Generac Power Systems 004912-0, 004912-1, 004913-0, 004913-1, Centurion 004912-0 Owner's Manual
...
Owner’s Manual
Liquid-cooled, Prepackaged Standby Generators
Models: 004912-0, 004912-1
(15 kW LP/15 kW Natural Gas)
120/240V Single-phase w/ 100 Amp
Transfer Switch
004913-0, 004913-1, 004913-2
(25 kW LP/25 kW Natural Gas)
120/240V Single-phase w/ 200 Amp
Transfer Switch
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
*This manual should remain with the unit.
CENTURION
®
CENTURIONCENTURION
DANGER
Generac®Power Systems, Inc.
INTRODUCTION
Thank you for purchasing this model of the standby
generator product line by Generac Power Systems.
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 Generac Authorized Service
Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert
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 personal injury
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. Generac strongly recommends that
the operator read this Owner's Manual and
thoroughly understand all instructions before using
this equipment. Generac 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 a Generac
Authorized Service Dealer. Normal maintenance
service and replacement of parts are the responsibility
of the owner/operator and, as such, are not
considered defects in materials or workmanship
within the terms of the warranty. Individual operating
habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of the generator ensure
a minimum number of problems and keep operating
expenses at a minimum. See a Generac Authorized
Service Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by a Generac Authorized Service Dealer or
other competent, qualified contractor. Installation of
this equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
contact a Generac Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all of servicing needs.
When contacting a Generac 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 CARD
affixed to the unit.
Model No. ____________ Serial No. ______________
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest GENERAC AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
OR
Locate us on the web at:
www.generac.com
DANGER
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Table of Contents
Centurion Liquid-cooled 15 kW and 25 kW Generators
Generac®Power Systems, Inc. 1
Introduction ................................Inside Front Cover
Read This Manual Thoroughly ............................IFC
Operation and Maintenance ................................IFC
How to Obtain Service..........................................IFC
Authorized Dealer Locator Number ........................IFC
Safety Rules ................................................................2
Section 1 – General Information ..........................4
1.1 Generator ..........................................................4
1.2 Transfer Switch ................................................4
1.3 Automatic System Operation ............................4
1.4 Generator AC Connection Systems....................4
1.5 Main Circuit Breaker ........................................5
1.6 Generator Fuel System ......................................5
1.7 Engine Protective Devices ..................................5
1.7.1 Low Oil Pressure Switch ......................5
1.7.2 High Coolant Temperature Switch ........5
1.7.3 Low Coolant Level Switch ....................6
1.7.4 Overspeed Shutdown ............................6
1.7.5 PCB Operation LED’s............................6
1.7.6 Overcrank Shutdown ............................6
1.8 Unpacking ........................................................6
1.8.1 Unpacking Precautions ........................6
1.8.2 Inspection ............................................6
1.9 Lifting the Generator ........................................6
1.10 Specifications ....................................................7
1.10.1 Generator..............................................7
1.10.2 Engine ..................................................7
1.11 Fuel Consumption ............................................7
1.12 Reconfiguring the Fuel System ..........................7
1.13 Torque Specifications ........................................8
1.14 Engine Oil Recommendations............................8
1.15 Coolant Recommendations................................8
1.16 Before Installation ............................................8
Section 2 — INSTALLATION ......................8
2.1 Generator Installation ......................................8
2.1.1 NFPA Standards....................................9
2.1.2 Other Published Standards ..................9
2.2 Generator Location............................................9
2.3 Generator Mounting and Support ....................9
2.4 Basic Standby Electric System ..........................9
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 Transfer Switch Start Signal Connections ......11
2.10 Battery Installation ..........................................11
2.10.1 Vented Batteries ..................................11
2.11 Preparation Before Start-Up ............................12
2.11.1 Prior to Initial Start-up ......................12
2.11.2 Transfer Switch ..................................12
2.11.3 Fuel System ........................................12
2.11.4 Generator Set Lubrication ..................12
2.11.5 Engine Coolant....................................12
2.11.6 Belt Tension ........................................12
2.11.7 Electrical System ................................12
Section 3 — OPERATION..........................13
3.1 Using a Standard “GTS” Transfer Switch........13
3.2 Control Console Components..........................13
3.2.1 Hourmeter ..........................................13
3.2.2 Auto/Off/Manual Switch ......................13
3.2.3 Fault Indicator Lamp ..........................13
3.2.4 15 Amp Fuse ......................................13
3.2.5 7.5 Amp Inline Fuse............................14
3.2.6 Set Exercise Time Switch....................14
3.3 Manual Transfer and Start-up ........................14
3.4 Automatic Operation ......................................14
3.5 Weekly Exercise Cycle......................................14
3.6 Engine Block Heater........................................14
Section 4 — MAINTENANCE ....................15
4.1 Maintenance Performed by
Authorized Service Facilities............................15
4.2 Cooling System................................................15
4.3 Overload Protection for Engine
DC Electrical System ......................................15
4.4 Checking Fluid Levels ....................................15
4.4.1 Check Engine Oil ................................15
4.4.2 Battery Fluid ......................................16
4.4.3 Engine Coolant....................................16
4.5 Maintenance Owner/Operator Can Perform ....16
4.5.1 Check Engine Oil Level ......................16
4.5.2 Check Battery ....................................16
4.5.3 Exercise System ..................................16
4.5.4 Inspect Cooling System ......................16
4.5.5 Perform Visual Inspection ..................16
4.5.6 Inspect Exhaust System ......................16
4.5.7 Check Fan Belt....................................16
4.5.8 Inspect Engine Governor ....................16
4.5.9 Changing Engine Oil ..........................16
4.5.10 Changing the Engine Air Cleaner ........17
4.5.11 Spark Plugs ........................................17
4.5.12 Coolant Change ..................................17
4.6 Miscellaneous Maintenance ............................17
4.6.1 Cleaning the Generator ......................17
4.6.2 Battery ................................................18
4.6.3 Battery Maintenance ..........................18
4.6.4 Battery Replacement ..........................18
4.6.5 Rodent Protection ..............................18
4.7 Out of Service Procedure ................................19
4.7.1 Removal From Service ........................19
4.7.2 Return to Service ................................19
4.8 Fuel Pipe Sizing ..............................................19
4.9 Scheduled Maintenance ..................................20
Section 5 — TROUBLESHOOTING ..........23
5.1 Troubleshooting Points....................................23
Section 6 — NOTES..................................24
Section 7 — INSTALLATION DIAGRAM....25
Section 8 — ELECTRICAL DATA ..............26
Section 9 — EXPLODED VIEWS AND
PARTS LISTS ......................30
Section 10 — WARRANTY .......................48
2 Generac®Power Systems, Inc.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The
generator can operate safely, efficiently and reliably only if
it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and
fundamental rules or precautions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warning
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
Generac does not specifically recommend, satisfy
yourself 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, Generac recommends that this
equipment be installed, serviced and repaired by a
Generac Authorized Service Dealer or other
competent, qualified electrician or installation
technician who is familiar with applicable codes,
standards and regulations. The operator also must
comply with all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical
and building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
generator is installed, operated and serviced in
accordance with the manufacturer’s instructions and
recommendations. Following installation, 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. Exhaust
gases must be piped safely away from any building
near the generator to an area where people, animals,
etc., will not be harmed. This exhaust system is
designed to comply with applicable codes and
standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and
ventilating air is critical 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.
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IMPORTANT SAFETY INSTRUCTIONS
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators, potential operators, and service and repair technicians for this equipment.
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SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.
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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:
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DANGER
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Generac®Power Systems, Inc. 3
• 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.
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 people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing
this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
• The National Electrical Code (NEC), Article 250
requires the frame and external electrically
conductive parts of the generator to be connected to
an approved earth ground and/or grounding rods.
This grounding will help prevent dangerous electrical
shock that might be caused by a ground fault
condition in the generator set or by static electricity.
Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum
electrical current (ampacity) to which they will be
subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage supplies
are positively turned off at their source. Failure to do
so will result in hazardous and possibly fatal
electrical shock.
• Connecting this unit to an electrical system normally
supplied by an electric utility shall be by means of a
transfer switch so as to isolate the generator electric
system from the electric utility distribution system
when the generator is operating. Failure to isolate the
two electric system power sources from each other by
such means will result in damage to the generator
and may also result in injury or death to utility power
workers due to backfeed of electrical energy.
• Generators installed with an automatic transfer
switch will crank and start automatically when
normal (UTILITY) source voltage is removed or is
below an acceptable preset level. To prevent such
automatic start-up and possible injury to personnel,
disable the generator’s automatic start circuit
(battery cables, etc.) before working on or around the
unit. Then, place a “Do Not Operate” tag on the
generator control panel and on the transfer switch.
• In case of accident caused by electric shock,
immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement, such
as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
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.
Consult the local fire department for any questions
pertaining to fire extinguishers.
EXPLOSION HAZARDS
• Provide adequate ventilation around the generator to
prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or
on or near the generator, as FIRE or EXPLOSION
may result. Keep the area surrounding the generator
clean and free from debris.
• Generac generator sets may operate using one of
several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating
the storage and handling of fuels. Inspect the unit’s
fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly
installed, purged and leak tested according to
applicable fuel-gas codes before placing this
equipment into service.
• Gases such as natural gas and liquid propane (LP)
gas are extremely EXPLOSIVE. Natural gas is lighter
than air, and LP gas is heavier than air; install leak
detectors accordingly.
Important Safety Instructions
Centurion Liquid-cooled 15 kW and 25 kW Generators
4 Generac®Power Systems, Inc.
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 004912 : Provides 15,000 watts (15 kW) of single-phase
power.
Model 004913: Provides 25,000 watts (25 kW) of single-phase
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 includes a matched automatic
transfer switch which is intended to be used in
conjunction with the Centurion generator. It is
supplied in a NEMA 3R enclosure. The NEMA 3R
enclosure is weather resistant 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.
• It is highly recommended to utilize a
Generac/Centurion transfer switch with this
generator or it may void the warranty.
1.3 AUTOMATIC SYSTEM OPERATION
When this generator, along with its transfer switch,
has been installed and interconnected, a circuit
board in the generator panel constantly monitors
utility power source voltage. Should that voltage drop
below a preset value, and remain at such a low state
for a preset amount of time, the generator cranks and
starts. After the generator starts, the transfer switch
transfers load circuits so the generator can power
them.
When utility source voltage has been restored, the
switch re-transfers back to the utility source voltage
and the generator then shuts down.
Please reference the transfer switch manual for
specific information.
1.4 GENERATOR AC CONNECTION
SYSTEMS
The generator was shipped from the factory with its
stator AC output leads connected in a single-phase,
three-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
120VAC, 60 Hertz. When the two windings are
connected in series, a 240VAC, 60 Hertz output
results. Typically the two “hot” leads in the circuit are
Wires No. 11 and 44. The “Neutral” leads are the
junction of Wires 22 and 33.
Figure 1.1 - Generator AC Connection System
NOTE:
Rated power of generator is subject to and limited
by such factors as ambient temperature, altitude,
engine condition, and other factors. Engine power
will decrease about 3% for each 1000 feet above
3000 feet and will decrease an additional 1.5% for
each 10°F above 77°F. Maximum output power of
the generator is limited by maximum engine
power.
Section 1 - General Information
Centurion Liquid-cooled 15 kW and 25 kW Generators
!
Generac®Power Systems, Inc. 5
1.5 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with
the unit. The breaker for each unit is described in
Figure 1.2.
1.6 GENERATOR FUEL SYSTEM
The generator has been factory tested and adjusted
using a natural gas fuel system. If propane (LP
requirements) gas is preferred, contact an authorized
service dealer. Refer to Secion 1.12.
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 being
used.
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.
1.7 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
1.7.1 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 10 psi (68
kPa), the switch contacts close and the engine shuts
down automatically (Figure 1.4).
Figure 1.4 - Low Oil Pressure Switch
1.7.2 HIGH COOLANT TEMPERATURE
SWITCH
This normally open (N.O.), thermostatic switch has
sensing tip which is immersed in captive coolant.
Should coolant temperature exceed about 250°F
(121°C), the switch contacts close, which causes the
engine to shut down automatically (Figure 1.5).
Section 1 - General Information
Centurion Liquid-cooled 15 kW and 25 kW Generators
Model Rating Phase Actual Current C/B Rating* Circuit Breaker
04912 15,000 1 62.5 70 70A BQ2
04913 25,000 1 104.2 125 125A BQ2
* Amp Rating of CB structured under model.
Figure 1.2 - Main Circuit Breaker
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6 Generac®Power Systems, Inc.
Figure 1.5- High Coolant Temperature Switch
1.7.3 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
1.7.4 OVERSPEED SHUTDOWN
The Pre-pack circuit board on liquid cooled units
receives AC frequency (rpm) signals directly from the
stator AC power windings, via sensing leads S15 and
S16. Should AC frequency exceed about 72 Hz,
circuit board action will automatically shutdown the
engine (Figure 1.7).
Figure 1.7 - Control Module Assembly
Circuit Board
1.7.5 PCB OPERATION LED’S
• LED 1 is RED. The LED will be on when utility
sensing is NOT available to the circuit board. This
LED will function only when the AUTO/OFF/
MANUAL switch is set in the Auto position.
• LED 2 is YELLOW. This LED will be on when the
circuit board battery charger is on. This LED will
cycle on and off with the battery charger, 4.85
hours on the 4.85 hours off.
• LED 3 is GREEN. This LED will flash when the
circuit board has load voltage available to it. This
LED will function when voltage is available across
T1 and T2.
1.7.6 OVERCRANK SHUTDOWN
After 90 seconds of crank-rest cycles, this function
ends cranking if the engine fails to start in that 90
second span.
1.7.6 DC FUSE
This clearly labeled fuse is located on the front panel
of the control system. It protects the panel wiring and
components from damaging overload. Always
remove this fuse before commencing work on the
generator. The unit will not start or crank if the fuse
is blown. Replace the fuse with one of the same size,
type, and rating. Generac normally uses an AGC fuse
rated at 15 amps (part number 022676).
1.8 UNPACKING
1.8.1 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.
1.8.2 INSPECTION
After unpacking, carefully inspect the generator for
any damage that may have occurred during
shipment. If loss or damage is noted at the time of
delivery, have the person(s) making delivery note all
damage on the freight bill or affix their signature
under the consignor’s memo of loss or damage.
1.9 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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17
1
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U1
U12
U2
U14
U13
U3
U5
U8
U15
U10
U16
U17
U9
U4
U7
C
C
3
C
2
C
3
C
4
C
5
CR16
C
0
C
1
C
4
C
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C
2
C
6
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CR1
CR7
C
7
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C23
C24
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C20
C21
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6
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6
R
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R2
R3
R4
R5
R6
R7
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7
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3
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1
R
2
R
3
R
4
R
6
R
7
R
0
R
1
R
2
R
3
56
R
7
R
9
60
R
1
R
2
R
3
R
5
R
7
68
R
9
R
0
R
1
R
2
R
4
R
5
R
6
R77
R
8
SW1
R
4
R
0
R
5
R
1
R
9
CR37
J2
3
M5
Q13
U6
Q7
3
C
8
C
0
C25
R
2
55
Q9
Q1
Q3
Q5
Q4
Q6
Q11
Q12
2
M8
MM
C5
C
C4
C8
CR41
U18
U19
R
3
U20
C14
C15
C16
C7
C10
C9
C11C1
C17
C18
C12
C22
J1
9
0
R
4
5
3
Q14
Q16
R
8
R
4
R
5
R
6
R
7
R
8
Q15
Section 1 — General Information
Centurion Liquid-cooled 15 kW and 25 kW Generators
R1
R
6
7
7
7
1
1
R2
R3
2
1
5
5
PRE-PACKAGED STANDB
R1
3
2
3
1
2
Q
2
2
8
R3
R3
5
6
M
7
8
R
R
5
7
4
R
8
5
4
3
3
4
3
R1
3
2
2
8
4
4
6
4
7
LED
R2
R3
R1
R1
R1
3
2
3
R1
3
4
4
2
6
8
8
8
T R
FOR 50H
M1
5
M1
R1
6
8
R4
R3
R3
M
R3
6
R
1
1
1
R2
5
R2
R2
K
7
6
8
R
2002 GENERAC POWER SYSTEMS, ASSY #076009
1.10 SPECIFICATIONS
1.10.1 GENERATOR
1.10.2 ENGINE
Make ................................................................Mitsubishi
Displacement ..................................92 inches
3
(1.5 liters)
Cylinder Arrangement ........................................4, in-line
Valve Arrangement ....................................Overhead Cam
Firing Order ..........................................................1-3-4-2
Number of Main Bearings ..............................................5
Compression Ratio ..................................................9 to 1
No. of Teeth on Flywheel ............................................104
Ignition Timing
at 1800 rpm ........................................35 degrees BTDC
at 3600 rpm ........................................43 degrees BTDC
Spark Plug Gap......................................0.020-0.025 inch
Recommended Spark Plugs
Champion ..........................................................RN11YC4
Oil Pressure........................................................30-50 psi
Crankcase Oil Capacity ............4.0 U.S. quarts (3.8 liters)
Recommended Engine Oil ............................SAE 15W-40
Type of Cooling System ........Pressurized, closed recovery
Cooling Fan ....................................................Pusher Type
Cooling System Capacity ............2 U.S. gallons (7.6 liters)
Recommended Coolant ................Use a 50-50 mixture of
ethylene glycol base and
deionized water.
1.11 FUEL CONSUMPTION
25 kW Models
Using Natural Gas ..............................441 cu. ft. per hour
Using LP Gas ....................175 cubic ft.(4.8 gal.) per hour
15 kW Models
Using Natural Gas ..............................277 cu. ft. per hour
Using LP Gas ....................110 cubic ft.(3.1 gal.) per hour
NOTE:
Fuel consumption is given at rated maximum
continuous power output when using natural gas
rated at 1000 Btu per cubic foot; or LP gas rated
2520 Btu per cubic foot. Actual fuel consumption
obtained may vary depending on such variables as
applied load, ambient temperature, engine
conditions and other environmental factors.
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
could affect engine durability.
1.12 RECONFIGURING THE FUEL
SYSTEM
NOTE:
All models are configured for natural gas from the
factory.
To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
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.
10. 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 simultaneous fuels has been
made.
Section 1 — General Information
Centurion Liquid-cooled 15 kW and 25 kW Generators
Generac®Power Systems, Inc. 7
Single-Phase
Model 004913 004912
Rated Max. Cont. 25 15
AC Power Output (kW)
Rated voltage (volts) 120/240
No. of Rotor Poles 2 4
Driven Speed of Rotor 3600 1800
Rotor Excitation System Direct excited brush type
Type of Stator 4 Wire
Rotor/Stator Insulation Class F/H
Port 1
PLUG
NG FUEL SYSTEM
FUEL HOSE
BRASS HOSE
FITTING
PORT 1
HOUSING
PORTS
OUT
FUEL HOSE
BRASS HOSE
FITTING
OUT
PORT 2
HOUSING
PORTS
Port 2
PLUG
LP FUEL SYSTEM
8 Generac®Power Systems, Inc.
Serious injury or damage may occur if not
configured properly. Please consult an
authorized Generac Service Dealer with any
questions.
1.13 TORQUE SPECIFICATIONS
Cylinder Head ................................15 (+ 90° + 90°) ft.lb.
Intake Manifold ....................................................13 ft.lb.
Exhaust Manifold..................................................13 ft.lb.
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:
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 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. Generac
also recommends that any soluble oil inhibitor
is NOT used 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. You may have to group the critical
(essential) loads together and wire them into a
separate “emergency” distribution panel.
This generator can be installed in conjunction with a
Generac “GTS” type engineered transfer switch, if
desired.
The standard transfer switch included has no
adjustable 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.
2.1 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 generator is to
be installed over non-combustible materials
and should be located such that combustible
materials are not capable of accumulating
under the generator set.
Only qualified, competent installation contractors or
electricians thoroughly familiar with applicable
codes, standards and regulations should install this
standby electric power system. The installation must
comply strictly with all codes, standards and
regulations pertaining to the installation.
This genset must be installed on a level surface. The
base frame must be level within two (2) inches all
around.
After the system has been installed, do nothing
that might render the installation in
noncompliance with such codes, standards and
regulations.
!
Section 2 — Installation
Centurion Liquid-cooled 15 kW and 25 kW Generators
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 30W or 15W-40
32° to 80° F (-1° to 27° C) SAE 20W-20 or 15W-40
Below 32° F (0° C) SAE 10W or 15W-40
DANGER
!
!
!
DANGER
Generac®Power Systems, Inc. 9
NOTE:
For more information about the installation of a
standby system, you can order Engine-Generator
Standby Electric Power Systems Installer’s Guide
and Reference Manual (part #046622) from a
Generac 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
SYSTEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE
AND USE OF PORTABLE FIRE EXTINGUISHERS.
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
is 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 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. Allow three feet of
space on all sides. NOTE: LOCAL LAWS OR
CODES MAY REQUIRE DIFFERENT OFFSET
DISTANCES.
• 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 steel mesh or
rebar reinforced 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 five inches thick and should extend beyond the
enclosure to a distance of at least three inches on all
sides. See page 25 for generator major dimensions.
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.
Section 2 — Installation
Centurion Liquid-cooled 15 kW and 25 kW Generators
10 Generac®Power Systems, Inc.
Figure 2.1 – Basic Standby Electric System
NOTE:
Generac 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 the 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.” Load circuits powered by that panel are
within the wattage/amperage capacity of the generator
set. When this method is used, it is difficult to
overload the generator. The transfer switch must
meet the following requirements:
• It must have an ampere rating equal to, or greater
than, the total amperage rating of the emergency
distribution panel circuit.
• Have it installed between the building’s main
distribution panel and the emergency distribution
panel.
2.6 TOTAL CIRCUIT ISOLATION
METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, use the “Total
Circuit Isolation Method.” It is possible for the
generator to be overloaded when this isolation
method is employed. The following apply to the
transfer switch in this type of system.
• Ampere rating of the transfer switch must be equal
to, or greater than, 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
The National Electrical Code requires the frame and
external electrically conductive parts of this
equipment to be properly connected to an approved
earth ground and/or grounding rods. For that
purpose, a GROUND LUG (Figure 2.2) is provided on
the generator mounting base. Consult a qualified
electrician for grounding requirements in 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
Centurion Liquid-cooled 15 kW and 25 kW Generators
DANGER
Generac®Power Systems, Inc. 11
2.8 GENERATOR AC NEUTRAL
CONNECTIONS
Generac uses an UNGROUNDED AC neutral.
Grounding is recommended only at the main service
entrance. If the neutral wire is grounded and one of
the phase loads becomes grounded, the excessive
current opens the load circuit breaker or collapses
the generator field. The actual result depends on the
electrical characteristics of the particular installed
generator.
2.9 TRANSFER SWITCH START SIGNAL
CONNECTIONS
If the generator is to be installed with an automatic
transfer switch, such as a Generac GTS-type switch,
it will be necessary to connect the two-wire start
control system.
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection,
which is located in the right hand corner inside the
control panel. Match wires 178 and 183 in the
transfer switch to 178 and 183 on the terminal strip
in the control panel. The conductors for the two-wire
start circuit must be in their own conduit.
2.10 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 the normal source
voltage at the transfer switch is correct and the
system is ready to be put into operation.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If the 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.
2.10.1 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.
• 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.
Recommended batter 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.
Section 2 — Installation
Centurion Liquid-cooled 15 kW and 25 kW Generators
DANGER
!
!
!
!
12 Generac®Power Systems, Inc.
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.
2.11 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.
2.11.1 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.”
2.11.2 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.
2.11.3 FUEL SYSTEM
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and
(b) is properly purged and leak tested according to
code. No fuel leakage is permitted. See Section 1.10,
“Specifications” for more information.
2.11.4 GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and, if necessary, add oil to the proper level – the
dipstick “FULL” mark. Never operate the engine with
the oil level below the dipstick “ADD” mark. See
Section 1.10, “Specifications” and Section 1.14,
“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.
2.11.5 ENGINE COOLANT
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
for leaks and other problems. See Section 1.10,
“Specifications” and “Recommended Coolant”.
2.11.6 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 5/8inch (10 to 16 mm).
2.11.7 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
Centurion Liquid-cooled 15 kW and 25 kW Generators
Generac®Power Systems, Inc. 13
3.1 USING A STANDARD “GTS”
TRANSFER SWITCH
When required, the pre-packaged standby generator
can be installed with an engineered Generac “GTS”
type engineered automatic transfer switch.
When a GTS type transfer switch is used, it controls
automatic operation and automatic transfer as
follows:
• Solid state circuits in the transfer switch monitor
utility power source voltage.
• When utility source voltage drops below a pre-set
level, transfer switch action closes the circuit. The
engine then cranks and starts as controlled by the
pre-packaged generator’s Control Module circuit
board.
• After the engine starts and when the generator AC
output voltage and frequency have reached a
pre-set value, transfer switch circuits signal the
transfer switch main contacts to actuate to the
“Standby” power source side. Generator AC output
then powers load circuits.
• When the utility power source voltage is restored
above a pre-set level, transfer switch solid state
circuits signal the switch main contacts to move
back to their utility power source side.
• Following re-transfer back to the utility power
source side, transfer switch circuit board action
opens the circuit. Engine then shuts down.
NOTE:
If the generator is installed in conjunction with an
engineered GTS type engineered transfer switch,
refer to the applicable transfer switch manual for
exact operating parameters and timing sequences.
3.2 CONTROL CONSOLE
COMPONENTS
The components of a liquid-cooled generator control
console (Figure 3.1) are as follows:
Figure 3.1 - Liquid-Cooled Generator Panel
3.2.1 HOURMETER
Indicates time the generator has operated, in hours
and tenths of hours. Use the hourmeter along with
the periodic maintenance schedule for the generator
set.
3.2.2 AUTO/OFF/MANUAL SWITCH
Use this three-position switch as follows:
• Set the switch to AUTO for fully automatic
operation. See Section 3.4, “Automatic Operation”.
• Set switch to MANUAL position to crank and start
the generator engine.
• Set switch to OFF position to shut down an
operating engine. With OFF selected, operation will
not be possible.
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 the
AUTO/OFF/MANUAL switch to OFF before
working on or around the unit. Then, place a
"DO NOT OPERATE" tag on control console.
3.2.3 FAULT INDICATOR LAMP
The lamp goes ON when one or more of the following
engine faults occurs and when engine shuts down.
• Low oil pressure • Overcrank
• High coolant temperature • Overspeed
• Low coolant level
3.2.4 15 AMP FUSE
The fuse protects the control console’s DC control
circuit against electrical overload. If the fuse has
melted open due to an overload, or is removed,
engine cranking and startup may still occur when the
AUTO/OFF/MANUAL switch is placed in the AUTO or
MANUAL positions.
NOTE:
To disable the control board and thus prevent
potential crank and run, the 15 amp fuse AND the
7.5 amp in-line fuse must both be removed or the
battery cables should be disconnected.
Should you need to replace the fuse, use only an
identical AGC 15-amp replacement fuse.
!
Section 3 - Operation
Centurion Liquid-cooled 15 kW and 25 kW Generators
DANGER
FUSE
HOUR METER
AUTO
OFF
MANUAL
15-A
AGC
FAULT
INDICATOR
SET
EXERCISE
TIME
ON
14 Generac®Power Systems, Inc.
3.2.5 7.5 AMP IN-LINE FUSE
This in-line fuse is connected in wire 15A which runs
between the AUTO/OFF/MANUAL switch and position
10 of the 076009A PCB. This fuse protects the start,
fuel, field boost, and transfer outputs from the PCB
and will open if there is excessive current draw on
any one of these outputs. If this fuse has melted open
or is removed, the control board will be disabled and
the unit will not be able to crank and run when the
AUTO/OFF/MANUAL switch is placed in the AUTO or
MANUAL positions. Replace the fuse with an identical
AGC 7.5 amp fuse.
NOTE:
This fuse will not remove the positive (+) battery
input power from the PCB when it opens. This
means the exercise timer will not be reset. If this
fuse does open, carefully check the wiring to the
start, fuel, field boost and transfer outputs before
replacing the fuse.
3.2.6 SET EXERCISE TIME SWITCH
This switch allows for programming the generator to
start and exercise automatically. See Section 3.5,
“Weekly Exercise Cycle.”
3.3 MANUAL TRANSFER AND
START-UP
To transfer electrical loads to the STANDBY
(GENERATOR) power source side and start the
engine manually, refer to the Owner’s Manual of the
particular transfer switch.
3.4 AUTOMATIC OPERATION
To set the system for fully automatic operation,
proceed as follows:
• Check that load circuits are connected to the
utility power supply.
• Set the AUTO/OFF/MANUAL switch to its AUTO
position.
• Set the generator main circuit breaker to its ON or
CLOSED position.
3.5 WEEKLY EXERCISE CYCLE
The generator will start and exercise once every seven
days. During this weekly exercise, the unit runs for
about 20 minutes and shuts down. Transfer of loads
to generator output does not occur during the
exercise period.
To select day and time for exercising, proceed as
follows:
• Set the AUTO/OFF/MANUAL switch to OFF.
• Set generator main circuit breaker to OFF or
OPEN.
• Locate the rocker switch on the control panel
identified with the words “Set Exercise Time”
(Figure 3.2).
• Push “Set Exercise Time” switch to ON position for
20 to 30 seconds and then release. Switch will
spring back into its original position when
released.
• Wait 30 seconds before setting the AUTO/OFF/
MANUAL switch to AUTO position.
If the AUTO/OFF/MANUAL switch is switched
too soon, the engine may start. If engine does
start, it will shut down automatically in about
two (2) minutes.
• Set the generator main circuit breaker to its ON or
CLOSED position.
• Generator is now programmed to start and
exercise every seven days thereafter, on day and
time of day the switch was actuated.
• Place a sign on the generator control panel and the
transfer switch, indicating the day and time the
generator will be exercising.
NOTE:
If battery terminals are disconnected, the exercise
timer needs to be reset for correct automatic
exercise operation.
Figure 3.2 - “Set Exercise” Switch
3.6 ENGINE BLOCK HEATER
This standby generator comes equipped with a block
heater (Figure 3.3), similar to the block heaters used
in automotive applications. The block heater is wired
to a grounded plug.
Section 3 - Operation
Centurion Liquid-cooled 15 kW and 25 kW Generators
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