Generac 005280, 005241, 005281, 005242, 005282 User Manual
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Installation and
Owner’s Manual
7, 10, 13 and 16kW Air-cooled,
Automatic Standby Generators
Models: 005240, 005280 (6 kW NG, 7 kW LP)
005241, 005281 (9 kW NG, 10 kW LP)
005242, 005282 (13 kW NG, 13 kW LP)
005243, 005244, (15 kW NG, 16 kW LP)
005283, 005284
Not intended for use as Primary Power in place of utility or in
life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
INTRODUCTION
Thank you for purchasing this model of the Guardian
product line by Generac Power Systems Inc. This
model is a compact, high performance, air-cooled,
engine-driven generator designed to automatically
supply electrical power to operate critical loads during a utility power failure.
This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either
vapor withdrawn liquid propane (LP) or natural gas
(NG).
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact
the nearest Authorized 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 operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death, in addition to property
damage.
After this heading, read instructions that, if not
strictly complied with, may result in serious 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 follows:
This symbol points out important safety infor-
mation that, if not followed, could endanger
personal safety and/or property of others.
This symbol points out potential explosion haz-
ard.
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 read this Owner's Manual
and thoroughly understand 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.
CONTENTS
This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts, for these different
models:
05240 & 05280 – 6 kW NG, 7 kW LP, single-cylin-
•
der GH-410 Engine
05241 & 05281 – 9.0 kW NG, 10 kW LP, V-twin
•
GT-530 Engine
05242 & 05282 – 13 kW NG, 13 kW LP, V-twin GT-
•
990 Engine
05243, 05244, 05283 & 05284 – 15 kW NG, 16 kW
•
LP, V-twin GT-990 Engine
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
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 the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Dealer
for service aids and accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
contact an Authorized Dealer for assistance. Service
technicians are factory-trained and are capable of
handling all service needs.
When contacting an Authorized Dealer about parts
and service, always supply the complete model number and serial number of the unit as given on its data
decal, which is located on the generator. See section
"The Generator" for decal location.
Model No. ____________ Serial No. ______________
AUTHORIZED
DEALER LOCATION
To locate the nearest AUTHORIZED
DEALER, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER or visit
www.guardiangenerators.com.
Table of Contents
Air-cooled Generators
Introduction ........................Inside Front Cover
Read This Manual Thoroughly ........................ IFC
Contents .......................................................... IFC
Operation and Maintenance ............................ IFC
How to Obtain Service ..................................... IFC
Authorized Dealer Locator Number ................... IFC
Safety Rules ........................................................2
Standards Index ..................................................3
Section 1 – General Information ...................4
1.1 Unpacking/Inspection .................................... 4
1.2 Protection Systems ........................................4
1.3 NEC Requirement for Arc Fault Circuit
Interruption Breaker for Bedrooms .............. 4
1.4 The Generator ...............................................5
1.5 Specifications ................................................ 6
1.6 System Set LED ............................................ 7
1.7 Fuel Requirements and Recommendations ...7
1.8 Fuel Consumption ......................................... 7
1.9 Reconfiguring the Fuel System ......................8
1.10 Location ........................................................9
1.11 Battery Requirements .................................. 10
1.12 Battery Installation ...................................... 10
1.13 The Battery .................................................11
Section 2 – Post Installation Start-up
and Adjustments .......................12
2.1 Before Initial Startup...................................12
2.2 Check Transfer Switch Operation ...............12
2.3 Electrical Checks ........................................13
2.4 Generator Tests Under Load .......................13
2.5 Checking Automatic Operation .................... 14
2.6 Adjusting the Fuel Regulator -
7kW (Natural Gas Only) ............................... 14
2.7 Engine Governor Adjustment ...................... 15
2.8 Voltage Regulator Adjustment ...................... 15
Section 3 – Operation ....................................16
3.1 Using the AUTO/OFF/MANUAL Switch ........ 16
3.2 Automatic Transfer Operation ..................... 16
3.3 Sequence of Automatic Operation ...............17
3.4 Manual Transfer Operation .........................17
3.5 Setting the Exercise Timer .......................... 18
3.6 Protection Systems ...................................... 18
Section 4 – Maintenance .............................. 20
4.1 Fuses ........................................................... 20
4.2 Checking the Engine Oil Level ..................... 20
4.3 Changing the Engine Oil .............................. 21
4.4 Changing the Engine Air Cleaner .................21
4.5 Spark Plug(s) .............................................. 22
4.6 Battery Maintenance .................................... 23
4.7 Adjusting GH-410/GT-530/990
Valve Clearance ............................................ 23
4.8 Cooling System ...........................................24
4.9 Attention After Submersion ......................... 24
4.10 Corrosion Protection ...................................25
4.11 Out of Service Procedure ............................. 25
4.12 Service Schedule .........................................26
Section 5 – Troubleshooting .........................27
5.1 Troubleshooting Guide ................................ 27
Section 6 – Notes ........................................... 28
Section 7 – Electrical Data ........................... 29
Section 8 – Exploded Views and
Parts Lists ................................... 40
Section 9 – Mounting Dimensions ............. 66
Section 10 – Warranty ................................... 68
1
IMPORTANT SAFETY INSTRUCTIONS
Air-cooled Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation
be copied and posted near the unit’s installation site. Safety should be stressed to all opera-
tors and potential operators of this equipment.
The engine exhaust from this product
•
contains chemicals known to the state
defects or other reproductive harm.
This product contains or emits chemicals
•
known to the state of California to cause
cancer, birth defects or other reproductive harm.
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.
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
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the generator unsafe.
WARNING:•
of California to cause cancer, birth
WARNING:•
DANGER
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 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 the installation, initial start-up and maintenance of this equipment is carried out by an
Authorized Dealer.
The engine exhaust fumes contain carbon monox-
•
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict compliance with applicable codes and standards.
Following installation, do nothing that might render the system unsafe or in noncompliance with
such 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 venti-
•
lating air is critical to 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. The
generator MUST be installed outdoors.
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 contact the
•
nearest Authorized Dealer for parts needing repair
or replacement.
Before performing any maintenance on the gen-
•
erator, disconnect its battery cables to prevent
accidental start up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or
(–) first, then remove the POSITIVE, POS or (+)
cable. When reconnecting the cables, connect the
POSITIVE cable first, the NEGATIVE 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.
2
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 does the standby generator when it is in operation. Avoid contact with bare wires, terminals,
connections, etc., while the unit is running. Ensure
all appropriate covers, guards and barriers are in
place, secured and/or locked 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.
•
The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical system.
•
After installing this home standby electrical sys-
tem, the generator may crank and start at any
time without warning. When this occurs, load circuits are transferred to the STANDBY (generator)
power source. To prevent possible injury if such a
start and transfer occur, always set the generator’s
AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the 15A
fuse from the generator control panel.
•
In case of accident caused by electric shock, imme-
diately 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 equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.
FIRE HAZARDS
For fire safety, the generator must be installed and
•
maintained properly. Installation 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 in
accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.
IMPORTANT SAFETY INSTRUCTIONS
Air-cooled Generators
•
Keep a fire extinguisher near the generator at all
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for
use on the standby electric system. Keep the extinguisher properly charged and be familiar with its
use. Consult the local fire department with any
questions pertaining to fire extinguishers.
EXPLOSION HAZARDS
•
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.
•
Gaseous fluids such as natural gas and liquid pro-
pane (LP) gas are extremely EXPLOSIVE. Install
the fuel supply system according to applicable
fuel-gas codes. Before placing the home standby
electric system into service, fuel system lines must
be properly purged and leak tested according to
applicable code. After installation, inspect the fuel
system periodically for leaks. No leakage is permitted.
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
ELECTRIC 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, avail-
able 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
LIQUIDS CODE, available same as Item 1.
3
Section 1 — General Information
Air-cooled Generators
DANGER
Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and regulations.
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for
damage.
•
This standby generator set is ready for installa-
tion with a factory supplied and pre-mounted base
pad and has a weather protective enclosure that is
intended for outdoor installation only.
•
This UL listed standby generator set is packaged
with an automatic transfer switch with built in
load center. The combination transfer switch and
load center is pre-wired with a two foot and 30 foot
conduit. Circuit breakers for emergency circuit
connections are included (if equipped).
•
This UL listed, 2-pole switch is rated at 100 AC
amperes at 250 volts maximum. This transfer
switch is for indoor use only (if equipped).
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 electrical system from the utility distribution
system when the generator is operating (NEC 700,
701 & 702). Failure to isolate an electrical system
by such means will result in damage to the generator and also may result in injury or death to
utility power workers due to backfeed of electrical
energy.
If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage
on the freight bill or affix their signature under the
consignor's memo of loss or damage.
If a loss or damage is noted after delivery, separate
the damaged materials and contact the carrier for
claim procedures.
“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later.
1.2 PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have
to run for long periods of time with no operator present to monitor engine conditions. For that reason, the
engine is equipped with the following systems that
protect it against potentially damaging conditions:
1. Low Oil Pressure Sensor 4. Overspeed
2. High Temperature Sensor 5. RPM Sensor
3. Overcrank 6. Low Battery
4
There are LED readouts on the control panel to notify
personnel that one of these faults has occurred.
There is also a System Set LED that is lit when all
of the conditions described in section "System Set
LED" are true. (See the "Protection Systems" section
for details.)
1.3 NEC REQUIREMENT FOR ARC
FAULT CIRCUIT INTERRUPTION
BREAKER FOR BEDROOMS
In 2001, the National Electric Code (NEC) introduced a requirement for new construction. This new
requirement indicates the need for Arc Fault Circuit
Interrupters to be used to protect the complete
branch circuit that feeds a dwelling bedroom. The
actual NEC requirement is indicated below.
1.3.1 SECTION 210.12 ARC FAULT CIRCUIT
INTERRUPTER PROTECTION
1. Definition: An arc fault circuit interrupter is a
device intended to provide protection from the
effects of arc faults by recognizing characteristics
unique to arcing and by functioning to de-energize the circuit when an arc fault is detected.
2. Dwelling Unit Bedrooms: All branch circuits that
supply 125 volt, single-phase, 15 and 20 ampere
outlets installed in dwelling unit bedrooms shall
be protected by an arc fault circuit interrupter
listed to provide protection of the entire branch
circuit.
Section 210.12 requires that AFCI protection be
provided on branch circuits that supply outlets
(receptacle, lighting, etc.) in dwelling bedrooms. The
requirement is limited to 15 and 20 ampere, 125
volt circuits. There is no prohibition against providing AFCI protection on other circuits or in locations
other than bedrooms. Because circuits are often
shared between a bedroom and other areas such as
closets and hallways, providing AFCI protection on
the complete circuit would comply with 210.12.
If during the installation of the home standby system
the decision is made to provide back up power to a
bedroom branch circuit, then the circuit breaker in
the transfer switch should be replaced with an Arc
Fault Circuit Interrupter.
It is most important that breakers only be switched
like for like. For instance, if replacing a 15A breaker,
it MUST be replaced with a 15A AFCI breaker.
Likewise, a 20A breaker MUST be replaced with a
20A AFCI.
These AFCI breakers are available at the nearest
hardware store.
Siemens Item # Description
Q115AF 15A Single Pole AFCI
Q120AF 20A Single Pole AFCI
1.4 THE GENERATOR
Section 1 — General Information
Air-cooled Generators
5
Section 1 — General Information
Air-cooled Generators
1.5 SPECIFICATIONS
1.5.1 GENERATOR
Model 05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244
05283 & 05284
Rated Max. Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP
Power Capacity (Watts*)
Rated Voltage 120/240 120/240 120/240 120/240
Rated Max. Continuous
Load Current (Amps)
120 Volts** 50.0 NG/58.3 LP 75.0 NG/83.3 LP 108.3 NG/108.3 LP 125 NG/133.3 LP
240 Volts 25.0 NG/29.2 LP 37.5 NG/41.7 LP 54.1 NG/54.1 LP 62.5 NG/66.6 LP
Main Line Circuit Breaker 30 Amp 45 Amp 55 Amp 65 Amp
Circuits***
50A, 240V - - - 1
40A, 240V - - 1 1
30A, 240V 1 1 1 -
20A, 240V - 1 - 1
20A, 120V 1 3 3 5
15A, 120V 5 3 5 5
Phase 1 1 1 1
Number of Rotor Poles 2 2 2 2
Rated AC Frequency 60 Hz 60 Hz 60 Hz 60 Hz
Power Factor 1 1 1 1
Recommended Air Filter Part # 0C8127 Part # 0E9581 Part # 0C8127 Part # 0C8127
Battery Requirement Group 26 Group 26 Group 26 Group 26
12 Volts and 12 Volts and 12 Volts and 12 Volts and
350 Cold-cranking 525 Cold-cranking 525 Cold-cranking 525 Cold-cranking
Amperes Minimum Amperes Minimum Amperes Minimum Amperes Minimum
Battery Warming Blanket 0F6148DSRV
Weight (Unit Only) 336 Pounds 375 Pounds 425.5 Pounds 445 & 414 Pounds
Enclosure Steel/Aluminum
Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240
volts.
*** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in main panel must be a 15 amp circuit in transfer switch.
1.5.2 ENGINE
Model 05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244
05283 & 05284
Type of Engine GH-410 GT-530 GT-990 GT-990
Number of Cylinders 1 2 2 2
Rated Horsepower 14.5 @ 3,600 rpm 18 @ 3,600 rpm 30 @ 3,600 rpm 30 @ 3,600 rpm
Displacement 410cc 530cc 992cc 992cc
Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast
Iron Sleeve Iron Sleeve Iron Sleeve Iron Sleeve
Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Overhead Valves
Ignition System Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto
Recommended Spark Plug RC14YC BPR6HS RC14YC RC14YC
Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 1.02 mm (0.040 inch)
Compression Ratio 8.6:1 9.5:1 9.5:1 9.5:1
Starter 12 Vdc 12 Vdc 12 Vdc 12 Vdc
Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.7 Qts Approx. 1.7 Qts Approx. 1.7 Qts
Recommended Oil Filter Part # 070185F Part # 070185F Part # 070185F Part # 070185F
Recommended Air Filter Part # 0C8127 Part # 0E9581 Part # 0C8127 Part # 0C8127
Operating RPM 3,600 3,600 3,600 3,600
6
Section 1 — General Information
Air-cooled Generators
1.6 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
1. The AUTO/OFF/MANUAL switch is set to the
AUTO position.
2. The utility voltage being supplied to the unit is
being sensed by the PCB. If the utility sense voltage is not connected to the unit or if it is below
approximately 150-160 volts AC, then the system
set light will flash rapidly. This indicates that if
the AUTO/OFF/ MANUAL switch is placed in the
Auto position, the generator will start.
3. No alarms are present, for example, low oil pres-
sure, high temperature, etc.
1.7 FUEL REQUIREMENTS
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed
above the liquid fuel in the storage tank.
The engine has been fitted with a fuel carburetion
system that meets the specifications of the 1997
California Air Resources Board for tamper-proof dual
fuel systems. The unit will run on natural gas or LP
gas, but it has been factory set to run on natural gas.
Should the primary fuel need to be changed to LP
gas, the fuel system needs to be reconfigured. See the
Reconfiguring the Fuel System section for instructions on reconfiguration of the fuel system.
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 5 inches
to 7 inches water column (0.18 to 0.25 psi); and
for liquid propane, 10 inches to 12 inches of water
column (0.36 to 0.43 psi).
NOTE:
All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and
NFPA 58 for liquid propane applications. Once the
generator is installed, verify that the fuel pressure
NEVER drops below four (4) inches water column
for natural gas or 10 inches water column for liquid propane.
Prior to installation of the generator, the installer
should consult local fuel suppliers or the fire marshall to check codes and regulations for proper
installation. Local codes will mandate correct routing
of gaseous fuel line piping around gardens, shrubs
and other landscaping to prevent any damage.
Special considerations should be given when installing the unit where local conditions include flooding,
tornados, hurricanes, earthquakes and unstable
ground for the flexibility and strength of piping and
their connections.
Use an approved pipe sealant or joint compound on
all threaded fitting.
All installed gaseous fuel piping must be purged and
leak tested prior to initial start-up in accordance with
local codes, standards and regulations.
1.8 FUEL CONSUMPTION
Unit Nat. Gas (*) LP Vapor (**)
1/2 Load Full Load 1/2 Load Full Load
6/7 kW 66 119 0.82/30 1.47/54
9/10 kW 102 156 1.25/46 1.93/70
13/13 kW 156 220 1.55/57 2.18/80
15/16 kW 173 245 1.59/59 2.51/92
*Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
1.8.1 BTU FLOW REQUIREMENTS -
NATURAL GAS
BTU flow required for each unit based on 1000 BTU
per cubic foot.
6kW — 119,000 BTU/Hour
•
9kW — 156,000 BTU/Hour
•
13kW — 220,000 BTU/Hour
•
15kW — 245,000 BTU/Hour
•
DANGER
Gaseous fuels such as natural gas and liquid
propane (LP) 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.
NOTE:
A minimum of one approved manual shut-off valve
must be installed in the gaseous fuel supply line.
The valve must be easily accessible. Local codes
determine the proper location.
7
Section 1 — General Information
Air-cooled Generators
1.9 RECONFIGURING THE
FUEL SYSTEM
1.9.1 7 KW, 410CC ENGINE
To reconfigure the fuel system from NG to LP, follow
these steps (Figure 1.4):
NOTE:
The primary regulator for the propane supply is
NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to
0.43 psi) to the fuel inlet of the generator MUST
BE SUPPLIED.
1. Turn off the main gas supply (if connected).
2. Open the roof and remove the door.
3. Remove the battery (if installed).
4. Disconnect wire #0 and wire #14 from the gas
solenoid on top of the demand regulator.
5. Remove the carburetor fuel hose from the outlet
port of the demand regulator.
6. Remove the demand regulator by removing the
fastener that retains the regulator mounting
bracket.
7. Remove the square headed steel pipe plug from
outlet port #1 and the brass hose barb fitting
from outlet port #2.
8. Refit the brass hose barb fitting to outlet port #1
and the square headed steel pipe plug to outlet
port #2.
Figure 1.4 – Demand Regulator
HOSE & PLUG
SWITCHED SIDES
FUEL HOSE
FUEL HOSE
BRASS HOSE
FITTING
OUTLET
PORT
FUEL JET
BRASS HOSE
FITTING
ADJUSTMENT
SCREW
PIPE
PLUG
NOTE:
Use an approved pipe sealant or joint compound
on all threaded fittings to reduce the possibility
of leakage.
9. Reverse procedure steps 1-6 to reinstall demand
regulator.
10. Take the plastic plug supplied in the poly-bag
with the generator and press it into the 3/4” hole
on the bottom of the air cleaner base (Figure
4.6).
11. Reverse the procedure to convert back to natural
gas.
12. Check for gas leakage at the pipe plug, hose connection and fittings.
1.9.2 10, 13 AND 16KW, V-TWIN ENGINES
To reconfigure the fuel system from NG to LP, follow
these steps:
NOTE:
The primary regulator for the propane supply is
NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to
0.43 psi) to the fuel inlet of the generator MUST
BE SUPPLIED.
1. Open the roof.
2. For 10kW units: Loosen clamp and slide back
the air inlet hose.
• Slide fuel selector on carburetor out towards the
back of the enclosure (Figures 1.5 and 1.6).
• Return the inlet hose and tighten clamp securely.
For 13 and 16kW units: remove the air cleaner
cover.
• Slide the selector lever out towards the back of
the enclosure (Figures 1.7 and 1.8).
• Return the air cleaner cover and tighten the two
thumb screws.
3. Close the roof.
4. Reverse the procedure to convert back to natural
gas.
8
NG FUEL SYSTEM
RUNNING
PRESSURE
TAP
LP FUEL SYSTEM
STATIC
PRESSURE
TAP
Section 1 — General Information
Air-cooled Generators
Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back)
Fuel Selection
Lever - "In"
Position for
Natural Gas
Fuel
Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back)
Fuel Selection
Lever - "Out"
Position for
Liquid Propane
(Vapor) Fuel
Figure 1.7 - 13/16kW, GT-990 (Airbox Cover
Removed)
Fuel Selection Lever - "In" Position for Natural Gas Fuel
Figure 1.8 - 13/16kW, GT-990 (Airbox Cover
Removed)
Fuel Selection Lever - "Out" Position for Liquid Propane
(Vapor) Fuel
1.10 LOCATION
1.10.1 GENERATOR
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available (Figure 1.9). Consider these factors:
The installation of the generator must comply
•
strictly with NFPA 37, NFPA 54, NFPA 58, and
NFPA 70 standards.
Install the unit where air inlet and outlet open-
•
ings 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. This unit must be
installed in accordance with current applicable
NFPA 37 and NFPA 70 standards; as well as any
other federal, state and local codes for minimum
distances from other structures. DO NOT install
under wooden decks or structures.
Install the unit where rain gutter down spouts,
•
roof fun-off, landscape irrigation, water sprinklers
or sump pump discharge does not flood the unit
or spray the enclosure, including any air inlet or
outlet openings.
Install the unit where services will not be affected
•
or obstructed, including concealed, underground
or covered services such as electrical, fuel, phone,
air conditioning or irrigation.
Where strong prevailing winds blow from one
•
direction, face the generator air inlet openings to
the prevailing winds.
9
Section 1 — General Information
Air-cooled Generators
•
Install the generator as close as possible to the fuel
supply, to reduce the length of piping.
•
Install the generator as close as possible to the
transfer switch. REMEMBER THAT LAWS OR
CODES MAY REGULATE THE DISTANCE AND
LOCATION.
•
The genset must be installed on a level surface.
The base frame must be level within two (2) inches
all around.
•
The generator is typically placed on pea gravel or
crushed stone. Check local codes if a concrete slab
is required. If a concrete base slab is required, all
federal, state and local codes should be followed.
Special attention should be given to the concrete
base slab which should exceed the length and
width of the generator by a minimum of six (6)
inches (0.152 meters) on all sides.
Figure 1.9 – Generator Clearances
Install the transfer switch indoors 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 mounting surface.
Never install the switch where water or any corro-
•
sive substance might drip onto the enclosure.
Protect the switch at all times against excessive
•
moisture, dust, dirt, lint, construction grit and
corrosive vapors.
If the AUTO/OFF/MANUAL switch is not set to its
OFF position, the generator can crank and start
as soon as the battery cables are connected. If
the utility power supply is not turned off, sparking can occur at the battery posts and cause an
explosion.
The engine exhaust fumes contain carbon mon-
oxide, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations,
can cause unconsciousness or even death. This
exhaust system must be installed properly, in
strict compliance with applicable codes and standards. Following installation, do nothing that
might render the system unsafe or in noncompliance with such codes and standards.
• Operate the generator outdoors ONLY.
• Keep exhaust gases from entering a confined area
through windows, doors, ventilation or other
openings (Figure 1.9).
1.10.2 TRANSFER SWITCH
1.10.2.1 7, 10, 13, and 16 kW Units (if equipped)
The transfer switch shipped with this generator is
enclosed in a NEMA 1 enclosure. This type of enclo-
sure is intended for indoor use only. Follow these
rules:
10
1.11 BATTERY REQUIREMENTS
See the Specifications section for correct battery size
and rating.
1.12 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if
necessary and have the battery fully charged before
installing it.
Before installing and connecting the battery, complete
the following steps:
1. Set the generator's AUTO/OFF/MANUAL switch to
OFF.
2. Turn off utility power supply to the transfer
switch.
3. Remove the 15A fuse from the generator control
panel.
Battery cables were factory connected at the generator (Figure 1.10). Connect cables to battery posts as
follows:
4. Connect the red battery cable (from starter contactor) to the battery post indicated by a positive,
POS or (+).
5. Connect the black battery cable (from frame
ground) to the battery post indicated by a negative, NEG or (—).
NOTE:
Dielectric grease should be used on battery posts
to aid in the prevention of corrosion.
NOTE:
Damage will result if battery connections are made
in reverse.
Figure 1.10 – Battery Cable Connections
NOTE:
In areas where temperatures regularly fall below
10° F (-12° C) it is recommended that a pad type
battery heater be installed to aid in cold climate
starting (see Specifications).
NOTE:
The generator is equipped with a battery trickle
charger that is active when the unit is set up for
automatic operation. With the battery installed
and utility power source voltage available to the
transfer switch, the battery receives a trickle
charge while the engine is not running, to prevent
self-discharge. The trickle charger is designed to
help extend the life of the battery by maintaining the battery when the unit is not running. The
trickle charge feature cannot be used to recharge
a discharged battery.
1.13 THE BATTERY
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following precautions are to be observed when working on
batteries:
• Remove the 15A fuse from the generator control
panel.
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
Section 1 — General Information
Air-cooled Generators
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
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 1 pound (500 grams) bicarbonate
of soda to 1 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
procedures are to be followed:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from body before touching the battery by first touching a grounded metal
surface.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as the
battery cables are connected.
Be sure the utility power supply is turned off
and the 15A fuse is removed from the generator
control panel, or sparking may occur at the battery posts as the cables are attached and cause
an explosion.
Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
See the Specifications section for the correct size
and rating when replacing the battery. When using a
maintenance-free battery, it is not necessary to check
the specific gravity or electrolyte level. Have these
procedures performed at the intervals specified in
the “Service Schedule.” A negative ground system is
used. Battery connections are shown on the wiring
diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity
when connecting the battery to the generator set.
11
Section 2 — Post Installation Start-up and Adjustments
Air-cooled Generators
2.1 BEFORE INITIAL START-UP
NOTE:
These units have been run and tested at the factory prior to being shipped and do not require any
type of break-in.
Before starting, complete the following:
1. Set the generator’s main circuit breaker to its
OFF (or OPEN) position.
2. Set the generator's AUTO/OFF/MANUAL switch to
the OFF position.
3. Turn OFF all breakers on the load center of the
transfer box (T1 and T2).
4. Turn OFF all loads connected to the transfer
switch terminals T1 and T2.
5. Check the engine crankcase oil level and, if necessary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark.
6. Check the fuel supply. Gaseous fuel lines must
have been properly purged and leak tested in
accordance with applicable fuel-gas codes. All
fuel shutoff valves in the fuel supply lines must
be open.
During initial start up, after installation, it is normal
for the generator to exceed the normal number of
start attempts and experience an “over crank” fault.
This is due to accumulated air in the fuel system during shipment.
To reduce or eliminate this problem on initial start
up, remove the air filter cover and partially cover the
fuel mixer inlet while the engine is cranking (Figures
2.1 and 2.2). This will cause an abnormal vacuum
in the system and purge the air from the system.
Once fuel reaches the engine, it will begin to run.
Remove the blockage from the mixer inlet as soon
as the engine begins to fire. The unit should then be
run several minutes to insure that all air is removed
from the fuel system. Once the engine is running, this
procedure is not required as long as the fuel supply
to the generator is not interrupted. This procedure
will only be required if the generator becomes disconnected from the fuel system for whatever reason.
NOTE:
This procedure applies to 13kW and 16kW units
only and should be performed by trained personnel.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
Figure 2.1 – Remove Air Filter Cover
Figure 2.2 – Restrict Air Flow During
Inital Start Up
2.2 CHECK TRANSFER SWITCH
OPERATION
Refer to the "Manual Transfer Operation" section, of
the owner’s manual for procedures.
DANGER
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
12
Section 2 — Post Installation Start-up and Adjustments
Air-cooled Generators
2.3 ELECTRICAL CHECKS
Complete electrical checks as follows:
1. Set the generator's main circuit breaker to its
OFF (or OPEN) position.
2. Set the generator's AUTO/OFF/MANUAL switch to
the OFF position.
3. Turn OFF all breakers on the load center of the
transfer box (T1 and T2).
4. Turn on the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
DANGER
The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extremely
hazardous and possibly fatal electrical shock.
Proceed with caution.
5. Use an accurate AC voltmeter to check utility
power source voltage across transfer switch terminals N1 and N2. Nominal line-to-line voltage
should be 240 volts AC.
6. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-toneutral voltage should be 120 volts AC.
7. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings,
turn OFF the utility power supply to the transfer
switch.
8. On the generator panel, set the AUTO/OFF/
MANUAL switch to MANUAL. The engine should
crank and start.
9. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set
the generator’s main circuit breaker to its ON (or
CLOSED) position.
DANGER
Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in dangerous and possibly fatal electrical shock.
10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1
and E2. 7kW voltage should be 242-252 volts at
a frequency of 61-63 Hertz. 10, 13, and 16kW
voltage should be 247-249 volts at a frequency of
57.5-59.5 Hertz.
11. Connect the AC voltmeter test leads across terminal lugs E1 and neutral; then across E2 and
neutral. In both cases, voltage reading should be
121-126 volts AC (7kW), and 125-126 volts AC
(10, 13 and 16kW).
12. Set the generator’s main circuit breaker to its
OFF (or OPEN) position. Let the engine run at noload for a few minutes to stabilize internal engine
generator temperatures.
13. Set the generator's AUTO/OFF/MANUAL switch to
OFF. The engine should shut down.
NOTE:
It is important not to proceed until certain that
generator AC voltage and frequency are correct
and within the stated limits. Generally, if both AC
frequency and voltage are high or low, the engine
governor requires adjustment* (*GH410 only). If
frequency is correct, but voltage is high or low, the
generator’s voltage regulator requires adjustment.
2.4 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied,
proceed as follows:
1. Set generator’s main circuit breaker to its OFF
(or OPEN) position.
2. Turn OFF all breakers on the load center of the
transfer box (T1 and T2).
3. Set the generator's AUTO/OFF/MANUAL switch to
OFF.
4. Turn OFF the utility power supply to the transfer
switch, using the means provided (such as a utility main line circuit breaker).
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
5. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's E1/E2 terminals. The transfer switch
operating lever should be down.
6. Set the generator's AUTO/OFF/MANUAL switch
to MANUAL. The engine should crank and start
immediately.
7. Let the engine stabilize and warm up for a few
minutes.
8. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.
9. Turn ON the load center of the transfer switch
(T1 and T2).
10. Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2.
• 7kW voltage should be greater than 230 volts and
frequency should be greater than 58 Hz.
13
Section 2 — Post Installation Start-up and Adjustments
• 10, 13 & 16kW voltage should be greater than
240 volts and frequency should be greater than
60 Hz.
11. Let the generator run at full rated load for 20-30
minutes. Listen for unusual noises, vibration or
other indications of abnormal operation. Check
for oil leaks, evidence of overheating, etc.
12. When testing under load is complete, turn OFF
electrical loads.
13. Set the generator's main circuit breaker to its
OFF (or OPEN) position.
14. Let the engine run at no-load for a few minutes.
15. Set the AUTO/OFF/MANUAL switch to OFF. The
engine should shut down.
2.5 CHECKING AUTOMATIC
OPERATION
To check the system for proper automatic operation,
proceed as follows:
1. Set generator’s main circuit breaker to its OFF
(or OPEN) position.
2. Check that the AUTO/OFF/MANUAL switch is set
to OFF.
3. Turn OFF the utility power supply to the transfer
switch, using means provided (such as a utility
main line circuit breaker).
4. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the utility power source side.
5. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a utility main line circuit breaker).
6. Set the generator's main circuit breaker to its ON
(or CLOSED)) position.
7. Set the AUTO/OFF/MANUAL switch to AUTO. The
system is now ready for automatic operation.
8. Turn OFF the utility power supply to the transfer
switch.
With the AUTO/OFF/MANUAL switch at AUTO, the
engine should crank and start when the utility source
power is turned OFF after a 10 second delay. After
starting, the transfer switch should connect load circuits to the standby side after a 15 second delay. Let
the system go through its entire automatic sequence
of operation.
With the generator running and loads powered by
generator AC output, turn ON the utility power supply
to the transfer switch. The following should occur:
After about 15 seconds, the switch should transfer
•
loads back to the utility power source.
About one minute after retransfer, the engine
•
should shut down.
2.6 ADJUSTING THE FUEL REGULATOR
- 7KW (NATURAL GAS ONLY)
NOTE:
All V-twin engine units DO NOT require a fuel regulator adjustment due to the fuel system design.
Although the generator has been factory set to provide maximum power, it may be necessary in some
areas to adjust this setting. If experiencing engine
problems at high or full load conditions, follow these
steps. It will require a frequency meter to perform
this procedure.
1. Turn off utility power to the main distribution
panel in the house. This can be done by switching
the service main breaker to the off or open position.
2. Allow the generator to start. Before loading the
generator, confirm that the No Load Frequency,
with the roof open and door off, is set to 63-63.5
Hz. Transfer load to emergency circuits.
3. Turn on appliances, lights, pumps, etc., that are
on the emergency circuits in an attempt to fully
load the generator. Be cautious not to overload
the generator. Use the following chart as a guide:
Unit 120 Volts 240 Volts
7 kW 50.0 amps 25.0 amps
4. When 3/4 load has been achieved. Connect a frequency meter to the output lugs of the generator’s
main line circuit breaker.
5. The fuel regulator is fitted with one adjustment
screw. While watching the frequency meter, slowly
turn the adjustment screw clockwise or counterclockwise until the highest frequency is read on
the meter. Only limited adjustment is available
because of the set pin. Under no circumstances
should any of the pins be removed (Figure 2.3).
Figure 2.3 — 7kW Fuel Regulator
ngine
Adjustment
Screw
(One Side
Only)
410cc Engine
Set
Pin
14
Section 2 — Post Installation Start-up and Adjustments
Air-cooled Generators
6. When the highest frequency is reached maximum
power has been set. From this point turn the
adjustment screw 1/4 turn counterclockwise. The
regulator is now set.
7. Turn utility power to the main distribution panel
back on. This can be done by switching the service main breaker to the on or closed position.
Allow the generator to shut down.
Do not make any unnecessary adjustments.
Factory settings are correct for most applications. However, when making adjustments, be
careful to avoid overspeeding the engine.
If this procedure or the test equipment is not available, locate the nearest Dealer and they can perform
the adjustments.
NOTE:
A service fee may be charged for this adjustment.
2.7 ENGINE GOVERNOR ADJUSTMENT
If both AC frequency and voltage are correspondingly
high or low, adjust the engine governor as follows:
2.7.1 7 KW UNITS
2. Hold the governor lever at its wide open throttle
position (clockwise), and rotate the governor
shaft clockwise as far as it will go. Then, tighten
the governor lever clamp bolt to 70 inch-pounds
(8 N-m).
3. Start the generator; let it stabilize and warm up
at no-load.
4. Connect a frequency meter across the generators
AC output leads.
5. Turn the primary adjust screw to obtain a frequency reading of 61.5 Hertz. Turn the secondary
adjust screw to obtain a frequency of 62.5 Hz.
6. When frequency is correct at no load, check the
AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment (See the
Voltage Regulator Adjustment section).
2.7.2 13 KW AND 16 KW UNITS
NOTE:
All V-twin units DO NOT require an engine governor adjustment due to their design.
2.7.3 ADDITIONAL CORROSION
PROTECTION
Periodically spray all engine linkage parts and brackets with corrosion inhibiting spray such as WD-40 or
a comparable product.
The engine must be OFF to perform steps 1 and
2.
1. Loosen the governor clamp bolt (Figure 2.4).
Figure 2.4 — Engine Governor Adjustment
Single Cylinder Engines
SECONDARY
ADJUST SCREW
GOVERNOR
SHAFT
GOVERNOR
CLAMP
BOLT
PRIMARY
ADJUST
SCREW
2.8 VOLTAGE REGULATOR
ADJUSTMENT
2.8.1 7KW UNITS
With the frequency between 62-63 Hertz at no-load,
slowly turn the slotted potentiometer (Figure 2.5)
until line voltage reads 248-252 volts.
2.8.2 10, 13, AND 16KW UNITS
With the frequency between 58-59 Hertz at no-load,
slowly turn the slotted potentiometer (Figure 2.3)
until line voltage reads 247-249 volts.
NOTE:
The access panel on top of the control panel must
be removed to adjust the voltage regulator.
NOTE:
The voltage regulator is housed above the generator's control panel. The regulator maintains a
voltage in direct proportion to frequency at a 2-to1 ratio. For example, at 62 Hertz, line-to-neutral
voltage will be 124 volts.
15
Section 3 — Operation
Air-cooled Generators
Figure 2.5 – Voltage Adjustment Potentiometer
Tur n t o
adjust voltage.
3.1 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 3.1)
3.1.1 “AUTO” POSITION
Selecting this switch position activates fully automatic
system operation. It also allows the unit to automatically start and exercise the engine every seven days
with the setting of the exercise timer (see the Setting
the Exercise Timer section).
3.1.2 “OFF” POSITION
This switch position shuts down the engine. This
position also prevents automatic operation.
Figure 3.1 – Generator Control Panel
CONTROL AND INFORMATION CENTER
SYSTEM SET
LOW BATTERY
AUTO. MAN.
OFF
SYSTEM FUSE
15A
ASSY: 0F8418/0F8419
SET
EXERCISE
TIME
LOW OIL
HIGH TEMP
OVER SPEED
NO RPM SENSE IF FLASHING
OVER CRANK
FLASHING GREEN LED=
NO UTILITY SENSE
5 FLASHING RED LEDS=
EXERCISER NOT SET
3.1.3 “MANUAL” POSITION
Set the switch to MANUAL to crank and start the
engine. Transfer to standby power will not occur
unless there is a utility failure.
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops below a preset level or during the normal exercise cycle. To
prevent possible injury that might be caused
by such sudden starts, always set the switch to
OFF and remove the fuses before working on or
around the generator or transfer switch. Then,
place a “DO NOT OPERATE” tag on the generator panel and on the transfer switch.
3.1.4 CHOKE OPERATION
1. 990 engines have an electric choke in the air box
that is automatically controlled by the electronic
control board.
2. 530 engines have an electric choke on the divider
panel air inlet hose that is automatically controlled by the electronic control board.
3. 410 engines do not have a choke.
3.2 AUTOMATIC TRANSFER
OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are
set to their UTILITY position, i.e., loads connected to the utility power source (Figure 3.2).
2. Be sure that normal UTILITY power source voltage is available to transfer switch terminal lugs
N1 and N2 (Refer to the Electrical Data section).
3. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
4. Set the generator’s main circuit breaker to its ON
(or CLOSED) position.
With the preceding steps complete, the generator will
start automatically when utility source voltage drops
below a preset level. After the unit starts, loads are
transferred to the standby power source. Refer to the
Sequence of Automatic Operation section.
16
Section 3 — Operation
Air-cooled Generators
3.3 SEQUENCE OF AUTOMATIC
OPERATION
The generator’s control panel houses a control logic
circuit board. This board constantly monitors utility power source voltage. Should that voltage drop
below a preset level, circuit board action will signal
the engine to crank and start. After the engine starts,
the circuit board signals the transfer switch to activate and connect load circuits to the standby power
supply (load terminal lugs T1/T2 connect to terminal
lugs E1/E2). Refer to the Electrical Data section.
The generator must run at 50 Hz or greater for the
transfer output to be activated. Once activated, it will
remain active even if the frequency dips below 50
Hz.
Upon restoration of utility source voltage above a
preset level, generator circuit board action signals the
transfer switch to transfer loads back to that power
supply. After retransfer, the engine is signalled to shut
down.
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board,
as follows:
A. Utility Voltage Dropout Sensor
• This sensor monitors utility source voltage.
• If utility source voltage drops below about 65
percent of the nominal supply voltage, the sensor
energizes a 10 second timer.
• Once the timer has expired, the engine will crank
and start if utility is still low.
B. Engine Warm-up Time Delay
• This mechanism lets the engine warm up for
about five (5) seconds before the load is transferred to the standby source.
C. Standby Voltage Sensor
• This sensor monitors generator AC output voltage. When the voltage has reached 50 percent of
the nominal rated voltage, transfer to standby
can occur.
D. Utility Voltage Pickup Sensor
• This sensor monitors utility power supply voltage. When that voltage is restored above 75 percent of the nominal source voltage, a retransfer
time delay starts timing.
E. Retransfer Time Delay
• This timer runs for about 15 seconds.
• At end of a 15-second delay, circuit board action
de-energizes transfer relay in the transfer switch
if utility is still present.
• Retransfer to utility power source then occurs.
F. Engine Cool-down Timer
• When the load is transferred back to utility power
source, the engine cool-down timer starts timing.
• The timer will run for about one minute, and the
generator will then shut down.
3.4 MANUAL TRANSFER OPERATION
3.4.1 TRANSFER TO GENERATOR
POWER SOURCE
To start the generator and activate the transfer switch
manually, proceed as follows:
1. Set the generator’s AUTO/OFF/MANUAL switch to
OFF.
2. Set the generator’s main circuit breaker to its
OFF (or OPEN) position.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
DANGER
Do not attempt to activate the transfer switch
manually until all power voltage supplies to the
switch have been positively turned off. Failure
to turn off all power voltage supplies may result
in extremely hazardous and possibly fatal electrical shock.
4. Use the manual transfer handle inside the transfer switch to move the main contacts to their
STANDBY position, i.e., loads connected to the
standby power source (Figure 3.2).
5. To crank and start the engine, set the AUTO/OFF/
MANUAL switch to MANUAL.
6. Let the engine stabilize and warm up for a few
minutes.
7. Set the generator’s main circuit breaker to its ON
(or CLOSED) position. The standby power source
now powers the loads.
Figure 3.2 – Manual Transfer Switch Operation
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Section 3 — Operation
Air-cooled Generators
3.4.2 TRANSFER BACK TO UTILITY POWER
SOURCE
When utility power has been restored, transfer back
to that source and shut down the generator. This can
be accomplished as follows:
1. Set the generator’s main circuit breaker to its
OFF (or OPEN) position.
2. Let the engine run for a minute or two at no-load
to stabilize the internal temperatures.
3. Set the generator’s AUTO/OFF/MANUAL switch to
its OFF (or OPEN) position. The engine should
shut down.
4. Check that utility power supply to the transfer
switch is turned OFF.
DANGER
Do not attempt to activate the transfer switch
manually until all power voltage supplies
to the switch have been positively turned off.
Failure to turn off all power voltage supplies
may result in extremely hazardous and possibly
fatal electrical shock.
5. Use the manual transfer handle inside the transfer switch to move the main contacts back to their
UTILITY position, i.e., loads connected to the utility power source (Figure 3.2).
6. Turn ON the utility power supply to the transfer
switch using the means provided.
7. Set the system to automatic operation as outlined
in Automatic Transfer Operation section.
3.5 SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
once every seven days, on the day of the week and at
the time of day the following sequence is completed.
During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of
loads to the generator output does not occur during
the exercise cycle unless utility power is lost.
A switch on the control panel (see Figure 3.1) permits selection of the day and time for the system to
exercise. At the chosen time, perform the following
sequence to select the desired day and time of day
the system will exercise. Remember seasonal time
changes affect the exercise time settings.
1. Verify that the AUTO/OFF/MANUAL switch is set
to AUTO.
2. Press and hold the "Set Exercise Time" switch for
several seconds, then release. All the red LED's
will flash for approximately 10 seconds and then
stop.
3. Once the red LED's stop flashing, the generator
will start and run for approximately 12 minutes
and then shut down. The exerciser is now set to
run at this time of day each week.
Example: If the "Set Exercise Time" switch is
pressed on Saturday afternoon at 2:00 p.m., the
generator will start and exercise for approximately 12 minutes every Saturday at 2:00 p.m..
NOTE:
The exerciser will only work in the AUTO mode
and will not work unless this procedure is performed. The exerciser will need to be reset every
time the 12-volt battery is disconnected and then
reconnected, and when the 15A fuse is removed.
The 16kW unit has a low speed exercise option. Dip
switch 1 on the control board is factory set to OFF.
This allows the engine to run at a slower speed during weekly exercise periods for quieter operation. If
this Dip switch is set to ON, the generator will exercise at it's normal speed.
This DIP switch position is only read at board power
up. If the DIP switch position is changed, power to
the board must be cycled for the micro controller to
recognize the new DIP switch position.
Low speed exercise will be handled as follows:
1. The standard start sequence will be initiated.
2. The unit will run at 2,400 RPM.
3. If utility is lost during exercise, the controller will
do the following:
• Wait 10 seconds for utility to return.
• If utility returns within 10 seconds, continue to
exercise at 2,400 RPM.
• If utility is still lost after 10 seconds, run the
engine up to 3600 RPM and transfer the load.
At this time the controller will exit the exercise
routine and assume full automatic operation.
3.6 PROTECTION SYSTEMS
3.6.1 LOW OIL PRESSURE SWITCH
This switch (Figure 3.3) has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure
drop below the 8 psi range, switch contacts close,
and the engine shuts down. The unit should not be
restarted until oil is added. The AUTO/OFF/MANUAL
switch must then be turned to OFF and then back to
AUTO.
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3.6.2 HIGH TEMPERATURE SWITCH
This switch’s contacts (Figure 3.3) close if the temperature should exceed approximately 144º C (293º
F), initiating an engine shutdown. The generator will
automatically restart and the LED on the generator
control panel will reset once the temperature has
returned to a safe operating level.
Figure 3.3 – Low Oil Pressure and
High Temperature Switches
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4.1 FUSES
The 15-amp fuse on the generator panel protects the
DC control circuit against overload (Figure 4.1). This
fuse is wired in series with the battery output lead
to the panel. If this fuse element has melted open,
the engine will not be able to crank or start. Replace
this fuse using only an identical 15-amp replacement
fuse. To replace the fuse, push the fuse holder cap
down and rotate it counterclockwise. Whenever the
fuse is removed or replaced, the exercise timer needs
to be reset.
Figure 4.1 – Generator Control Panel
CONTROL AND INFORMATION CENTER
SYSTEM SET
LOW BATTERY
OFF
AUTO. MAN.
SYSTEM FUSE
15A
ASSY: 0F8418/0F8419
SET
EXERCISE
TIME
LOW OIL
HIGH TEMP
OVER SPEED
NO RPM SENSE IF FLASHING
OVER CRANK
FLASHING GREEN LED=
NO UTILITY SENSE
5 FLASHING RED LEDS=
EXERCISER NOT SET
4.2 CHECKING THE ENGINE
Figure 4.2 — Oil Dipstick and Fill, 7kW
Oil Dipstick and Fill
Figure 4.3 — Oil Dipstick and Fill, 10kW
OIL LEVEL
For oil capacities, see the Specifications section.
For engine oil recommendations, see the Engine Oil
Recommendations section. To check the engine oil
level, proceed as follows (Figures 4.2, 4.3 and 4.4):
1. Move the AUTO/OFF/ MANUAL switch to the OFF
position.
2. Remove the dipstick and wipe it dry with a clean
cloth.
3. Completely insert the dipstick; then, remove it
again. The oil level should be at the dipstick “Full”
mark. If necessary, add oil to the “Full” mark
only. DO NOT FILL ABOVE THE “FULL” MARK.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
4. Install the dipstick.
5. Reset the AUTO/OFF/MANUAL switch to its original position.
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