Generac 004475-0, 004124-1, 004090-2, 004125-1, 004126-1 User Manual

...
POWER SYSTEMS, INC.
®
Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
(Natural Gas) 004090-2 004091-2 004092-2 004093-2 004094-2 004095-2 004096-2 004097-2 004474-0 (w/TS)
(Liquid Propane Vapor)
004124-1 004125-1 004126-1 004127-1 004128-1 004130-1 004131-1 004475-0 (w/TS)
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
Generac®Power Systems, Inc.
INTRODUCTION
Thank you for purchasing this model of the standby gen­erator set product line by Generac Power Systems.
Every effort was expended to make sure that the infor­mation and instructions in this manual were both accu­rate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
READ THIS MANUAL THOROUGHLY
If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing pro­cedures.
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to spe­cial instruction about a particular service or operation that may be hazardous if performed incorrectly or care­lessly. Observe them carefully. Their definitions are as fol­lows:
After this heading, you can read instructions that, if not strictly complied with, will result in personal injury or property damage.
After this heading, you can read instructions that, if not strictly complied with, may result in personal injury or property damage.
After this heading, you can read instructions that, if not strictly complied with, could result in damage to equip­ment and/or property.
NOTE:
After this heading, you can read explanatory state­ments that require special emphasis.
These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.
Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:
This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of you and others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock hazard.
The operator is responsible for proper and safe use of the equipment. We strongly recommend that the opera­tor read this Owner's Manual and thoroughly under­stand all instructions before using this equipment. We also strongly recommend instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe oper­ation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or work­manship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your Generac Authorized Service Dealer for service aids and accessories.
Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When your generator requires servicing or repairs, sim­ply contact a Generac Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.
When contacting a Generac Authorized Service Dealer or the factory about parts and service, always supply the complete model number of your unit as given on the front cover of this manual or on the DATA CARD affixed to the unit.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the GENERAC AUTHORIZED SERVICE
DEALER nearest you, please call this number:
1-800-333-1322
OR
Locate us on the web at:
www.generac.com
Table of Contents
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 1
INTRODUCTION ............................................................IFC
SAFETY RULES ........................................................................2
Section 1
GENERAL INFORMATION ........................................................4
Generator ....................................................................................4
Automatic System Operation ......................................................4
Generator AC Connection Systems ............................................4
Main Circuit Breaker....................................................................5
Generator Fuel System ..............................................................5
Engine Protective Devices ..........................................................5
Generator Specifications ............................................................6
Unpacking....................................................................................7
Lifting the Generator ..................................................................7
Engine Specifications ..................................................................7
Fuel Consumption ......................................................................7
Lifting the Generator ..................................................................7
Torque Specifications ..................................................................8
Engine Oil Recommendations ....................................................8
Coolant Recommendations ........................................................8
Before Installation........................................................................8
Section 2
STANDBY GENERATOR INSTALLATION ................................9
Basic Standby Electric System..............................................................9
Emergency Circuit Isolation Method....................................................10
Total Circuit Isolation Method ..............................................................10
Grounding the Generator ....................................................................10
Generator AC Neutral Connections ....................................................10
Transfer Switch Start Signal Connections ..........................................10
Battery Installation ..............................................................................10
Preparation Before Start-Up ................................................................11
Section 3
OPERATION ............................................................................12
Using a Standard “GTS” Transfer Switch ..................................12
Control Console Components ..................................................13
Manual Transfer and Startup ....................................................13
Retransfer and Shutdown..........................................................14
Automatic Operation..................................................................14
Weekly Exercise Cycle..............................................................14
Engine Heater ..........................................................................14
Section 4
MAINTENANCE........................................................................15
Maintenance Performed by
Authorized Service Facilities ....................................................15
Overload Protection for Engine DC Electrical System..............15
Checking Fluid Levels ..............................................................15
Maintenance Owner/Operator Can Perform..............................16
Miscellaneous Maintenance ......................................................17
Section 5
TROUBLESHOOTING..............................................................18
Section 6
SCHEDULED MAINTENANCE ................................................19
Section 7
WIRING DIAGRAMS AND SCHEMATICS..........................22-27
Section 8
EXPLODED VIEWS AND PARTS LISTS ............................28-45
Section 9
INSTALLATION DRAWINGS ..............................................46-47
Section 10
WARRANTY .......................................................48- Back Cover
Figure 1- Water Cooled Emergency Power System
2 Generac®Power Systems, Inc.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The genera­tor can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many acci­dents are caused by failing to follow simple and funda­mental rules or precautions.
Generac cannot possibly anticipate every possible cir­cumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You also must make sure the procedure, work method or operating technique that you choose does not render the generator unsafe.
Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment.
Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.
Parts of the generator are rotating and/or hot during operation. Exercise care near running gen­erators.
GENER
AL HAZARDS
• For safety reasons, Generac recommends that this equipment be installed, serviced and repaired by a Generac Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regula­tions.
• Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the gener­ator is installed, operated and serviced in accordance with the manufacturer’s instructions and recommen­dations. Following installation, you must not do any­thing that might render the unit unsafe or in non­compliance with the aforementioned codes, stan­dards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, ade­quate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilat­ing air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• Keep the area around the generator clean and unclut­tered. Remove any materials that could become haz­ardous.
• When working on this equipment, remain alert at all times. Never work on the equipment when you are physically or mentally fatigued.
Important Safety Instructions
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:
Generac®Power Systems, Inc. 3
• Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
ELE
CTRICAL HAZARDS
• All generators covered by this manual produce dan­gerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dan­gerous voltages to the transfer switch as well as the standby generator. Avoid contact with bare wires, ter­minals, connections, etc., on the generator as well as the transfer switch, if applicable. Ensure all appropri­ate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If people must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.
• The National Electrical Code (NEC), Article 250 requires the frame and external electrically conduc­tive parts of the generator to be connected to an approved earth ground and/or grounding rods. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condi­tion in the generator set or by static electricity. Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord sets must be adequate to handle the maximum elec­trical current (ampacity) to which they will be sub­jected.
• Before installing or servicing this (and related) equip­ment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.
• Generators installed with an automatic transfer switch will crank and start automatically when nor­mal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, disable the generator’s automatic start circuit (battery cables, etc.) before working on or around the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.
• In case of accident caused by electric shock, immedi­ately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.
F
IREHAZARDS
• Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• Generac generator sets may operate using one of sev­eral types of fuels. All fuel types are potentially FLAM­MABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly.
Important Safety Instructions
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
4 Generac®Power Systems, Inc.
GENERATOR
This equipment is an water-cooled, engine-driven gen­erator set. The generator is designed to supply electrical power that operates critical electrical loads during util­ity power failure. The unit has been factory-installed in a weather resistant, all metal sound attenuated enclo­sure and is intended for outdoor installation only. Use this generator as a source of electrical power for the operation of 120 and/or 240 volts, single or 3-phase loads, or 120 and/or 208 volts, 3-phase loads.
These models are available. They are rated as follows:
Model 004090: Provides 10,000 watts (10 kW) of 1-phase power.
Model 004091: Provides 10,000 watts (10 kW) of 3-phase power.
Model 004124: Provides 10,000 watts (10 kW) of 1-phase power.
Model 004125: Provides 10,000 watts (10 kW) of 3-phase power.
Model 004092: Provides 15,000 watts (15 kW) of 1 phase power.
Model 004093: Provides 15,000 watts (15 kW) of 3 phase power.
Model 004126: Provides 15,000 watts (15 kW) of 1 phase power.
Model 004127: Provides 15,000 watts (15 kW) of 3 phase power.
Model 004094: Provides 20,000 watts (20 kW) of 1-phase power.
Model 004095: Provides 20,000 watts (20 kW) of 3-phase power.
Model 004128: Provides 20,000 watts (20 kW) of 1-phase power.
Model 004096: Provides 25,000 watts (25 kW) of 1 phase power.
Model 004097: Provides 25,000 watts (25 kW) of 3 phase power.
Model 004130: Provides 25,000 watts (25 kW) of 1 phase power.
Model 004131: Provides 25,000 watts (25 kW) of 3 phase power.
Model 004474: Provides 25,000 watts (25 kW) of 1 phase power.
Model 004475: Provides 25,000 watts (25 kW) of 1 phase power.
WARNING: If this generator is used to power electrical load circuits normally powered by a utility power source, you are required by code to install a transfer switch. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 701). Failure to isolate an electri­cal system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to back­feed of electrical energy.
AUTOMATIC SYSTEM OPERATION
When this generator along with its transfer switch has been installed and interconnected, a circuit board in the generator panel constantly monitors utility power source voltage. Should that voltage drop below a preset value, and remain at such a low state for a preset amount of time, the generator cranks and starts. After the generator starts, the transfer switch transfers load circuits so the generator can power them.
When utility source voltage has been restored, the switch re-transfers back to the utility source voltage and the generator then shuts down.
GENERATOR AC CONNECTION SYSTEMS
The generator was shipped from the factory with its sta­tor AC output leads connected in one of the “Delta” con­figurations, as shown in Figure 2. This type of connec­tion system will supply a 120 and/or 240 volts, 1 or 3-phase output as shown in the illustration.
Figure 2 - Generator AC Connection System
If, however, load voltage requires 120/208 volts, 3-phase output, generator will require reconnecting of the sta­tor’s output leads. This task should only be performed by a qualified Generac service technician. Refer to the installation manual (Part No. 079699) for details.
Section 1 - General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 5
Figure 3 represents a single-phase, 3-wire generator AC connection system. The stator assembly in this system consists of a pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 120 volts AC, 60 Hertz. When the two windings are connected in series, a 240 volts, 60 Hertz AC output results. Typically the two “hot” leads in the circuit are Wires No. 11 and 44. The “Neutral” leads are the junc­tion of Wires 22 and 33.
Figure 3 - Generator AC Connection System
MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with the unit as shipped from the factory. The breaker for each unit is described in Figure 5 below.
GENERATOR FUEL SYSTEM
Your unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is pre­ferred, contact an authorized service dealer.
WARNING: Gaseous fuels such as natural and LP
(propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.
ENGINE PROTECTIVE DEVICES
The engine has several safety switches which cause the engine to automatically shut down under the following conditions: low oil pressure, high coolant temperature, engine overspeed, low coolant level or overcrank.
LOW OIL PRESSURE SWITCH:
This switch is normally-closed (N.C.) but is held open by engine oil pressure during engine running. Should operating oil pressure drop below about 8-10 psi (55-68 kPa), the switch contacts close and the engine shuts down automatically (Figure 4).
Figure 4 - Low Oil Pressure Switch
Section 1 - General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Model Rating Phase Actual Current C/B Rating* % over rating Circuit Breaker
004090-2 10,000 1 41.7 50 120% 50A BQ2 004091-2 10,000 3 30.1 40 133% 40A BQ3 004124-1 10,000 1 41.7 50 120% 50A BQ2 004125-1 10,000 3 30.1 40 133% 40A BQ3 004092-2 15,000 1 62.5 70 112% 70A BQ2 004093-2 15,000 3 45.2 60 133% 60A BQ3 004126-1 15,000 1 62.5 70 112% 70A BQ2 004127-1 15,000 3 45.2 60 133% 60A BQ3 004094-2 20,000 1 83.3 90 108% 90A BQ2 004095-2 20,000 3 60.2 70 116% 70A BQ3 004128-1 20,000 1 83.3 90 108% 90A BQ2 004096-2 25,000 1 104.2 125 120% 125A BQ2 004097-2 25,000 3 75.3 90 120% 90A BQ3 004130-1 25,000 1 104.2 125 120% 125A BQ2 004131-1 25,000 3 75.3 90 120% 90A BQ3 004474-0 25,000 1 104.2 125 120% 125A BQ2 004475-0 25,000 1 104.2 125 120% 125A BQ2
* Amp Rating of C/B structured under model.
Figure 5 - Main Circuit Breaker
6 Generac®Power Systems, Inc.
HIGH COOLANT TEMPERATURE SWITCH:
Normally open (N.O.) thermostatic switch has sensing tip which is immersed in captive coolant. Should coolant temperature exceed about 230°F (110°C), the switch contacts close, which causes the engine to shut down automatically (Figure 6).
Figure 6- High Coolant Temperature Switch
LOW COOLANT LEVEL SWITCH:
Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating without automatic shut down, the engine has a low coolant level sensor. If the engine coolant drops too low, the engine automatically shuts down (Figure 7).
Figure 7 - Low Coolant Level Sensor
OVERSPEED SHUTDOWN:
The CMA circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator AC power windings, via sensing leads S15 and S16. Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine (Figure 8).
*Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an additional 1% for each 10°F above 60°F. Maximum output power of the generator is limited by
maximum engine power.
Section 1 — General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
SPECIFICATIONS
GENERATOR SPECIFICATIONS
3-Phase 1-Phase
Mode
l 004097 004095 004093 004091 004096 004094 004092 004090
004131 004127 004125 004130 004126 004128 004124 *Rated Max. Cont. AC Power Output (kW) 25 20 15 10 25 20 15 10 Rated Voltage (volts) 120/240 120/240 Rated Max. Cont. Current @ 240 V, 1Ø N/A N/A N/A N/A 104.2 83.3 62.5 41.7 Current @ 240 V, 3Ø 75.3 60.2 45.2 30.1 N/A N/A N/A N/A No. of Rotor Poles 2 4 2 4 Driven Speed of Rotor 3600 3600 1800 1800 3600 3600 1800 1800 Rotor Excitation System Direct excited brush type system Type of Stator 12 wire reconnectable Rotor/Stator Insulation Class F
† Models 004474 & 004475 has same specifications as models 004096 & 004130 below.
Figure8-ControlModule Assembly Circuit Board
OVERCRANK SHUTDOWN:
After 90 seconds of crank-rest cycles, this function ends cranking if the engine fails to start in that 90-second span.
DC FUSE
This clearly labeled fuse is located on the front panel of the control system. It protects the panel wiring and components from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rat­ing. Generac normally uses an AGC fuse rated at 30 amps.
UNPACKING
UNPACKING PRECAUTIONS:
Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, collision, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton.
INSPECTION:
After unpacking, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix his signature under the consignor’s memo of loss or damage.
LIFTING THE GENERATOR
WARNING: When lifting or hoisting equipment is used,
be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.
SPECIFICATIONS
ENGINE SPECIFICATIONS
Make................................................................................Mitsubishi
Displacement ................................................92 inches
3
(1.5 liters)
Cylinder Arrangement........................................................4, in-line
Valve Arrangement..................................................Overhead Cam
Firing Order..........................................................................1-3-4-2
Number of Main Bearings ............................................................5
Compression Ratio ................................................................9 to 1
No. of Teeth on Flywheel ..........................................................104
Ignition Timing
at 1800 rpm ....................................................35 degrees BTDC
at 3600 rpm ....................................................43 degrees BTDC
Spark Plug Gap ....................................................0.020-0.025 inch
Recommended Spark Plugs
Champion ......................................................................RN11YC4
Oil Pressure......................................................................30-50 psi
Crankcase Oil Capacity..........................4.0 U.S. quarts (3.8 liters)
Recommended Engine Oil..........................................SAE 15W-40
Type of Cooling System ....................Pressurized, closed recovery
Cooling Fan ................................................................Pusher Type
Cooling System Capacity ........................2 U.S. gallons (7.6 liters)
Recommended Coolant ..............................Use a 50-50 mixture of
ethylene glycol base.
FUEL CONSUMPTION
Models 004096, 004097, 004130, 004131, 004474, 004475
Using Natural Gas ....................................441 cu. ft. per hour
Using LP Gas ........................175 cubic ft.(4.8 gal.) per hour
Models 004094, 004095, 004128
Using Natural Gas ....................................359 cu. ft. per hour
Using LP Gas ........................143 cubic ft. (4.0 gal.) per hour
Model 004092, 004093, 004126, 004127
Using Natural Gas ....................................277 cu. ft. per hour
Using LP Gas ........................110 cubic ft.(3.1 gal.) per hour
Models 004090, 004091, 004124, 004125
Using Natural Gas ....................................195 cu. ft. per hour
Using LP Gas ..........................77 cubic ft. (2.2 gal.) per hour
NOTE:
Fuel consumption is given at rated maximum con­tinuous power output when using natural gas rated at 1000 Btu per cubic foot; or LP gas rated 2520 Btu per cubic foot. Actual fuel consumption obtained may vary depending on such variables as applied load, ambient temperature, engine condi­tions and other environmental factors.
Section 1 — General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 7
8 Generac®Power Systems, Inc.
TORQUE SPECIFICATIONS
Cylinder Head ......................................15 (+ 90° + 90°) ft.lb.
Intake Manifold ..........................................................13 ft.lb.
Exhaust Manifold ......................................................13 ft.lb.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the factory. Use a high-quality detergent oil classified “For Service CC, SD, SE, SF.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:
CAUTION: Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate, ethylene glycol base anti-freeze and half soft water. Cooling system capacity is about 8 U.S. quarts (8.5 liters). Use only soft water and only low silicate anti-freeze. If desired, add a high quality rust inhibitor to the recommended coolant mix­ture. When adding coolant, always add the recom­mended 50-50 mixture.
Do not use any chromate base rust inhibitor with eth­ylene glycol base anti-freeze or chromiumhydroxide (“green slime”) forms and will cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or additives will also cause overheating. We also recommend that you DO NOT use any soluable oil inhibitor for this equipment.
BEFORE INSTALLATION
Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Isolation Method” and “Total Circuit Isolation Method” in the installation manual (Part No.
079699).
The generator’s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. You may have to group the critical (essential) loads together and wire them into a separate “emer­gency” distribution panel.
This generator can be installed in conjunction with a standard Generac “GTS” type transfer switch, if desired.
The standard transfer switch has no sensing or con­trolling circuit boards. Instead, the generator control console houses a “Control Module Assembly”, which controls all phases of operation, including engine start up and load transfer.
Section 1 — General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 30W or 15W-40
32° to 80° F (-1° to 27° C) SAE 20W-20 or 15W-40
Below 32° F (0° C) SAE 10W or 15W-40
Generac®Power Systems, Inc. 9
If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set.
Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations per­taining to the installation.
After the system has been installed, you must not do anything that might render the installation in noncom­pliance with such codes, standards and regulations.
NOTE:
For more information about the installation of a stand­by system, you can order Engine-Generator Standby
Electric Power Systems Installer’s Guide and Reference Manual (part #046622) from your Generac
Authorized Service Dealer.
NFPA STANDARDS
The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 02269:
• NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS.
OTHER PUBLISHED STANDARDS
In addition to NFPA standards, the following informa­tion pertaining to the installation and use of standby electric systems is available:
• Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 909 University Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTE­NANCE OF FARM STANDBY ELECTRIC POWER, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES AND VENTING SYS­TEMS, available from the American National Standard Institute, 1430 Broadway, New York, N.Y.
10018.
BASIC STANDBY ELECTRIC SYSTEM
Figure 2.1 shows a schematic diagram of a basic stand­by electric system. Both the UTILITY power supply and the STANDBY (generator) output are connected to an approved transfer switch. The transfer switch is required by electrical code and serves the following functions:
• Permits the LOAD circuits to be connected to only one power supply at a time.
• Prevents electrical backfeed between the generator and the UTILITY power circuits.
Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker.
NOTE:
Generac recommends the use of a Generac power systems “GTS” type transfer switch in conjunction with this generator.
Figure 2.1 – Basic Standby Electric System
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Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
STANDBY GENERATOR INSTALLATION
Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch (such as the Generac “GTS” type transfer switch), so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy.
10 Generac®Power Systems, Inc.
EMERGENCY CIRCUIT ISOLATION METHOD
This prevents overloading the generator by keeping elec­trical loads below the wattage/amperage capacity of the generator. If the generator is powering only critical loads, within the wattage/amperage capacity, during util­ity power outages, you might consider using the emer­gency circuit isolation method.
Critical electrical loads are grouped together and wired into a separate “Emergency Distribution Panel.” Load circuits powered by that panel are within the wattage/amperage capacity of the generator set. When this method is used, it is difficult to overload the gener­ator. The transfer switch must meet the following requirements:
• It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit.
• Have it installed between the building’s main distribu­tion panel and the emergency distribution panel.
TOTAL CIRCUIT ISOLATION METHOD
When a generator capable of powering all electrical loads in the circuit is to be installed, you may use the “Total Circuit Isolation Method.” It is possible for the generator to be overloaded when this isolation method is employed. The following apply to the transfer switch in this type of system.
• Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service.
• The transfer switch is installed between the utility service entrance and the building distribution panel.
GROUNDING THE GENERATOR
The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected to an approved earth ground and/or grounding rods. For that purpose, a GROUND LUG (Figure 2.2) is provided on the generator mounting base. Consult a qualified electrician for grounding requirements in your area. Grounding procedures must meet local regulations.
Do not connect the ground wire to any pipe that carries a flammable or explosive substance – FIRE or an EXPLOSION may result.
Proper grounding helps protect personnel against electri­cal shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.
Figure 2.2 – Generator Grounding Lug (typical)
GENERATOR AC NEUTRAL CONNECTIONS
Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actu­al result depends on the electrical characteristics of the particular installed generator.
TRANSFER SWITCH START SIGNAL CONNECTIONS
If your generator is to be installed with an automatic transfer switch, such as a Generac GTS-type switch, it will be necessary to connect the two-wire start control system.
Connect the two-wire start signal from the automatic transfer switch to the automatic start connection, which is located in the right hand corner inside the control panel. Match wires 178 and 183 in the transfer switch to 178 and 183 on the terminal strip in the control panel. The conductors for the two-wire start circuit must be in their own conduit.
BATTERY INSTALLATION
Standby generators installed with automatic trans­fer switches will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to per­sonnel, do not connect battery cables until you are certain that normal source voltage at the transfer switch is correct and you are ready to place the system into operation.
Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause
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Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 11
an explosion. Such an explosion can shatter the bat­tery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If you spill the fluid, flush the affected area immediately with clear water.
Do not dispose of the battery in a fire. The battery is capable of exploding.
Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes.
The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles.
VENTED BATTERIES
The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically con­ductive and corrosive. The following procedures are to be observed:
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off immediately with water,
• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical atten­tion, and
• Spilled electrolyte is to be washed down with an acid­neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.
Lead acid batteries present a risk of fire because they generate hydrogen gas. The following proce­dure are to be followed:
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touching batteries by first touching a grounded metal surface.
Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
For recommended batteries, see “Specifications.” All batteries must be at 100 percent state-of-charge before they are installed on the generator.
When using maintenance-free batteries, it is not neces­sary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals spec­ified in Section 4, “Maintenance.” A negative ground sys­tem is used. Battery connections are shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight. Observe battery polarity when connecting batteries to the generator set.
Note:
Damage will result if the battery connections are made in reverse.
PREPARATION BEFORE START-UP
The instructions in this section assume that the standby generator has been properly installed, serviced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules” on Pages 2 and 3, as well as all other safe­ty information in this manual, before attempting to operate this (and related) equipment.
PRIOR TO INITIAL START-UP
Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quanti­ties of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.
Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service inter­vals, please refer to Section 4, “Maintenance.”
Transfer Switch
If this generator is used to supply power to any electri­cal system normally powered by an electric utility, the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents electrical backfeed between two different electrical systems. (For additional information, see the applicable transfer switch manual for this unit.) The transfer switch, as well as the generator and other standby components, must be properly located and mounted in strict compli­ance with applicable codes, standards and regulations.
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Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
12 Generac®Power Systems, Inc.
Fuel System
Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and (b) is properly purged and leak tested according to code. No fuel leakage is permitted. See “Specifications” (Page
7) for more information.
Generator Set Lubrication
Check the engine crankcase oil level before operating and add oil to the proper level – the dipstick “FULL” mark. Never operate the engine with the oil level below the dipstick “ADD” mark. See “Specifications” (Page 7) and “Engine Oil Recommendations” (Page 8).
NOTE:
This engine is shipped from the manufacturer with 15W-40 oil. This oil should be changed after 30 hours of operation.
Engine Coolant
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” (Page 7) and “Coolant” (Page 8).
Belt Tension
Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approx­imately 22 pounds (10 kg), applied midway between pulleys, deflects the belt about 3/8- to 5/8-inch (10 to 16 mm).
Electrical System
Make sure the generator is properly connected to an approved earth ground and/or ground rod.
Make sure the generator battery is fully charged, proper­ly installed and interconnected, and ready for use.
Check to ensure that there are no loose electrical con­nections. Restrain any loose wires to keep them clear of any moving generator set components.
USING A STANDARD “GTS” TRANSFER SWITCH
When required, the pre-packaged standby generator can be installed with a standard Generac “GTS” type automatic transfer switch.
When you use a standard GTS type transfer switch, it controls automatic operation and automatic transfer as follows:
• Solid state circuits in the transfer switch monitor util­ity power source voltage.
• When utility source voltage drops below a pre-set level, transfer switch action closes the circuit. The engine then cranks and starts as controlled by the pre-packaged generator’s Control Module circuit board.
• After the engine starts and when the generator AC output voltage and frequency have reached a pre-set value, transfer switch circuits signal the transfer switch main contacts to actuate to the “Standby” power source side. Generator AC output then powers load circuits.
• When the utility power source voltage is restored above a pre-set level, transfer switch solid state cir­cuits signal the switch main contacts to move back to their utility power source side.
• Following re-transfer back to the utility power source side, transfer switch circuit board action opens the circuit. Engine then shuts down.
NOTE:
If your generator is installed in conjunction with a standard GTS type transfer switch, refer to the applicable transfer switch manual for exact oper­ating parameters and timing sequences.
CONTROL CONSOLE COMPONENTS
The components of a water-cooled generator control console (Figure 8) are as follows:
Figure 8 - Water-Cooled Generator Panel
AC VOLTMETER:
The voltmeter displays generator AC output voltage dur­ing operation. Voltage is regulated by a solid state volt­age regulator and is proportional to AC frequency. Refer to your unit’s DATA PLATE for rated AC voltage.
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Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 13
AC AMMETER:
Indicated current draw of connected electrical loads during operation. DO NOT EXCEED YOUR UNIT’S RATED MAXIMUM CONTINUOUS CURRENT. Refer to the unit DATA PLATE.
AC FREQUENCY METER:
Indicates generator AC output frequency in “Hertz” (cycles per second). Frequency is proportional to engine speed. Units with a 4-pole rotor supplies 60 Hertz at 1800 rpm. Units with a 2-pole rotor supplies 60 Hz at 3600 rpm. Frequency reading with no electrical loads connected (no-load condition) should be between 59-61 Hertz.
DC VOLTMETER:
The generator is equipped with a belt-driven DC alternator, which maintains battery state of charge when the engine operates. The Control Module Assembly also incorporates a trickle charge circuit which maintains battery state of charge during non-operating periods. Battery voltage should read about 12.5 to 14.5 volts DC. A low battery voltage indicates the battery is discharging.
HOURMETER:
Indicates time the engine-generator has operated, in hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for your gener­ator set.
AUTO/OFF/MANUAL SWITCH:
Use this 3-position switch as follows:
• Set the switch to “Auto” for fully automatic operation. See “Automatic Operation”.
• Set switch to “Manual” position to crank and start the generator engine.
• Set switch to “Off ” position to shut down an operat­ing engine. With “Off ” selected, operation will not be possible.
DANGER! With switch set to "auto", engine can crank and start suddenly without warning. Such automatic start up normally occurs when utility source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set AUTO/OFF/MANUAL switch to "off" before working on or around the unit. Then, place a "do not operate" tag on con­trol console.
FAULT INDICATOR LAMP:
Lamp goes ON when one or more of the following engine faults occurs and when engine shuts down.
• Low oil pressure • Overcrank
• High coolant temperature • Overspeed
• Low coolant level
30 AMP FUSE:
Fuse protects the control console’s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. Should you need to replace the fuse, use only an identical 30-amp replacement fuse. (Type AGC)
7.5 AMP INLINE FUSE:
A 7.5 Amp inline fuse has been added to the wire har­ness of all units starting in the second half of 2001. This inline fuse is connected in the 15A line that runs between the Auto/Off/Manual switch and position 10 of the 76009A PCB. This fuse protects the start, fuel, field boost, and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outputs.
NOTE:
This fuse will not remove the + battery input power from the PCB when it opens. This means the exercise timer will not be reset. If this fuse does open, carefully check the wiring to the start, fuel, field boost and transfer outputs before replacing the fuse.
METER READING SELECTOR SWITCH:
Switch permits you to select either line-to-line or line-to-neutral voltage and amperage readings on the console AC voltmeter and AC ammeter.
SET EXERCISE TIME SWITCH:
Switch allows you to program the generator to start and exercise automatically. “See Weekly Exercise Cycle.”
MANUAL TRANSFER AND START UP
To transfer electrical loads to the “Standby” (generator) power source side and start the engine manually, refer to the Owner’s Manual of your particular transfer switch.
Section 3 - Operation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
14 Generac®Power Systems, Inc.
RETRANSFER AND SHUTDOWN
When utility power source voltage has been restored, electrical loads may be transferred back to that source and the generator can be shut down as follows:
• Verify that utility power supply voltage to the transfer switch has been positively turned “Off,” using what­ever means provided (such as utility main line circuit breaker).
• Set the generator’s main circuit breaker to its “Off” or “Open” position.
• Let the generator engine run at no-load for a few min­utes, to stabilize internal unit temperatures.
• On the generator console, set the Auto-Off-Manual switch to “Off”. Wait for engine to come to a com­plete stop.
• For transfer to utility position, refer to the Owner’s Manual of your particular transfer switch.
• Turn on the utility power supply to the transfer switch, using whatever means provided (such as a utility main line circuit breaker). The utility power source now powers the loads.
AUTOMATIC OPERATION
To set the system for fully automatic operation, proceed as follows:
• Check that load circuits are connected to the utility power supply.
• Set the Auto/Off/Manual switch to its “Auto” position.
• Set the generator main circuit breaker to its “On” or “Closed” position.
WEEKLY EXERCISE CYCLE
The generator will start and exercise once every 7 days. During this weekly exercise, the unit runs for about 20 minutes and shuts down. Transfer of loads to genera­tor output does not occur during the exercise.
To select day and time for exercising, proceed as follows:
• Set the Auto/Off/Manual switch to OFF.
• Set generator main circuit breaker to OFF or OPEN.
• Locate the rocker switch on the control panel identi­fied with the words “Set Exercise Time” (Figure 9).
• Push “Set Exercise Time” switch to ON position for 20 to 30 seconds and then release. Switch will spring back into its original position when released.
• Wait 30 seconds before setting the Auto/Off/Manual switch to “AUTO” position.
CAUTION: If you switch the Auto/Off/Manual switch too soon, the engine may start. If engine does start, it will shut down automatically in about two (2) minutes.
• Set the generator main circuit breaker to its ON or CLOSED position.
• Generator is now programmed to start and exercise every 7 days thereafter, on day and time of day the switch was actuated.
• Place a sign on the generator control panel and the transfer switch, indicating the day and time the generator will be exercising.
NOTE:
If battery terminals are disconnected or control panel fuse is removed, the exercise timer needs to be reset for correct automatic exercise operation.
Figure 9 - “Set Exercise” Switch
ENGINE HEATER
Your Generac standby generator comes equipped with a block heater (Figure 10), similar to the block heaters used in automotive applications.
Figure 10 - Engine Block Heater
Refer to applicable wiring diagram(s) and electrical schematic(s) at back of manual for wiring connections. Customer supplies a 120V 15A Utility fed circuit for the block heater.
Section 3 — Operation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
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