Generac 005030-0, 005031-0 User Manual

Owner’s Manual

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

This manual should remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model Number 005030-0 (15kW)

005028-0 (20kW) 005031-0 (25kW)

INTRODUCTION

Thank you for purchasing this model of the QuietSource™ standby generator series.

Every effort was expended to make sure that the information and instructions in this manual are 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 any portion of this manual is not understood, contact the nearest 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 personnel to special instructions 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, read instructions that, if not strictly complied with, will result in serious personal injury, including death, or property damage.

After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, 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 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. The manufacturer strongly recommends that the operator reads this Owner's Manual and thoroughly understands all instructions before using this equipment. The manufacturer also strongly recommends 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 an Authorized Service Dealer. Normal maintenance service adjustments 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 the generator ensures a minimum number of problems and keep operating expenses at a minimum. See an Authorized Service Dealer for service aids and accessories.

Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent, qualified contractor. Installation of this equipment is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

When contacting an Authorized Service Dealer about parts and service, always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit.

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AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

Locate us on the web at:

www.generac.com

DANGER

Table of Contents

Liquid-cooled 15, 20 and 25 kW Generators

INTRODUCTION................................................IFC

Read this Manual Thoroughly......................................IFC

Operation and Maintenance ........................................IFC

How to Obtain Service ................................................IFC

Authorized Service Dealer Location ............................IFC

SAFETY RULES ....................................................2

Standards Index..............................................................3

Section 1 — GENERAL INFORMATION ............4

1.1 Generator ..............................................................4

1.2 Transfer Switch ....................................................4

1.3 ATS Mode (Automatic Operation) ..........................4

1.4 Engineered Transfer Switch (2-wire Start

GTS Mode) ............................................................4

1.5 Generator AC Connection Systems........................4

1.6 Main Circuit Breaker ............................................5

1.7 Generator Fuel System ..........................................5

1.8 Engine Protective Devices ......................................5

1.9 Unpacking ............................................................6

1.10 Lifting the Generator ............................................6

1.11 Specifications ........................................................7

1.12 Fuel Consumption ................................................7

1.13 Reconfiguring the Fuel System for LP Vapor..........7

1.14 Engine Oil Recommendations ..............................8

1.15 Coolant Recommendations....................................8

1.16 Before Installation ................................................8

Section 2 — INSTALLATION ............................9

2.1 Standby Generator Installation ............................9

2.2 Generator Location................................................9

2.3 Generator Mounting and Support ........................9

2.4 Basic Standby Electric System ............................10

2.5 Emergency Circuit Isolation Method....................10

2.6 Total Circuit Isolation Method ............................10

2.7 Grounding the Generator ....................................10

2.8 Generator AC Neutral Connections......................11

2.9 Automatic Transfer Switch (ATS Mode) ..............11

2.10 Engineered Transfer Switch (2-wire Start

GTS Mode) ..........................................................12

2.11 Battery Installation ..............................................13

2.12 Preparation Before Start-Up................................14

Section 3 — OPERATION ................................15

3.1 Control Console Components..............................15

3.2 Manual Transfer and Startup..............................15

3.3 Engine Governor Gain Adjustments ....................16

3.4 Manual Retransfer and Shutdown ......................17

3.5 Automatic Operation ..........................................17

3.6 Weekly Exercise Cycle..........................................17

3.7 Control Board DIP Switch Settings ....................18

3.8 Voltage Regulator Adjustment..............................18

Section 4 — MAINTENANCE ..........................19

4.1 Maintenance Performed by Authorized

Service Facilities ..................................................19

4.2 Exhaust Manifold Procedure ..............................19

4.3 Intake Manifold Procedure ..................................19

4.4 Cylinder Head Procedure ....................................20

4.5 Cooling System....................................................20

4.6 Overload Protection for Engine DC

Electrical System ................................................20

4.7 Checking Fluid Levels ........................................20

4.8 Maintenance Owner/Operator

Can Perform ........................................................21

4.9 Miscellaneous Maintenance ................................22

4.10 Scheduled Maintenance ......................................24

Section 5 — TROUBLESHOOTING ..................27

Section 6 — NOTES ........................................28

Section 7 — ELECTRICAL DATA ....................30

Section 8 — EXPLODED VIEWS AND

PARTS LISTS ..............................38

Section 9 — INSTALLATION DIAGRAM ..........55

Section 10 — WARRANTY ...............................56

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The gen- erator 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.

The manufacturer cannot 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 using a procedure, work method or operating technique that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen 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.

GENERAL HAZARDS

• For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by an 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, do nothing 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.

• 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 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 physically or mentally fatigued.

• 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.

Important Safety Instructions

Liquid-cooled 15, 20 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:

DANGER

ELECTRICAL 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 work must be done 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 personnel 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.

FIRE HAZARDS

• 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 there are any questions pertaining to fire extinguishers, consult the local fire department.

EXPLOSION HA

ZARDS

• 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.

• These 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.

• 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.

STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and laws, the published information listed below may be used as installation guide for this equipment.

1. NFPA No. 37, STATIONARY COMBUSTION ENGINES

AND GAS TURBINES, available from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA

02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR

HEALTH CARE FACILITIES, available same as Item 1.

3. NFPA No. 54, NATIONAL FUEL GAS CODE, available

same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR

STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELEC-

TRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available from

the American Insurance Association, 85 John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, available from the

Food and Energy Council, 909 University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF

FARM STANDBY ELECTRICAL SYSTEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQ-

UIDS CODE, available same as Item 1.

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Important Safety Instructions

Liquid-cooled 15, 20 and 25 kW Generators

1.1 GENERATOR

This equipment is a liquid-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 enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the operation of 120 and/or 240VAC, single-phase loads.

These models are available. They are rated as follows:

Model 005031-0: Provides 25,000 watts (25 kW) of singlephase power.

Model 005028-0: Provides 20,000 watts (20 kW) of singlephase power.

Model 005030-0: Provides 15,000 watts (15 kW) of singlephase power.

If this generator is used to power electrical load circuits normally powered by a utility power source, it is 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.

1.2 TRANSFER SWITCH

This generator system is intended to be used with a matched automatic transfer switch. It may be supplied in either a NEMA 1 enclosure or a NEMA 3R enclosure. The NEMA 1 enclosure is intended for indoor use only. The NEMA 3R enclosure is weather proof and can be used indoors or outdoors. Follow these rules:

• Install the transfer switch on a firm, sturdy supporting structure.

• To prevent switch distortion, level the switch if necessary. This can be done by placing washers between the switch enclosure and the mounting surface.

• Never install the switch where water or any corrosive substance might drip onto the enclosure.

• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive vapors.

If a transfer switch is not included, one may be purchased separately from an Authorized Dealer.

1.3 AUTOMATIC TRANSFER SWITCH (ATS MODE)

When this generator, along with an HS Type automatic transfer switch has been installed and connected, a circuit board in the generator control panel constantly monitors the utility voltage and controls the operation of the transfer switch.

In ATS Mode utility voltage sensing, weekly exercising, and load transferring is under the control of the generator.

Should the utility voltage drop below a preset value, and remain at this low voltage for a preset amount of time, the generator cranks and starts. After the generator starts, the transfer switch transfers the load circuits to the generator so the generator can power them. When the utility source voltage has been restored, the transfer switch re-transfers the load circuits back to the utility source voltage and the generator shuts down.

1.4 ENGINEERED TRANSFER SWITCH (2-WIRE START GTS MODE)

When required, the pre-packaged standby generator can be installed with an engineered W-type transfer switch which controls utility voltage sensing, weekly exercising and load transferring.

UTILITY voltage sensing, weekly exercising and load transferring is then under the control of the Engineered W-type transfer switch (GTS Mode).

1.5 GENERATOR AC CONNECTION SYSTEMS

The generator was shipped from the factory with its stator AC output leads connected in a single-phase, 3-wire generator AC connection system (Figure 1.1). 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 VAC, 60 Hertz. When the two windings are connected in series, a 240 VAC, 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.

Section 1 - General Information

Liquid-cooled 15, 20 and 25 kW Generators

Model Rating Phase Actual Current C/B Rating* % over rating Circuit Breaker

005031-0 25,000 W 1 104.2 A 125 A 120% 125A BQ2 005028-0 20,000 W 1 83.3 A 100 A 120% 100A BQ2 005030-0 15,000 W 1 62.5 70 A 112% 70A BQ2

* Amp Rating of C/B structured under model.

Figure 1.2 - Main Circuit Breaker

Figure 1.1 - Generator AC Connection System

1.6 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 1.2.

1.7 GENERATOR FUEL SYSTEM

This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is preferred, refer to Section 1.13, Reconfiguring the Fuel System for LP Vapor.

Fuel pressure for a natural gas set up should be five

inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

A seperate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and affect engine durability.

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.

1.8 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 (Figure 1.3).

Figure 1.3 - Engine Protective Devices

1.8.1 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 1.4).

Figure 1.4 - Low Oil Pressure Switch

1.8.2 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 1.5).

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Section 1 - General Information

Liquid-cooled 15, 20 and 25 kW Generators

(BLACK)

NEUTRAL

(WHITE)

(BLACK)

Figure 1.5- High Coolant Temperature Switch

1.8.3 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 1.6).

Figure 1.6 - Low Coolant Level Sensor

1.8.4 OVERSPEED SHUTDOWN

Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine.

1.8.5 OVERCRANK SHUTDOWN

The engine control board uses a cyclic cranking process when attempting to start the engine. The first crank cycle is a 15-second crank followed by a sevensecond rest. This is followed by five more crank cycles each with a seven second crank followed by a seven-second rest.

If the engine fails to start after all six attempts, the start attempt is stopped and the overcrank LED turns on.

1.8.6 LOW BATTERY

The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 12 VDC for one minute. Low battery voltage is a non-latching alarm, which will automatically clear if the battery voltage rises above 12 VDC. If battery voltage goes below 6 VDC during cranking, the low battery voltage alarm is latched, cranking is terminated, and the low battery LED stays on.

1.8.7 15A DC FUSE

This fuse is located inside the control panel. It protects the panel wiring and components from damaging overload. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating.

1.9 UNPACKING

1.9.1 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.

1.9.2 INSPECTION

Upon delivery, 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 their signature under the consignor’s memo of loss or damage.

1.10 LIFTING THE GENERATOR

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.

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Section 1 — General Information

Liquid-cooled 15, 20 and 25 kW Generators

1.11 SPECIFICATIONS

1.11.1 ENGINE

Make ......................................................................................Ford

Displacement ............................................153 inches

(2.5 liters)

Cylinder Arrangement......................................................4, in-line

Valve Arrangement................................................Overhead Cam

Firing Order........................................................................1-3-4-2

Number of Main Bearings............................................................5

Compression Ratio..........................................................9.37 to 1

No. of Teeth on Crank ............................................................36-1

Ignition Timing (Waste Spark System)

at 1800 rpm (NG) ..........................................36 degrees BTDC

at 1800 rpm (LP vapor) ................................28` degrees BTDC

Spark Plug Gap ............................................................0.044 inch

Recommended Spark Plugs

Motorcraft ................................................................AWSF-52-C

Oil Pressure....................................................................30-50 psi

Crankcase Oil Capacity......................4.5 U.S. quarts (4.26 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 and deionized water.

Home standby control board assembly part number 0E9704 must be used on 1800 rpm generators.

1.12 FUEL CONSUMPTION

15 kW Models

Using Natural Gas ........................................236 cu. ft. per hour

Using LP Gas ..................................................92 cu. ft. per hour

20 kW Models

Using Natural Gas ........................................307 cu. ft. per hour

Using LP Gas ................................................122 cu. ft. per hour

25 kW Models

Using Natural Gas ........................................441 cu. ft. per hour

Using LP Gas ................................................175 cu. ft. 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.

Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

1.13 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR

NOTE:

All models are configured for natural gas (NG) from the factory.

To reconfigure the fuel system from NG to LP vapor, follow these steps:

1. Turn the main gas supply off.

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Section 1 — General Information

Liquid-cooled 15, 20 and 25 kW Generators

1.11.2 GENERATOR

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* Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other fac-

tors. 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.

Single-phase Single-phase Single-phase

Model 005031-0 005028-0 005030-0 Rated Max. Cont. 25 20 15 AC Power Output (kW)* Rated Voltage (volts) 120/240 120/240 120/240 No. of Rotor Poles 4 4 4 Driven Speed of Rotor (rpm) 1800 1800 1800 Rotor Excitation System Direct excited brush type Direct excited brush type Direct excited brush type Type of Stator 4 Wire 4 Wire 4 Wire Rotor Insulation Class F Class F Class F Stator Insulation Class H Class H Class H

2. Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure

1.8).

3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure and type for configuration (not to exceed 14 inches water column).

10. Move DIP switch position 4 on the control board to the off position (LP vapor, see Figure 3.2 and Section 3.7).

11. Reverse the procedure to convert back to natural gas.

Figure 1.8 — Reconfigure the Fuel System

NOTE:

Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made.

Serious injury or damage may occur if not configured properly. Please consult an Authorized Service Dealer with any questions.

1.14 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:

NOTE:

Synthetic oil is highly recommended when the generator will be operating in ambient temperatures which regularly exceed 90° F and/or fall below 30° F.

Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.

1.15 COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base anti-freeze and half deionized water. Cooling system capacity is about 8 U.S. quarts (7.6 liters). Use only deionized 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. DO NOT use any soluble oil inhibitor for this equipment.

1.16 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. It may be necessary to group the critical (essential) loads together and wire them into a separate “emergency” distribution panel.

This generator can be installed in conjunction with an engineered transfer switch, if necessary (see Section 2.10).

The standard prepackaged transfer switch (ATS mode) does not have sensing or controlling circuit boards. Instead, the generator control console houses a “Printed Circuit Board Assembly”, which controls all phases of operation, including engine start up and load transfer.

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

Section 1 — General Information

Liquid-cooled 15, 20 and 25 kW Generators

Port 1

PLUG

NG FUEL SYSTEM

FUEL HOSE

BRASS HOSE FITTING

OUT

PORT 1

FUEL INLET

FUEL HOSE

BRASS HOSE FITTING

OUT PORT 2

Port 2

PLUG

LP FUEL SYSTEM

DANGER

2.1 STANDBY GENERATOR

INSTALLATION

Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a 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.

If an open bottom is used, the engine-generator must 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, do nothing that might render the installation in noncompliance with such codes, standards and regulations.

NOTE:

For more information about the installation of a standby system contact an Authorized Service Dealer.

2.1.1 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 SYS-

TEMS 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.

2.1.2 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.

2.2 GENERATOR LOCATION

Install the generator set, in its protective enclosure outdoors, where adequate cooling and ventilating air always is available. Consider these factors:

• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit.

• Install the generator on high ground where water levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator for maintenance and servicing. A required minimum allowance of space to any solid structure is three feet. Five feet allowance of space is recommended.

• Where strong prevailing winds blow from one direction, face the generator air inlet openings into the prevailing winds.

• Install the generator as close as possible to the transfer switch. This reduces the length of wiring and conduit.

• Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE.

2.3 GENERATOR MOUNTING AND

SUPPORT

Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides.



Section 2 — Installation

Liquid-cooled 15, 20 and 25 kW Generators

DANGER

2.4 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.

Figure 2.1 – Basic Standby Electric System

NOTE:

The manufacturer recommends the use of a Generac Power Systems transfer switch in conjunction with this generator.

2.5 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 its wattage/amperage capacity, during utility power outages, consider using the emergency circuit isolation method.

Critical electrical loads are grouped together and wired into a separate “Emergency Distribution Panel.” The generator only supplies electrical circuits connected to the emergency distribution panel during utility power outages. Load circuits powered by that panel must be within the wattage/amperage capacity of the generator set. 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.

• It must be installed between the building’s main distribution panel and the emergency distribution panel.

2.6 TOTAL CIRCUIT ISOLATION

METHOD

When a generator capable of powering all electrical loads in the circuit is to be installed, the “Total Circuit Isolation Method” may be used. 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.

2.7 GROUNDING THE GENERATOR

A GROUNDING LUG (Figure 2.2) is provided on the generator mounting base for the purpose of grounding the frame and the external electrically conductive parts of the equipment to an approved earth ground and/or grounding rods where required by the National Electrical Code. Consult a qualified electrician for grounding requirements in the 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)

Section 2 — Installation

Liquid-cooled 15, 20 and 25 kW Generators

DANGER

2.8 GENERATOR AC NEUTRAL CONNECTIONS

The manufacturer 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.

2.9 AUTOMATIC TRANSFER SWITCH (ATS MODE)

To implement this mode of operation, Position 2 of the eight-position DIP switch, which is located on the generator circuit board (see Figure 3.2), must be in the OFF position. In ATS Mode utility voltage sensing, weekly exercising, and load transferring is under the control of the generator.

The HS Type transfer switch is controlled by the generator circuit board via control wires 23 and 194. Wire 23 connects the relay driver output (collector of an NPN transistor) on the generator circuit board to the "low side" (Terminal 23) of the transfer relay coil in the transfer switch. Wire 194 connects positive battery voltage from the generator circuit board to the "high side" (Terminal 194) of the transfer relay coil in the transfer switch.

If generator wires 23 and 194 are not wired to the correct terminals in the transfer switch, the circuit board in the generator control panel will be damaged.

In order for the generator utility voltage sensing and battery charging functions to work, it is necessary to provide a 5 amp fused 240Vac utility source connection from the transfer switch main N1 and N2 terminals to the generator control panel N1 and N2 terminals (See Figure 2.3).

Transfer Switch terminals N1 and N2 (also called Utility 1 and Utility 2) are the input utility AC power connections to the Transfer Switch. Transfer Switch terminals T1 and T2 (also called Load 1 and Load 2) are the transfer switch AC output power terminals that go to the load circuit distribution panel. Transfer Switch terminals E1 and E2 are the AC power terminals that come from the generator's main alternator.

Section 2 — Installation

Liquid-cooled 15, 20 and 25 kW Generators

Figure 2.3 - Connection Diagram (ATS Mode)

FUSE

N1 N2

FUSE

HS TYPE

TRANSFER

SWITCH

FROM UTILITY

N1 N2

194

E1 E2

MAIN LINE

CIRCUIT

BREAKER

OR FUSE

T1 T2

TO LOAD

FEEDER CIRCUITS

LOAD

DISTRIBUTION

PANEL

GENERATOR

194

178 183

N2 N1

E1 E2

2.10 ENGINEERED TRANSFER SWITCH (2-WIRE START GTS MODE)

When required, the pre-packaged standby generator can be installed with an engineered W Type transfer switch which controls utility voltage sensing, weekly exercising and load transferring.

When Position 2 of the eight-position DIP switch, which is located on the generator circuit board (See Figure 3.2), is in the ON position then utility voltage sensing, weekly exercising and load transferring is under the control of the Engineered W Type transfer switch (GTS Mode).

Generator DIP Switch Position 2 ON = 2-Wire Start GTS Mode

• The generator control board will NOT monitor the

utility.

• The generator control board will NOT perform a

weekly exercise. (The five red LEDs will flash one at a time in GTS mode.)

• The generator control board will NOT activate the

transfer output.

The generator control board WILL monitor all engine conditions and shut down on all the faults listed in this document.

For the W Type transfer switch to control utility voltage sensing, weekly exercising and load transferring, suitable wiring must also be connected from the transfer switch 178 and 183, 2-Wire Start terminals to the corresponding generator 178 and 183 2-Wire

Start terminals. Recommended wire gauge sizes for the 2-Wire Start wiring depend on the length of the wire (see wiring length chart).

Route the 2-Wire Start control wires through suitable, approved conduit which is separate from the AC power leads. Connection of wire 178 to wire 183 by relay contact closure action (volt free switch contacts) in the transfer switch must result in generator engine cranking and startup (See Figure 2.4).

Do NOT connect battery voltage, utility voltage (N1/N2) or load voltage (T1/T2) to either the 178 or the 183 2-Wire start terminals as this will damage the generator control board.

In order for the generator battery charging function to work, it is necessary to provide a 5 amp fused 240Vac utility source connection from the transfer switch main N1 and N2 terminals to the generator control panel N1 and N2 terminals (See Figure 2.4).

Figure 2.4 - Connection Diagram (GTS Mode)

MAXIMUM WIRE LENGTH RECOMMENDED WIRE

SIZE

460 feet (140m) No. 18 AWG.

461 to 730 feet (223m) No. 16 AWG.

731 to 1,160 feet (354m) No. 14 AWG.

1,161 to 1,850 feet (565m) No. 12 AWG.

Section 2 — Installation

Liquid-cooled 15, 20 and 25 kW Generators

FUSE

FROM UTILITY

N1 N2 N1 N2

W-TYPE

TRANSFER

SWITCH

E1 E2

MAIN LINE

BREAKER

OR FUSE

178 183

CIRCUIT

T1 T2

TO LOAD

FEEDER CIRCUITS

LOAD

DISTRIBUTION

PANEL

GENERATOR

194

178 183

N2 N1

E1 E2

When in GTS mode, the control board will respond as follows based on the generator AUTO/OFF/MANUAL switch position.

OFF — The generator will not start and run in this position

MANUAL — The generator control board will start and run the generator whenever the switch is in the manual position.

AUTO — The generator control board will monitor the 2-Wire start circuit (terminals 178 and 183 in the generator control panel). When a 2-Wire start signal is issued by the W type engineered transfer switch, via a relay contact closure that connects wire 178 to wire 183, the generator control board will immediately start and run the generator. When the 2-Wire start signal is removed the control board will immediately stop the generator.

2.11 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 certain that normal source voltage at the transfer switch is correct; the generator main line circuit breaker is switched to OFF; the AUTO/OFF/MANUAL switch on the control console is switched to OFF; the 15A and 5A fuses have been removed from the control console; utility fed supply to battery charger (terminals N1 and N2) is removed; and the system is ready to be placed into operation. Ensure that the 5A and 15A fuses in the control panel are removed when connecting or disconnecting battery cables.

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 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 corrosive 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 fluid is spilled, 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.

2.11.1 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 acid-neutralizing 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.



Section 2 — Installation

Liquid-cooled 15, 20 and 25 kW Generators

DANGER

The recommended battery is Group 26, 12VDC, 550 CCA/75 AH minimum. 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.

2.12 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.

2.12.1 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.”

2.12.2 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.

2.12.3 FUEL SYSTEM

Make sure the fuel supply system to the generator (a) delivers the correct fuel at the correct pressure and volume and, (b) is properly purged and leak tested according to code. No fuel leakage is permitted.

2.12.4 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” and “Engine Oil Recommendations”.

NOTE:

This engine is shipped from the manufacturer with 15W-40 oil. This oil should be changed after 30 hours of operation.

2.12.5 ENGINE COOLANT

Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” and “Coolant”.

2.12.6 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 5/8inches (10 to 16 mm).

2.12.7 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.



Section 2 — Installation

Liquid-cooled 15, 20 and 25 kW Generators

Section 3 - Operation

Liquid-cooled 15, 20 and 25 kW Generators

3.1 CONTROL CONSOLE COMPONENTS

The components of a home standby generator control console (Figure 3.1) are as follows:

Figure 3.1 - Generator Control Console

3.1.1 AUTO/OFF/MANUAL SWITCH

Use this three-position switch as follows:

• Set the switch to AUTO for fully automatic opera-

tion. See “Automatic Operation” (Section 3.6).

• Set switch to MANUAL position to crank and start

the generator engine.

• Set switch to OFF position to shut down an oper-

ating engine. With OFF selected, operation will not be possible.

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.

3.1.2 FAULT INDICATOR LEDS

(SEE CHART ON PAGE 16)

These red LEDs turn ON when one or more of the following engine faults occurs and the engine shuts down.

• Low Oil Pressure

• Overcrank

• Low Battery

• Overspeed/Engine Speed Signal Fault

• High Coolant Temperature/Low Coolant Level

See Section 1.7 for further explanation of engine protection functions.

3.1.3 15 AMP FUSE

This fuse protects the control console’s DC control circuit against electrical overload and is located inside the control panel. If the fuse has melted open because of an overload, engine cranking and startup cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse (type ATO).

3.1.4 5 AMP FUSE

This fuse protects the battery charger against electrical overload and is located inside the control panel. If the fuse needs to be replaced, use only an identical 5amp replacement fuse (type ATO).

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.

3.1.5 SET EXERCISE TIME SWITCH

This switch allows programming the generator to start and exercise automatically. “See Weekly Exercise Cycle” (see Figure 3.3 and Section 3.6).

3.1.6 SYSTEM READY LED

The System Ready LED (green) has two main purposes. First, the LED will be ON when the AUTO/OFF/MANUAL switch is in the AUTO position, utility is present, and there are no system alarms. This ON state indicates the system is fully ready for automatic operation.

The system ready LED will be OFF when the switch is in the MANUAL or OFF positions.

The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes. The LED will flash at the rate of 1/2 second on, 1/2 second off if the utility sensing level is below the transfer back threshold.

This secondary function is only available with DIP switch two in the OFF position (ATS - automatic transfer switch application).

3.2 MANUAL TRANSFER AND START-UP

To transfer electrical loads to the Standby (EMERGENCY) power source side and start the engine manually, refer to the Owner’s Manual of the particular transfer switch.



CAUTION

TENTION: POUR L'ALIMENTATION DE RESERVE, CONNECTER LA SORTIE DE

ATRICE A UN COMMUTATEUR DE CALIBRE APPROPRIE, CONFORMENENT AU

OUTDOO

USE OF S

0F2629

SET

)

SYS

OFF

(

)

OFF

COO

SS.

(

)

VER CRAN

VER SPEE

LOW

L. LEVE

L. TEMP

LOW OIL PRE

LED INDICATOR

FLASHING GREEN LED = NO UTILITY SEN

FLASHING RED LED'S = EXERCISER NOT SE

IN AUTO MODE ONLY

SOLID GREEN LED = SYSTEM READY, UTILITY POWER O

RED LED'S = INDIVIDUAL FAUL

SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS

EXERCI

1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION

2) HOLD "SET EXERCISE TIME" SWITCH IN "ON" POSITION FOR THREE SECOND

AND RELEASE. (SEE OWNER'S MANUAL FOR COMPLETE DETAILS

THE EXERCISER IS NOW SET. ALL FIVE RED LED'S WILL FLASH FOR 10 SECOND

THEN THE UNIT WILL START, RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN

TO SET EXERCISER TIM

LOW BATTER

AUT

MANUA

TEM READ

DANGER

RISK OF ELECTRICAL SHOCK. DO NOT REMOVE COVER. NO USER SERVICEABLE

PARTS INSIDE. REFER SERVICING TO

FOR STAND-BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATED TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE

CANADIEN DE L'ECTRICITE, PREMIERE PARTIE

UALIFIED SERVICE PERSONNEL

PART I

WARNIN

AN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE

REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATT

ERVICIN

WARNIN

THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR

R INSTALLATION ONLY

YNTHETIC OIL IS RECOMMENDE

E7193

3.3 ENGINE GOVERNOR GAIN ADJUSTMENTS

Engine speed governing is also controlled by the engine control board. The engine governor has been set by the factory during final testing of the generator and should not be adjusted.

If, however, adjustments are necessary, the following procedure should be followed (Figure 3.2 and Section

3.7):

1. Move DIP switch 8 to the TEST mode (OFF posi-

tion).

2. Set all three potentiometers (pots) fully counter-

clockwise.

3. Under no load condition, increase the GAIN pot

as much as possible without causing instability.

4. Apply 1/4, 1/2, 3/4 and full load to the unit.

Decrease the GAIN pot if there is instability at any load point.

5. Under full load condition, increase the stability

pot until the unit returns to 60 Hertz (or 50 Hertz in 50 Hertz applications).

Figure 3.2 — Control Board Dip Switch Location

Section 3 - Operation

Liquid-cooled 15, 20 and 25 kW Generators

Condition System Low Low High Over Over Switch Position

Ready (Green) Bat (Red) Oil (Red) Temp (Red) Speed (Red) Crank (Red) Manual Auto Off

Generator Switch is OFF X OFF OFF OFF OFF O in the OFF Mode.

System Ready for ON X OFF OFF OFF OFF O Automatic Start

Generator Switch is OFF X OFF OFF OFF OFF O in the MANUAL Mode

Weekly Exerciser X Flashing Flashing Flashing Flashing Flashing O O O is not set (-----------------------------------1 sec rate---------------------------------------)

Battery Voltage <12.2V X ON OOO for >1 minute (Non-latching)

Battery Voltage <6V OFF ON OO

Unit Shutdown due OFF X ON O O to Low Oil Pressure

Unit Shutdown due to High Coolant Temperature OFF X ON O O or Low Coolant Level

Unit Shutdown due OFF X ON O O to Engine Overspeed

Unit Failed to Start OFF X ON O O during it’s Crank Cycle

Utility Voltage is Flashing X OO <45% of Nominal 1 sec rate

Engine Speed Signal Fault OFF X Flashing O O

Control Board is OFF X The five RED LED’s will turn on one at a time O O O in GTS Mode

X = indicates that the LED can be ON or OFF depending on the operating conditions.

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