e weekly monthly quarterly etc Have a Lennox dealer service the generator set at the designated intervals in the service schedule for the life of the generator set Service units subject to extreme weather long operating hours or dusty or dirty conditions more frequently Contact a Lennox dealer for parts XP 6515 4 09 4 2 Service Schedule RGEN17 18 Procedure See Visually System Component or Procedure Section Inspect Change Fuel Flexible lines and connections Main tank supply level Fuel piping Lubrication Oil level Change oil Y or 150 Replace filter Y or 150 Crankcase breather hose Y or 500 Oil cooler Y Y or 100 Cooling Air ducts louvers Exhaust System Leakage Insulation fire hazards Obstructions or combustible materials near exhaust outlet DC El
25. Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Refer to this section for general battery information and maintenance Also consult the battery manufacturer s instructions for battery maintenance All generator set models use a negative ground with a 12 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide battery connection information See Figure 3 6 for typical battery connections EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 6 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Section 3 Scheduled Maintenance RGEN12 23 Clean the battery and cables and tighten battery terminals using the service schedule recommendations To prevent corrosion maintain tight dry el
26. cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Refer to this section for general battery information and maintenance Also consult the battery manufacturer s instructions for battery maintenance All generator set models use a negative ground with a 12 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide battery connection information See Figure 4 7 for typical battery connections 6 ra EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 4 7 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Section 4 Scheduled Maintenance RGEN17 18 31 Clean the battery and cables and tighten battery terminals using the service schedule recommendations
27. displays Crank indication Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Software version number The software version number v is displayed when entering configuration mode See the installation manual Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 6 Select and Use the arrow buttons to step through the data displays See Figure 2 3 arrow buttons The keypad is also used for controller setup and adjustment The setup and adjustment functions are password protected Have setup and adjustments performed only by a Lennox dealer Generator set master switch Three position switch Figure 2 2 Controls and Indicators 2 3 2 Controller Keypad The three buttons on the controller keypad are Select Up and Down When the generator set is running the up and down arrow buttons can be used to step through system data displays as shown in Figure 2 3 After 10 seconds the display returns to engine runtime hours Engine Runtime XXX X hours Y Output Voltage VAC Output Frequency Hz Battery Voltage VDC 1 Generator set master switch in AUTO 2 Step through using up or down arrow buttons 3 After 10 seconds display returns to runtime hours Figure 2 3 Data Displays XP
28. dy for use This float charging current will gradually decrease to as low as 0 1 amps as the battery reaches 100 charge It will now be kept at full charge without overcharging If the green LED stays on when your battery is known to be low refer to Section 5 4 in this manual Figure 2 7 Battery Charger LED Indicator Functions Section 2 Operation 17 Section 3 Scheduled Maintenance RGEN12 A WARNING PLA Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 18 Section 3 Scheduled Maintenance RGEN12 Servic
29. e of the fault condition Then reset the controller See Section 2 6 3 Corrective Action Replace the fuse If the fuse blows again contact a Lennox dealer Check connections Check the engine starting battery and battery charger See Figure 5 3 Generator set master switch is in the OFF RESET position Move generator set master switch to the AUTO or RUN position In AUTO the display will not turn on until the first start command is received Figure 5 1 Troubleshooting Chart 34 Section 5 Troubleshooting The controller is in sleep mode See Section 2 4 2 Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position Use the remote switch to start generator set and activate the controller display if desired See Section 2 4 Controllers with application code version 1 13 or higher can be configured to enable or disable the sleep mode See the generator set Installation Manual for instructions XP 6515 4 09 Problem The generator set does not crank Possible Cause Fault shutdown Corrective Action Check for a fault code on the controller display See Section 2 6 Battery weak or dead Check power to the battery charger Recharge or replace the battery Battery charger fuse blown Replace the fuse Contact a Lennox dealer for service if fuse blows repeatedly Battery connections reversed or poor C
30. e eee eee eee 24 3 10 Circuit Protection 000 00s 24 3 11 Storage Procedure 00e esas 25 Section 4 Scheduled Maintenance RGEN17 18 26 4 1 Routine Maintenance 26 4 2 Service Schedule RGEN17 18 27 4 3 Lubrication System 00 e eee eee 28 4 4 Spark Plugs 0 cece eee eee eee 29 4 5 Air Cleaner Service 000 000s 30 4 6 Cooling System 0 eee eee eee 30 4 7 Exhaust System 000 eee eee eee 31 4 8 Battery si0ccce ughatene anes arsaetancae eres 31 4 9 Battery Charger cece eee eee ee eee 32 4 10 Circuit Protection 0 eee eee 32 4 11 Storage Procedure 00 eeu 33 Section 5 Troubleshooting 0eeeee 34 5 1 Introduction 0 0 cece eee ee 34 5 2 Controller Troubleshooting 34 5 3 Generator Set Troubleshooting 35 5 4 Battery Charger Troubleshooting 36 California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field ins
31. ectrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease 3 9 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery The charger s DC leads are factory wired Figure 3 7 illustrates the battery charger Periodically tighten all connections No other maintenance on the battery charger is required 4 4 en D ff VA i 4 h iT nie Sd N 1 LED indicators 2 Mounting flanges 3 AC power cord 4 Fuse 5 Battery leads 12 VDC Figure 3 7 6 Amp Float Equalize Battery Charger 24 Section 3 Scheduled Maintenance RGEN12 3 10 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 5 Troubleshooting for possible causes 3 10 1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown i
32. ectrical System Battery charger operation charge rate Remove corrosion clean and dry battery and rack Clean and tighten battery terminals and inspect boots Battery electrolyte level and specific gravity AC Electrical System Tighten control and power wiring connections Remote control system if equipped Visible wear or damage Q Wire abrasions where subject to motion 6 months 6 months Wire cable insulation condition 3Y or 500 Engine and Mounting Visible wear or damage W Air cleaner service Spark plugs Replace stepper motor coupling and bushing Generator Visible wear or damage Exercise generator set Brushes and collector ring Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected General Condition of Equipment Evidence of vibration leakage deterioration unusual or excessive noise or temperature W Interior of sound enclosure Q Not necessary for maintenance free batteries Each use Number hours of operation Service more frequently under extremely dusty dirty conditions Weekly D Lennox dealer only Megger is a registered trademark of Biddle Instruments Monthly R Replace FS necessary SE S M Service Manual early XP 6515 4 09 Section 4 Scheduled Maintenance RGEN17 18 27 4 3 Lubrication System
33. em Overheating and severe generator damage may occur 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake Figure 4 6 Cooling Air Intake and Exhaust XP 6515 4 09 4 7 Exhaust System Remove all combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft from the exhaust outlet Periodically inspect the exhaust system components for cracks leaks and corrosion e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is clear 4 8 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in
34. er element Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 5 Saturate the precleaner with new engine oil Squeeze out all of the excess oil 6 Reinstall the precleaner over the paper element 7 Reinstall the air cleaner cover Secure the cover with the cover retaining knob 8 Reconnect the power to the battery charger 9 Reconnect the generator set engine starting battery negative lead last 3 5 2 Paper Element Service Use the following procedure to replace the paper element at the intervals specified in the service schedule Replace the paper element more often under extremely dusty or dirty conditions 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Loosen the cover retaining knob and remove the cover 5 Remove the element cover nut element cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or clean it with pressurized air as this will damage the element 22 Section 3 Scheduled Maintenance RGEN12 7 Replace the element if itis dirty bent or damaged 8 Check the air cleaner base Make sure it is secure and not
35. filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Clean the gasket sealing surface of the oil filter adapter c Apply a light coat of clean oil to the rubber seal of the new oil filter d Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner 3 Fill with oil a Remove the oil fill cap and fill the engine to the F mark on the dipstick The engine oil capacity is 1 9 L 2 0 qt See Section 3 3 3 Engine Oil Recommendation for oil selection b Reinstall the dipstick and the oil fill cap c Check thatthe generator set master switch is in the OFF position XP 6515 4 09 d Reconnect the generator set engine starting battery negative lead last 3 5 Air Cleaner Element and Precleaner e Reconnect the power to the battery charger The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 3 4 f Start and run the generator set for a minute to allow the oil pressure to reach the operating range g Stop the generator set wait 1 minute and then recheck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fix leaks and recheck the oil level c Reinstall the housing side panel 3 4 Spark Plugs Reset
36. generator set will automatically reset when the problem is corrected For example the high engine temperature switch resets automatically when the generator set cools However the fault does not clear until the controller is reset 2 6 2 Warnings The controller displays a fault code but the generator set does not shut down on a high battery voltage warning or a low battery voltage warning The controller resets automatically after a battery voltage fault condition is corrected XP 6515 4 09 2 6 3 Resetting Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Check the fault code displayed on the controller and refer to Figure 2 4 to identify and correct the fault condition before proceeding Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to OFF RESET 2 Disconnect the generator set from the load using the line circuit breaker or ATS See the safety precautions at the beginning of this manual before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this manual before proceeding Refer to Section 5 Troubleshooting XP 6515 4 09 4 Start the generator set by moving the generator set master switch to RUN Test operate the generator set to verify that the cause of the shutdown has been corrected
37. gine to the F mark on the dipstick The engine oil capacity is approximately 2 8L 3 0 qt See Section 4 3 3 Engine Oil 4 4 Spark Plugs Recommendation for oil selection Reset the spark plug gap or replace the plugs with new b Reinstall the dipstick and the oil fill cap plugs as necessary c Check thatthe generator set master switch is in 1 Clean the area around the base of the spark plug to the OFF position keep dirt and debris out of the engine d Reconnect the generator set engine starting 2 Remove the spark plug and check its condition battery negative lead last Replace the spark plug if it is worn or if its reuse is questionable e Reconnect the power to the battery charger 3 Check the spark plug gap using a wire feeler f Start and run the generator set for a minute to gauge Adjust the gap to 0 76 mm 0 030 in by allow the oil pressure to reach operating range carefully bending the ground electrode See Figure 4 3 and Figure 4 4 g Stop the generator set wait 1 minute and then recheck the oil level Add oil to bring the level 4 Reinstall the spark plug into the cylinder head up to the F mark on the dipstick Torque the spark plug to 24 4 29 8Nm 18 22 ft Ib 4 Check for leaks a Check for oil leaks b Fix leaks and recheck the oil level c Reinstall the housing side panel 4 3 5 Oil Cooler Inspect and clean the oil cooler at the intervals indicated in the service schedule The oil cooler
38. hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 b of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the XP 6515 4 09 neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death
39. he area Safety Precautions and Instructions 3 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by
40. he battery charger manufacturer s recommendations Section 3 Scheduled Maintenance RGEN12 25 Section 4 Scheduled Maintenance RGEN17 18 A WARNING A WARNING PLA Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation 26 Section 4 Scheduled Maintenance RGEN17 18 Hazardous voltage Moving parts Can cause severe injury or death
41. heck the connections Fuse F2 blown Replace the fuse Contact a Lennox dealer for service if fuse blows repeatedly Fuse F3 blown Replace the fuse Contact a Lennox dealer for service if fuse blows repeatedly Generator set master switch in the OFF position Move the master switch to AUTO for remote start or to RUN for local start The generator set cranks but does not start starts hard lacks power or operates erratically Air cleaner clogged Clean and or replace the air cleaner Battery weak or dead Check power to the battery charger Recharge or replace the battery Battery connection poor Clean and tighten the battery connections Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check the oil level Fuel pressure insufficient Check the fuel supply and valves Engine malfunction Contact a Lennox a Lennox dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on the generator set AC circuit breaker tripping because of short circuit Contact a Lennox dealer for service Auxiliary winding fuse F1 blown Replace the fuse Contact a Lennox dealer for service if fuse blows repeatedly Low output or excessive drop in voltage Generator set overloaded Reduce the load
42. hile the engine is still warm drain the engine lubrication oil from the engine crankcase 4 Refill engine crankcase with oil See Section 4 3 3 for oil recommendations 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set 4 11 2 Fuel System 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position XP 6515 4 09 4 11 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs 3 Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 4 11 4 Exterior Preparation 1 Clean the exterior surface of the generator set 2 Seal all openings in the engine with nonabsorbent adhesive tape 3 Mask all areas to be used for electrical contact 4 Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion 4 11 5 Battery Perform battery storage last 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery negative lead first 3 Clean the battery 4 Place the battery in a warm dry location 5 Connect the battery to a float equalize battery cha
43. ing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set 3 1 Routine Maintenance Refer to the following service schedule and the runtime hours displayed on the controller display to schedule routine maintenance Have a Lennox dealer service the generator set at the designated intervals in the service schedule for the life of the generator set Service units subject to extreme weather long operating hours or dusty or dirty conditions more frequently Contact a Lennox dealer for parts XP 6515 4 09 3 2 Service Schedule RGEN12 System Component or Procedure Fuel See Section Procedure Visually Inspect Check Change Frequency Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly
44. l top view See control 7 detail ADV 7341A B Muffler Oil drain valve Oil check Exhaust outlet Oil fill Carburetor heater access opening Air cleaner LP fuel orifice location inside hose fitting Spark plug locations both sides Gas regulator assembly Oil filter DSAI leads Oil cooler location Fuel solenoid valve Controller user interface Fuel inlet Generator set master switch RUN OFF RESET AUTO a Line circuit breaker Air intake Fuses Battery cables RS 232 connector for application program updates Battery charger Engine starting battery location battery purchased separately Field connection terminal block location Oil drain hose 120 VAC receptacles for battery charger and optional Nameplate location on base carburetor heater OMNONRWDN Figure 1 2 Generator Set Components RGEN17 18 XP 6515 4 09 Section 1 Features 11 Section 2 Operation 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery co
45. mation during the crank cycle Ifthe generator set does not start in three attempts the system shuts down on an overcrank fault See Section 2 6 2 5 2 Stopping Generator Set Local Stopping 1 Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown 14 Section 2 Operation 2 Move the generator set master switch to the OFF RESET position The engine stops Automatic Stopping With the generator set master switch in the AUTO position open the contact across engine start leads 3 and 4 to signal the generator set to stop An automatic transfer switch ATS connected to controller leads 3 and 4 operates as follows 1 The ATS disconnects the load from the generator set 2 If the ATS is equipped with an engine cooldown time delay the generator set continues to run for a preset engine cooldown time Note There is no engine cooldown time delay on the controller 3 The ATS opens the connection between controller leads 3 and 4 The generator set shuts down The controller enters standby mode and displays engine runtime hours 2 6 1 Shutdowns Under the fault shutdown conditions listed in Figure 2 4 the generator set shuts down automatically and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 3 to reset the controller after a fault shutdown The shutdown switches on the
46. ment Replace a dirty bent or damaged element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 30 Section 4 Scheduled Maintenance RGEN17 18 4 When servicing the air cleaner check the air cleaner base and latch Make sure itis secured and not bent or damaged Also check the element cover for damage or improper fit Replace all damaged air cleaner components Note If any loose dirt or debris fell on the air cleaner base when the element was removed carefully remove it and wipe the base clean Be careful that none of it drops into the intake throat 5 Reinstall the paper element onto the air cleaner base Make sure the element is flat and properly seated Rotate the latch clockwise over the molded lip on the element 6 Install the air cleaner cover and secure with the two retaining knobs 7 When element replacement is necessary order genuine Kohler parts 4 6 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery The alternator fan draws cooling air through openings on the side walls of the enclosure The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet See Figure 4 6 To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times Note Do not block the generator set cooling air inlets or mount other equipment above th
47. n Figure 1 1 or Figure 1 2 The circuit breaker rating is 50 amps Ifthe circuit breaker trips reduce the load and switch the breaker back to the ON position With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load 3 10 2 Fuses Two 10 amp and one 20 amp inline fuse are mounted on the controller junction box See Figure 3 8 Another 10 amp fuse is located in the battery charger lead Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 5 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts Part Number Location Auxiliary winding Lead 55 Relay interface board Controller Lead PF2 Lead PF1 Battery charger DC lead See Figure 3 7 Battery charger Figure 3 8 Fuses XP 6515 4 09 3 11 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer Follow the engine manufacturer s recommendations for storage if available Note Run the generator set monthly whenever possible 3 11 1 Lubricating System 1 Operate the generator set until it reaches operating temperature or about 15 minutes 2 Stop the generator set 3 While the engine is still warm drain the engine lubrication oil from the engine crankcase 4 Refill engine crankcase wi
48. ndards for EPA CARB KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 AND CA 2008 AND LATER EXH EMISSION REGS FOR SI SORE FAMILY DISPL CC MODEL NO SPEC NO SERIAL NO BUILD DATE GQ N11236 EMISSION COMPLIANCE PERIOD EPA CATEGORY A CARB EXTENDED CERTIFIED ON LPG NATURAL GAS REFER TO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 KohlerEngines com KOHLER CO KOHLER WISCONSIN USA Figure 1 Emissions Label RGEN12 Engine CH740 This engine generator is certified to operate using natural gas or propane fuel The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB emission requirements The following table provides the engine compliance period in hours associated with the category descriptor found on the certification label Emission Compliance Period Hour Moderate Intermediate Extended Figure2 RGEN12 Refer to the certification label for engine displacement The exhaust emission control system for the CH 740 engine is EM Introduction 7 Emission Compliance RGEN17 18 The RGEN17 18 generator set engine is certified to meet emission regulations for U S EPA phase 2 small off road engines and CA 2006 and later LSI engines large spark ignited engines at or below 1 liter KOHLER IMPORTANT ENGINE INFORMATION TH
49. nnections Consult the battery manufacturer s instructions regarding battery care and maintenance Exhaust System Check for exhaust leaks and blockages Check the muffler condition and check for tight exhaust system connections Inspect the exhaust system components for cracks leaks and corrosion e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Exercising Generator Set Operate the generator set without load once each week for 20 minutes If the generator set is not connected to an automatic transfer switch ATS with an exercise option exercise the unit in the presence of an operator The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks Check the air inlets and outlets and remove any items restricting the air flow 12 Section 2 Operation 2 3 Controls and Indicators Figure 2 1 illustrates the user i
50. ntake valves and pistons cleaner 4 3 4 Oil Change Procedure Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner Drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position b Disconnect the power to the battery charger c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Clean the area around the dipstick and oil fill cap f Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container g Open the oil drain valve on the engine h Remove the dipstick and oil fill cap Allow time for the engine oil to drain completely i Close the oil drain valve Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip j Replace the dipstick 2 Replace the oil filter a Clean the area around the oil filter Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Clean the gasket sealing surface of the oil filter adapter c Apply alight coat of clean oil to the rubber seal of the new oil filter d Install the new oil filter following the instructions provided with the filter XP 6515 4 09 3 Fill with oil Clean the outside of the oil cooler fins with a brush or with compressed air a Fillthe en
51. nterface and other items on the generator set junction box Figure 2 2 describes the controls and indicators DEFINITION Crank Cycle Hl Hig le ac OUTPUT POWER g BREAKER in LED display Up and down arrow buttons Generator set master switch Line circuit breaker Fuses RS 232 connector for application program upgrade Select button use for setup and adjustment only Figure 2 1 Controls 2 3 1 LED Display The LED display is activated by a start or RUN command as follows e Move the master switch to RUN e With the master switch in AUTO send a remote start command close the remote start contact across leads 3 and 4 The LED display indicates generator set status as shown in Figure 2 2 When the generator set is running engine runtime hours are shown unless the arrow buttons are used to step through the other displays as described in Section 2 3 2 When the master switch is in AUTO the display turns off 48 hours after generator set shutdown See Section 2 4 Controller Power XP 6515 4 09 Control or Indicator LED display Runtime hours Description Displays total generator set runtime hours while the generator set is running and when no other codes are displayed Metering display Displays AC voltage output frequency and battery voltage Press the up or down arrow when runtime hours are displayed to step through these
52. or 500 hours Change oil Yearly or 100 hours Replace filter Yearly or 200 hours Cooling Air ducts louvers Yearly Exhaust Line Leakage Weekly Insulation fire hazards Yearly Obstructions or combustible materials near exhaust outlet Weekly DC Electrical System Battery charger operation charge rate if equipped Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect boots Yearly Battery electrolyte level and specific gravity Yearly AC Electrical System Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Wire cable insulation condition 3 Years or 500 hours Engine and Mounting Visible wear or damage Weekly Air cleaner and precleaner service Yearly or 100 hours Spark plugs Yearly or 300 hours Replace stepper motor coupling and bushing 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly Brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 Years General Condition of Equipment Evidence of
53. rger or charge the battery monthly using a trickle charger Follow the battery charger manufacturer s recommendations Section 4 Scheduled Maintenance RGEN17 18 33 Section 5 Troubleshooting 5 1 Introduction Use the following charts to diagnose and correct common problems First check for simple causes such as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of common problems possible causes of the problem and recommended corrective actions If the procedures in this manual do not explain how to correct the problem contact a Lennox dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to the equipment 5 2 Controller Troubleshooting Figure 5 1 contains troubleshooting diagnostic and repair information for the controller Problem Possible Cause Controller LED display is off No power to the controller Controller fuse F3 is blown Low or no battery voltage 5 3 Generator Set Troubleshooting Figure 5 2 contains generator set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Fault Codes The digital control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended actions are listed in Section 2 6 If a fault code is displayed identify and correct the caus
54. s down 3 seconds after the fault is detected Check the fuel supply spark plug and battery Check for loose connections Contact a Lennox dealer for service if problem continues Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for more than 5 seconds This function becomes active 10 seconds after engine start 10 second inhibit Contact a Lennox dealer for service if problem continues Overspeed shutdown Shutdown occurs if the engine speed exceeds 110 of the normal running speed for more than 0 3 seconds Contact a Lennox dealer for service if problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact a Lennox dealer for service if problem continues Underfrequency shutdown Shutdown occurs if the governed frequency falls below 54 Hz for more than 5 seconds Shutdown also occurs if the governed frequency falls below 56 5 Hz for more than 60 seconds This function becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact a Lennox dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls below 80 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Contact a Lennox
55. s from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft from the exhaust outlet Periodically inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace clamps and or hangers as needed e Check for and remove loose insulation in the exhaust duct e Check that the exhaust outlet is clear 3 8 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in
56. shorting the terminals together Engine Backfire Flash Fire A WARNING Z Gh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 4 Safety Precautions and Instructions Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death
57. sing fuels Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble XP 6515 4 09 Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply
58. talled kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indica
59. tes the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals XP 6515 4 09 Accidental Starting A WARNING DOo Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command froma remote computer Battery A WARNING Sulfuric acid in batteries
60. th oil See Section 3 3 3 for oil recommendations 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set 3 11 2 Fuel System 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position XP 6515 4 09 3 11 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs 3 Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 3 11 4 Exterior Preparation 1 Clean the exterior surface of the generator set 2 Seal all openings in the engine with nonabsorbent adhesive tape 3 Mask all areas to be used for electrical contact 4 Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion 3 11 5 Battery Perform battery storage last 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery negative lead first 3 Clean the battery Refer to Section 3 8 for the cleaning procedure 4 Place the battery in a warm dry location 5 Connect the battery to a float equalize battery charger or charge the battery monthly using a trickle charger Follow t
61. the last carrier 506088 01 OPERATION MANUAL RGEN12 RGEN17 18 RESIDENTIAL GENERATOR SET XP 6515 4 09a Table of Contents Product Identification Information 2 Safety Precautions and Instructions 3 INTFOAUCHION ieee erected ee beled tates eters 7 Section 1 Features 0cceeee eee 9 1 1 Specifications 0 cee eee 9 1 2 Generator csi eee bere nerd won bed es 9 1 3 Enge oboe ete et Gu dae mien Mira eae 9 1 4 Controller 0 0 ccc ccc eee 9 1 5 Generator Set Components 10 Section 2 Operation 00cceeeee eee 12 2 1 Prestart Checklist 00 00 ee aee 12 2 2 Exercising Generator Set 12 2 3 Controls and Indicators 12 2 4 Controller Power 00 cece eens 13 2 5 Generator Set Operation 4 14 2 6 Faults os det dhaeieedieaekedin cede ne 14 2 7 Battery Charger 0c cece eee eee eee 17 Section 3 Scheduled Maintenance RGEN12 18 3 1 Routine Maintenance 18 3 2 Service Schedule RGEN12 19 3 3 Lubrication System 0 eee eee eee 20 3 4 Spark Plugs 0 cece eee eee 21 3 5 Air Cleaner Element and Precleaner 21 3 6 Cooling System 0 ccc eee 22 3 7 Exhaust System 0 00 eee 23 38 Battery c o sakien th Se Gh Rie Shag Dae 23 3 9 Battery Charger ce
62. ulation system ensures reliable motor starting and consistent voltage levels It utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage The generator set has a four cycle twin cylinder air cooled Kohler engine The engine operates on clean burning natural gas or propane LP vapor Engine features include e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Dependable maintenance free electronic ignition e Precision formulated cast iron construction of parts subjected to the most wear and tear e Field convertible multi fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB emission certification Digital spark advance optimizes ignition timing for the selected fuel XP 6515 4 09 Section 1 Features 1 4 Controller Controller features include the following e Compact controller e integrally mounted to the generator set e LED display e Engine runtime hours e AC voltage e Frequency Hz e Battery voltage e Crank cycle status e Setup information e Application software version e LED display communicates faults High battery voltage High engine temperature Low battery voltage Low oil pressure Overcrank safety Overfrequency Overspeed Overvoltage Underfrequency e Undervoltage e
63. vibration leakage excessive noise temperature or deterioration x Weekly Interior of sound enclosure x Quarterly Not necessary for maintenance free batteries Megger is a registered trademark of Biddle Instruments XP 6515 4 09 Lennox dealer only Action Replace as necessary Section 3 Scheduled Maintenance RGEN12 19 3 3 Lubrication System See Section 3 2 Service Schedule for oil change and oil filter replacement intervals See Section 1 5 for the oil drain oil check oil fill and oil filter locations For extended operation check the oil level every 8 hours Maintain the oil level at or near not over the full mark on the dipstick 3 3 1 Low Oil Pressure Shutdown The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below 24 1 kPa 13 8 kPa 3 5 psi 1 5 psi because of oil pump failure or other malfunction The shutdown feature does not protect against damage caused by operating with the oil level below the safe range it is not a low oil level shutdown Check the oil level regularly and add oil as needed 3 3 2 Oil Check The generator set is shipped with oil Before operating a new generator set check the engine oil in the crankcase See Section 1 5 Generator Set Components Verify that the oil level is at the F mark on the dipstick Add oil that has a viscosity appropriate for the climate See Section 3

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