Generac Power Systems MD500 User manual

Generator image used for illustration purposes only
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Industrial Diesel Generator Set
EPA Certified Stationary Emergency
500 kW Diesel
Standby Power Rating
625kVA 500kW 60Hz
features benefits
primary codes and standards
Generator Set
=PROTOTYPE & TORSIONALLY TESTED 4PROVIDES A PROVEN UNIT
=UL2200 TESTED 4ENSURES A QUALITY PRODUCT
=RHINOCOAT PAINT SYSTEM 4IMPROVES RESISTANCE TO ELEMENTS
=WIDE RANGE OF ENCLOSURES AND TANKS 4PROVIDES A SINGLE SOURCE SOLUTION
Engine
=EPA COMPLIANT 4MEETS EPA STANDARDS
=INDUSTRIAL TESTED, GENERAC APPROVED 4ENSURES INDUSTRIAL STANDARDS
=POWER-MATCHED OUTPUT 4ENGINEERED FOR PERFORMANCE
=INDUSTRIAL GRADE 4IMPROVES LONGEVITY AND RELIABILITY
Alternator
=TWO-THIRDS PITCH 4ELIMINATES HARMFUL 3RD HARMONIC
=LAYER WOUND ROTOR & STATOR 4IMPROVES COOLING
=CLASS H MATERIALS 4HEAT TOLERANT DESIGN
=DIGITAL 3-PHASE VOLTAGE CONTROL 4FAST AND ACCURATE RESPONSE
Controls
=ENCAPSULATED BOARD W/ SEALED HARNESS 4EASY, AFFORDABLE REPLACEMENT
=4-20mA VOLTAGE-TO-CURRENT SENSORS 4NOISE RESISTANT 24/7 MONITORING
=SURFACE-MOUNT TECHNOLOGY 4PROVIDES VIBRATION RESISTANCE
=ADVANCED DIAGNOSTICS & COMMUNICATIONS 4HARDENED RELIABILITY
MD500
PARALLELING UNIT

ENGINE SPECIFICATIONS
General Cooling System
Make Perkins Cooling System Type Closed Recovery
EPA Emissions Compliance Stationary Emergency Water Pump Centrifugal Type, Belt-Driven
EPA Emissions Reference See Emissions Data Sheet Fan Type Pusher
Cylinder # 6 Fan Speed (rpm) 1658 rpm
Type In-Line Fan Diameter mm (in.) 927 (36.5)
Displacement - L 15.2 Coolant Heater Standard Wattage 1500
Bore - mm (in.) 137 (5.39) Coolant Heater Standard Voltage 120VAC
Stroke - mm (in.) 171 (6.73)
Compression Ratio 16.0:1 Fuel System
Intake Air Method Turbocharged/Aftercooled Fuel Type Ultra Low Sulfur Diesel #2
Cylinder Head Type 4 Valve Fuel Specifications ASTM
Piston Type Aluminum Fuel Filtering (microns) Primary 10 - Secondary 2
Connecting Rod Type I-Beam Section Fuel Injection Electronic
Fuel Pump Type Engine Driven Gear
Engine Governing Injector Type MEUI
Governor Electronic Isochronous Engine Type Pre-Combustion
Frequency Regulation (Steady State) ± 0.25% Fuel Supply Line - mm (in.) 12.7 (½"NPT)
Fuel Return Line - mm (in.) 12.7 (½"NPT)
Lubrication System
Oil Pump Type Gear Engine Electrical System
Oil Filter Type Full-Flow Cartridge System Voltage 24VDC
Crankcase Capacity - L (Gal) 60 (15.8) Battery Charging Alternator 70 Amps at 24V
Battery Size (at 0ºC) 1155 CCA
Battery Group 8D
Battery Voltage (2) - 12VDC
Ground Polarity Negative
ALTERNATOR SPECIFICATIONS
Standard Model WEG Voltage Regulator Type Digital
Poles 4 Number of Sensed Phases All
Field Type Revolving Regulation Accuracy (Steady State) ± 1%
Insulation Class - Rotor H
Insulation Class - Stator H
Total Harmonic Distortion < 3%
Telephone Interference Factor (TIF) < 50
Standard Excitation Permanent Magnet
Bearings Single Sealed Cartridge
Coupling Direct, Flexible Disc
Load Capacity - Standby 100%
Prototype Short Circuit Test Yes
CODES AND STANDARDS COMPLIANCE (WHERE APPLICABLE) PARALLELING CONTROLS
NFPA 99 BS5514 Auto-Synchronization Process
NFPA 110 SAE J1349 Isochronous Load Sharing
ISO 8528-5 DIN6271 Reverse Power Protection
ISO 1708A.5 IEEE C62.41 TESTING Maximum Power Protection
ISO 3046 NEMA ICS 1 Electrically Operated, Mechanically Held Paralleling Switch
Sync Check System
Independent On-Board Paralleling
Optional Programmable Logic Full Auto Back-Up Control (PLS)
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Rating Definitions:
Standby – Applicable for a varying emergency load for the duration of a utility power outage with no overload capability. (Max. load factor = 70%)
Prime – Applicable for supplying power to a varying load in lieu of utility for an unlimited amount of running time. (Max. load factor = 80%) A 10% overload capacity is available for 1 out of
every 12 hours.
MD500 application and engineering data
500 kW Diesel

Deration – Operational characteristics consider maximum ambient conditions. Derate factors may apply under atypical site conditions. Please consult a Generac Power Systems Industrial
Dealer for additional details. All performance ratings in accordance with ISO3046, BS5514, ISO8528 and DIN6271 standards.
POWER RATINGS (kW)
STARTING CAPABILITIES (sKVA)
FUEL
COOLING
COMBUSTION AIR REQUIREMENTS
ENGINE EXHAUST
STANDBY
Three-Phase 277/480VAC @0.8pf 500 kW Amps: 752
Three-Phase 346/600VAC @0.8pf 500 kW Amps: 601
sKVA vs. Voltage Dip
480VAC
Alternator kW 10% 15% 20% 25% 30% 35%
Standard 500 457 686 914 1143 1371 1600
Upsize 1 642 471 707 943 1179 1414 1650
Upsize 2 832 757 1136 1514 1893 2271 2650
Fuel Consumption Rates*
STANDBY
Fuel Pump Lift - m (ft) Percent Load gph lph
3.7 (12) 25% 10.5 39.7
50% 19.5 73.8
75% 23.7 89.7
100% 31.2 118.1
* Refer to "Emissions Data Sheet" for maximum fuel flow for EPA and SCAQMD permitting purposes.
STANDBY
Coolant Flow per Minute gpm (lpm) 114.1 (432)
Heat Rejection to Coolant BTU/hr 1,198,080
Inlet Air cfm (m3/min) 30,582 (866)
Max. Operating Radiator Air Temp Fº (Cº) 122 (50)
Max. Operating Ambient Temperature Fº (Cº) 104 (40)
Coolant System Capacity gal (L) 13 (49)
Maximum Radiator Backpressure in H2O 0.5
STANDBY
Flow at Rated Power cfm (m3/min) 1483 (42)
STANDBY
Rated Engine Speed rpm 1800
Horsepower at Rated kW** hp 762
Piston Speed ft/min 2020
BMEP psi 366
** Refer to “Emissions Data Sheet” for maximum bHP for EPA and SCAQMD
permitting purposes.
STANDBY
Exhaust Flow (Rated Output) cfm (m3/min) 3955 (112)
Max. Backpressure (Post Silencer) inHg (Kpa) 2.01 (6.8)
Exhaust Temp (Rated Output) ºF (ºC) 1022 (550)
Exhaust Outlet Size (Open Set) 5"
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MD500 operating data (60Hz)
500 kW Diesel

GENERATOR SET
Genset Vibration Isolation Std
IBC/OSHPD Seismic Certified Opt
Extended warranty Opt
Gen-Link Communications Software Opt
Steel Enclosure Opt
Aluminum Enclosure Opt
Enclosure Lighting Kits Opt
ENGINE SYSTEM
General
Oil Drain Extension Std
Oil Heater Opt
Air cleaner Std
Fan guard Std
Radiator duct adapter Std
Stainless steel flexible exhaust connection Std
Critical Exhaust Silencer Opt
Fuel System
Secondary fuel filter Std
Flexible fuel lines Opt
Primary fuel filter Std
UL 142 Fuel Tank Opt
Cooling System
120VAC Coolant Heater Std
Closed Coolant Recovery System Std
UV/Ozone resistant hoses Std
Factory-Installed Radiator Std
Radiator Drain Extension Std
Engine Electrical System
Battery charging alternator Std
Battery cables Std
Battery heater Opt
Solenoid activated starter motor Std
10A UL float/equalize battery charger Opt
Rubber-booted engine electrical connections Std
ALTERNATOR SYSTEM
GENprotect™ Alternator Protection Algorithm Std
Main Line Circuit Breaker Std
Alternator Upsizing Opt
Anti-Condensation Heater Opt
Tropical coating Opt
Permanent Magnet Generator Std
CONTROL SYSTEM
Control Panel
Digital H Control Panel - Dual 4x20 Display na
Digital G-200 Paralleling Control Panel - Touchscreen Std
Programmable Crank Limiter Std
21-Light Remote Annunciator Opt
Remote Relay Panel (8 or 16) Opt
7-Day Programmable Exerciser Std
Special Applications Programmable PLC Std
RS-232 Std
RS-485 Std
All-Phase Sensing DVR Std
Full System Status Std
Utility Monitoring (Req. H-Transfer Switch) Std
2-Wire Start Compatible Std
Power Output (kW) Std
Power Factor Std
Reactive Power Std
All phase AC Voltage Std
All phase Currents Std
Oil Pressure Std
Coolant Temperature Std
Coolant Level Std
Oil Temperature Opt
Engine Speed Std
Battery Voltage Std
Frequency Std
Date/Time Fault History (Alarm & Event Log) Std
Low-Speed Exercise -
Isochronous Governor Control Std
-40deg C - 70deg C Operation Std
Waterproof Plug-In Connectors Std
Audible Alarms and Shutdowns Std
Not in Auto (Flashing Light) Std
Auto/Off/Manual Switch Std
E-Stop (Red Mushroom-Type) Std
Remote E-Stop (Break Glass-Type, Surface Mount) Opt
Remote E-Stop (Red Mushroom-Type, Surface Mount) Opt
Remote E-Stop (Red Mushroom-Type, Flush Mount) Opt
NFPA 110 Level I and II (Programmable) Std
Remote Communication - RS232 Std
Remote Communication - Modem Opt
Remote Communication - Ethernet Opt
10A Run Relay Opt
Alarms (Programmable Tolerances, Pre-Alarms and Shutdowns)
Low Fuel Opt
Oil Pressure (Pre-programmed Low Pressure Shutdown) Std
Coolant Temperature (Pre-programmed High Temp Shutdown) Std
Coolant Level (Pre-programmed Low Level Shutdown) Std
Oil Temperature Opt
Engine Speed (Pre-programmed Overspeed Shutdown) Std
Voltage (Pre-programmed Overvoltage Shutdown) Std
Battery Voltage Std
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MD500 standard features and options
500 kW Diesel

Tank Options
MDEQ OPT
Florida DERM/DEP OPT
Chicago Fire Code OPT
IFC Certification CALL
ULC CALL
Other Custom Options Available from your Generac Industrial Power Dealer
*All measurements are approximate and for estimation purposes only. Weights and dBA are available on install drawings and sound data sheets, respectively.
OPEN SET
RUN TIME HOURS USABLE CAPACITY (GAL)
NO TANK -
10 334
32 1001
32 1001
64 2002
STANDARD ENCLOSURE
RUN TIME HOURS USABLE CAPACITY (GAL)
NO TANK -
10 334
32 1001
32 1001
64 2002
LEVEL 1 SOUND ENCLOSURE
RUN TIME HOURS USABLE CAPACITY (GAL)
NO TANK -
10 334
32 1001
32 1001
64 2002
LEVEL 2 SOUND ENCLOSURE
RUN TIME HOURS USABLE CAPACITY (GAL)
NO TANK -
10 334
32 1001
32 1001
64 2002
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MD500 enclosure and tank configurations
YOUR FACTORY RECOGNIZED GENERAC INDUSTRIAL DEALER
Generac Power Systems, Inc. • S45 W29290 HWY. 59, Waukesha, WI 53189 • generac.com
©2012 Generac Power Systems, Inc. All rights reserved. All specifications are subject to change without notice. Bulletin 0197170SBY-B / Printed in U.S.A. 12/06/12
Specification characteristics may change without notice. Dimensions and weights are for preliminary purposes only. Please consult a Generac Power Systems Industrial Dealer for detailed installation drawings.
500 kW Diesel