Guardian Technologies 004992-2 User Manual
Owner’s Manual
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
This manual should remain with the unit.
Liquid-cooled, Prepackaged
Standby Generators
Model Nos. 004992-2
37kW NG, 40kW LP
2
INTRODUCTION
Thank you for purchasing this model of the Guardian
standby generator product line by Generac Power
Systems, Inc.
Every effort was expended to make sure that the
information and instructions in this manual are both
accurate and current at the time the manual was written. However, the manufacturer reserves the right to
change, alter or otherwise improve this product(s) at
any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest authorized service dealer for starting,
operating and servicing procedures.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
After this heading, read instructions that, if not
strictly complied with, will result in severe personal injury, including death, or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing the
service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates is as follows:
This symbol points out important safety information that, if not followed, could endanger personal
safety and/or property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator 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.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an authorized
service dealer. Normal maintenance service 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 the authorized service
dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by an authorized service dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
contact an authorized service dealer for assistance.
Service technicians are factory-trained and are capable of handling all service needs.
When contacting an authorized service dealer about
parts and service, always supply the complete model
number of the unit as given on the front cover of this
manual or on the DATA LABEL affixed to the unit.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE DEALER,
please call this number:
1-800-333-1322
OR
Locate us on the web at:
www.guardiangenerators.com
DANGER
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Table of Contents
40kW Liquid-cooled Generators
1
INTRODUCTION................................................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 ............................................4
1.6 Generator Fuel System ..........................................5
1.7 Engine Protective Devices ......................................5
1.8 Unpacking ............................................................6
1.9 Lifting the Generator ............................................6
1.10 Specifications ........................................................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 Standby Generator Installation ............................8
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......................10
2.9 Transfer Switch Start Signal Connections ..........11
2.10 Battery Installation ..............................................11
2.11 Preparation Before Start-Up................................12
Section 3 — OPERATION ................................13
3.1 Using an Engineered “GTS” Transfer Switch ......13
3.2 Control Console Components..............................13
3.3 Manual Transfer and Startup..............................14
3.4 Engine Governor Adjustments ............................14
3.5 Retransfer and Shutdown....................................15
3.6 Automatic Operation ..........................................15
3.7 Weekly Exercise Cycle..........................................15
Section 4 — MAINTENANCE ..........................16
4.1 Maintenance Performed by Authorized
Service Facilities ..................................................16
4.2 Cooling System....................................................16
4.3 Overload Protection for Engine DC
Electrical System ................................................16
4.4 Checking Fluid Levels ........................................16
4.5 Maintenance Owner/Operator
Can Perform ........................................................17
4.6 Miscellaneous Maintenance ................................18
4.7 Scheduled Maintenance ......................................20
Section 5 — TROUBLESHOOTING ..................23
Section 6 — ELECTRICAL DATA ....................24
Section 7 — EXPLODED VIEWS AND
PARTS LISTS ..............................28
Section 8 — INTALLATION DIAGRAM ............43
Section 9 — NOTES ........................................44
Section 10 — WARRANTY .................Back Cover
2
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 that the manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work
method or operating technique chosen does not render
the generator unsafe.
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or maintain this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running generators.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by an authorized service dealer or other
competent, qualified electrician or installation technician who is familiar with applicable codes, standards
and regulations. The operator also must comply with
all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical
and building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is installed, operated and serviced in accordance
with the manufacturer’s instructions and recommendations. Following installation, do nothing that might
render the unit unsafe or in noncompliance with the
aforementioned codes, standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide
gas, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason, adequate ventilation must be provided. Exhaust gases
must be piped safely away from any building or
enclosure that houses the generator to an area where
people, animals, etc., will not be harmed. This
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical 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.
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IMPORTANT SAFETY INSTRUCTIONS
40kW Liquid-cooled 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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3
• Inspect the generator regularly, and promptly repair
or replace all worn, damaged or defective parts using
only factory-approved parts.
• Before performing any maintenance on the generator,
disconnect its battery cables to prevent accidental
start-up. Disconnect the cable from the battery post
indicated by a NEGATIVE, NEG or (–) first.
Reconnect that cable last.
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
ELE
CTRICAL HAZARDS
• All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical
shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the
standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as
the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before
operating the generator. If 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.
F
IRE HAZARDS
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher
properly charged and be familiar with its use. If there
are any questions pertaining to fire extinguishers,
consult the local fire department.
EXPLOSION HAZARDS
• Properly ventilate any room or building housing the
generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or
on or near the generator, as FIRE or EXPLOSION
may result. Keep the area surrounding the generator
clean and free from debris.
• These generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled
with care. Comply with all laws regulating the storage
and handling of fuels. Inspect the unit’s fuel system
frequently and correct any leaks immediately. Fuel
supply lines must be properly installed, purged and
leak tested according to applicable fuel-gas codes
before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids
such as natural gas and liquid propane (LP) gas are
extremely EXPLOSIVE. Natural gas is lighter than air,
and LP gas is heavier than air; install leak detectors
accordingly.
IMPORTANT SAFETY INSTRUCTIONS
40kW Liquid-cooled Generators
4
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.
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 200 amp
automatic transfer switch which is intended to be
used in conjunction with the 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.
1.3 AUTOMATIC SYSTEM OPERATION
When this generator, along with a 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 AC output
results. Typically the two HOT leads in the circuit are
wires 11 and 44. The NEUTRAL leads are the junction of Wires 22 and 33. The NEUTRAL is not
grounded.
Figure 1.1 - Generator AC Connection System
1.5 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with
the unit as shipped from the factory. The breaker for
this unit is described in Figure 1.2.
Section 1 - General Information
40kW Liquid-cooled Generators
Model Rating Phase Actual Current C/B Rating* Circuit Breaker
004992-2 37,000 NG 1 154.2 200 200A QN2
40,000 LP 1 166.7 200 200A QN2
* Amp Rating of C/B structured under model.
Figure 1.2 - Main Circuit Breaker
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5
1.6 GENERATOR FUEL SYSTEM
The unit has been factory tested and adjusted using a
natural gas fuel system. If propane (LP) gas is necessary, refer to Section 1.12 for conversion.
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 8-10 psi
(55-68 kPa), the switch contacts close, the engine
shuts down automatically, and the low oil pressure
LED is turned ON (Figure 1.4).
NOTE:
The Low Oil Pressure, High Coolant Temperature
and Low Coolant Level are not monitored for the
first 10 seconds of engine run time.
Figure 1.4 - Low Oil Pressure Switch
1.7.2 HIGH COOLANT TEMPERATURE
SWITCH
Normally open (N.O.) thermostatic switch has sensing tip which is immersed in captive coolant. Should
coolant temperature exceed about 230°F (110°C), the
switch contacts close. This causes the engine to shut
down automatically and turns on the high coolant
temperature/low coolant level LED (Figure 1.5).
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 and turns on the high coolant temperature/low coolant level LED (Figure 1.6 on page 6).
Section 1 - General Information
40kW Liquid-cooled Generators
!
High Coolant
Temperature Switch
Low Coolant
Level Sensor
Low Oil Pressure Switch
6
Figure 1.6 - Low Coolant Level Sensor
1.7.4 OVERSPEED SHUTDOWN
The engine control board receives AC frequency signals from an engine run winding in the alternator.
Should AC frequency exceed about 72 Hertz for three
seconds or 75 Hertz instantaneously, the engine
shuts down and the overspeed LED turns on. Should
AC frequency exceed about 72 Hertz, circuit board
action will automatically shutdown the engine (Figure
1.7).
Figure 1.7 - Printed Circuit Board Assembly
1.7.5 RPM SENSOR LOSS
If the engine control board does not receive a proper
rpm signal from the starter during cranking or running, it shuts down the engine on rpm sensor loss
and flash the overspeed LED.
1.7.6 OVERCRANK SHUTDOWN
The engine control board uses a cyclic cranking
process when attempting to start the engine. The first
crank cycle is a 15-second crank followed by a sevensecond rest. This is followed by five more crank
cycles each with a seven second crank followed by a
seven-second rest.
If the engine fails to start after all six attempts, the
start attempt is stopped and the overcrank LED
turned on.
1.7.7 LOW BATTERY
The engine control board continually monitors the
battery voltage and turns on the low battery LED if
the battery voltage falls below 11.0 VDC for one
minute. Low battery voltage is a non-latching alarm,
which will automatically clear if the battery voltage
rises above 11.0 VDC.
The control system will not attempt to start the
engine if there is a low battery condition, however, if
the engine is already running when the low battery
condition occurs, the engine will continue to run as
long as possible.
Battery voltage is NOT monitored during the crank
cycle.
1.7.8 ALARM RESET
If the engine control board shuts down the generator
for any of the above reasons, the engine remains
stopped until the alarm is cleared by placing the
AUTO/OFF/MANUAL switch into the OFF position.
1.7.9 DC FUSE
These fuses are located on the front panel of the control system. They protect the panel wiring and components from damaging overload. Always remove the
15 amp main fuse before working on the generator.
The unit will not start or crank if this fuse is blown.
Replace the fuse with one of the same size, type, and
rating (main AGC-15, battery charger AG4).
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..
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 his 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 1400 pounds
requires proper tools, equipment, and qualified
personnel to be used in all phases of handling
and unpacking.
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Section 1 — General Information
40kW Liquid-cooled Generators
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1.10 SPECIFICATIONS
1.10.1 GENERATOR SPECIFICATIONS
1.10.2 ENGINE SPECIFICATIONS
Make..................................................................................................Chrysler
Displacement ....................................................................................3.9 liters
Cylinder Arrangement ..............................................................................V-6
Valve Arrangement ................................................................Overhead Valve
Firing Order ..................................................................................1-6-5-4-3-2
Number of Main Bearings ............................................................................4
Compression Ratio ............................................................................9.1 to 1
No. of Teeth on Flywheel ..........................................................................164
Ignition Timing at 1800 rpm ..............................................30 degrees BTDC
Spark Plug Gap................................................................1.01mm (0.040 in.)
Recommended Spark Plugs
Champion......................................................................................RC12LC4
Oil Pressure ....................................................................................30-80 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 ..................................5.0 U.S. gallons (19.3 liters)
Recommended Coolant ............................................Use a 50-50 mixture of
ethylene glycol base
and de-ionized water.
1.11 FUEL CONSUMPTION
Natural Gas:
% of Load 25% 50% 75% 100%
m3/hr 4.1 7.7 11.0 14.2
ft3/hr 143.1 271.1 388.5 502.0
LP
Vapor:
% of Load 25% 50% 75% 100%
m3/hr 1.7 3.3 4.7 6.0
ft3/hr 60.7 115.0 164.9 213.0
NOTE:
Fuel consumption is given at rated maximum continuous power output when using natural gas rated
at 1000 Btu per cubic foot. LP gas is rated at 2520
Btu per cubic foot. Actual fuel consumption
obtained may vary depending on such variables as
applied load, ambient temperature, engine conditions and other environmental factors.
Fuel pressure for a natural gas set up should be five
inches to 14 inches of water column (0.18 to 0.5
psi) at all load ranges.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
1.12 RECONFIGURING THE FUEL
SYSTEM
Fuel pressure for both natural gas and liquid
propane set ups should be 11 inches to 14 inches of
water column (0.4 to 0.5 psi) at all load ranges.
NOTE:
All models are configured for natural gas from the
factory.
To reconfigure the fuel system from NG to LP vapor,
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 dual fuel has been made.
Section 1 — General Information
40kW Liquid-cooled Generators
7
Single-phase
Model 4992-2
Rated Max. Cont. 37 (NG), 40 (LP)
AC Power Output (kW)
Rated voltage (volts) 120/240
No. of Rotor Poles 4
Driven Speed of Rotor 1800
Rotor Excitation System Direct excited brush type
Type of Stator 4 Wire
Rotor/Stator Insulation Class F/H
Port 2
PLUG
LP FUEL SYSTEM
PLUG
Port 1
NG FUEL SYSTEM
FUEL HOSE
BRASS HOSE
FITTING
PORT 1
HOUSING
PORTS
OUT
FUEL HOSE
BRASS HOSE
FITTING
OUT
PORT 2
HOUSING
PORTS
8
Serious injury or damage may occur if not configured properly. Please consult an authorized
service dealer with any questions.
1.13 TORQUE SPECIFICATIONS
Tighten the bolts from the middle out, in a crisscross pattern.
Cylinder Head ....................................50 ft.lb./105 ft.lb./105 ft.lb.
Intake Manifold ....................................48 in.lb./84 in.lb./84 in.lb.
Exhaust Manifold..............................................................25 ft.lb.
1.14 ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service CC, SD, SE, SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
NOTE:
Synthetic oil is highly recommended in any element with temperatures above 90° F or below 30°
F.
Any attempt to crank or start the engine before
it has been properly serviced with the recommended oil may result in an engine failure.
1.15 COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base
anti-freeze and half de-ionized water. Cooling system
capacity is about 20 U.S. quarts (19.3 liters). Use
only de-ionized water and only low silicate antifreeze. 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. It is also recommend
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 Sections 2.5 and 2.6.
The generator’s rated wattage/amperage capacity
must be adequate to handle all electrical loads that
the unit will power. The critical (essential) loads may
need to be grouped together and wired into a separate “emergency” distribution panel.
The standard transfer switch has no 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 STANDBY GENERATOR
INSTALLATION
Connecting this generator to an electrical system normally supplied by an electric utility
shall be by means of a transfer switch, so as to
isolate the electric system from the utility distribution system when the generator is operating.
Failure to isolate the electric system by these
means will result in damage to the generator
and may also result in injury or death to utility
workers due to backfeed of electrical energy.
If an open bottom is used, the engine-generator 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.
Section 2 — Installation
40kW Liquid-cooled Generators
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 15W-40
32° to 80° F (-1° to 27° C) SAE 15W-40
Below 32° F (0° C) SAE 15W-40
DANGER
!
!
!
DANGER
9
After the system has been installed, do nothing
that might render the installation in noncompliance with such codes, standards and regulations.
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:
NOTE:
It is essential to use the latest version of any standard to ensure correct and current information.
• 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:
NOTE:
It is essential to use the latest version of any standard to ensure correct and current information.
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYSTEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
2.2 GENERATOR LOCATION
Install the generator set, in its protective enclosure
outdoors, where adequate cooling and ventilating air
always is available. Consider these factors:
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• This genset must be installed on a level surface.
The base frame must be level within 1/2 inch all
around.
• Allow sufficient room on all sides of the generator
for maintenance and servicing. A good rule is to
allow five feet of space on all sides.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings into
the prevailing winds.
• Install the generator as close as possible to the
transfer switch. This reduces the length of wiring
and conduit.
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping. HOWEVER,
REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE.
2.3 GENERATOR MOUNTING AND
SUPPORT
Retain the generator compartment to a concrete slab
with 1/4-inch masonry type anchor bolts. Be sure the
bolts are long enough to retain the compartment. The
slab should be at least six inches thick and should
extend beyond the enclosure to a distance of at least
three inches on all sides. See Section 6 for generator
major dimensions.
2.4 BASIC STANDBY ELECTRIC
SYSTEM
Figure 2.1 (on page 10) 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:
• Allows 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
40kW Liquid-cooled Generators
10
Figure 2.1 – Basic Standby Electric System
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 the total
amperage rating of the emergency distribution
panel circuit.
• Have it installed between the building’s main dis-
tribution 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 equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility
service entrance and the building distribution
panel.
• In accordance wtih electrical code, an approved
means of service disconnect must be installed
between the normal incoming utiltiy service
entrance and the transfer switch.
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)
2.8 GENERATOR AC NEUTRAL
CONNECTIONS
The manufacturer uses an UNGROUNDED AC neutral. Grounding is recommended only at the main
service entrance. If the neutral wire is grounded and
one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actual result depends
on the electrical characteristics of the particular
installed generator.
Failure to connect the generator neutral properly will result in unbalanced line-to-neutral
voltages. Resulting high voltages will cause
equipment damage.
!
GROU
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Section 2 — Installation
40kW Liquid-cooled Generators
DANGER
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2.9 TRANSFER SWITCH SIGNAL
CONNECTIONS
2.9.1 PRE-PACKAGED ATS
If the generator is to be installed with a pre-packaged
transfer switch, it is necessary to connect the control
wires to the generator and set position two of the
four-position dip switch to OFF.
Setting switch two to OFF allows the control PCB to
perform the ATS control functions.
Control system interconnections consist of N1 and
N2, and leads 23 and 194. Control system interconnection leads must be run in a conduit that is separate from the AC power lead. Recommended wire
gauge sizes for this wiring depends on the length of
the wire, as recommended below:
2.9.2 GTS-TYPE ATS
If the generator is to be installed with an engineered
automatic transfer switch, such as a GTS-type
switch, it is 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 middle, on the bottom, 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. (See
Section 3.1 for further explanation.)
NOTE:
It will be necessary to provide a UTILITY supply to
the integral battery charger. This battery charger
is located in the engine generator control panel.
Locate the six position terminal strip in the control panel. Connect a 240 VAC UTILITY supplied
source to terminals labeled N1 and N2. The 240
VAC circuit should be protected by a 15A maximum rated circuit breaker.
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 certain that normal source voltage
at the transfer switch is correct and the system
is ready to be placed 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 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
!
Section 2 — Installation
40kW Liquid-cooled Generators
MAXIMUM WIRE LENGTH RECOMMENDED WIRE
SIZE
460 feet (140m) No. 18 AWG.
461 to 730 feet (223m) No. 16 AWG.
731 to 1,160 feet (354m) No. 14 AWG.
1,161 to 1,850 feet (565m) No. 12 AWG.
DANGER
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!
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12
• Spilled electrolyte is to be washed down with an
acid-neutralizing agent. A common practice is to
use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The following procedure are to be followed:
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touching batteries by first touching a grounded metal
surface.
Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
The recommended battery is Group 27F, 12V negative ground, 700 CCA/90 AH minimum capacity. All
batteries must be at 100 percent state-of-charge
before they are installed on the generator.
When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals
specified in Section 4, “Maintenance.” A negative
ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries to
the generator set.
NOTE:
Damage will result if the battery connections are
made in reverse.
2.11 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
“Specifications” (Section 1.10) for more information.
2.11.4 GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
(Section 1.10) and “Engine Oil Recommendations”
(Section 1.14).
NOTE:
This engine is shipped from the manufacturer
with 5W-20 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 “Specifications”
(Section 1.10) and “Coolant” (Section 1.15).
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.
!
Section 2 — Installation
40kW Liquid-cooled Generators
13
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.
3.1 USING AN ENGINEERED “GTS”
TRANSFER SWITCH
When required, the pre-packaged standby generator
can be installed with an engineered “GTS” type automatic transfer switch.
In this application, the GTS is responsible for utility
sensing, weekly exercising, and load transferring.
Position two of the four-position dip switch is used to
turn over this control to the GTS.
Pos2 ON — GTS Application
• The control board will NOT monitor utility.
• The control board will NOT perform a weekly exercise. (The five red LEDs will not flash in this
mode.)
• The control board will NOT activate the transfer
output.
• The control board WILL monitor all engine conditions and shut down on all the faults listed in this
document.
Pos2 OFF — ATS Application (Included switch)
• The control board will perform all of the automatic features listed in this document.
• The two-wire start connections should NOT be
used.
GTS Mode Operation
When in GTS mode, the control board will respond
as follows based on the AUTO/OFF/MANUAL switch
position.
OFF — The generator will not start and run in this
position.
MANUAL — The control board will start and run the
generator whenever the switch is in the manual position.
AUTO — The control board will monitor the two-wire
start circuit. When a two-wire start is issued the control board will immediately start and run the generator. Whe the two-wire start is removed the control
board will immediately stop the generator.
NOTE:
If the generator is installed in conjunction with an
engineered GTS type 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 home standby generator control
console (Figure 3.1) are as follows:
Figure 3.1 - Home Standby Generator Panel
3.2.1 AUTO/OFF/MANUAL SWITCH
Use this three-position switch as follows:
• Set the switch to AUTO for fully automatic opera-
tion. See “Automatic Operation” (Section 3.5).
• Set switch to MANUAL position to crank and start
the generator engine.
• Set switch to OFF position to shut down an oper-
ating engine. With OFF selected, operation will not
be possible.
With switch set to AUTO, engine can crank and
start suddenly without warning. Such automatic start up normally occurs when utility source
voltage drops below a pre-set level. To prevent
possible injury that might be caused by such
sudden starts, set AUTO/OFF/ MANUAL switch
to OFF before working on or around the unit.
Then, place a “DO NOT OPERATE” tag on control console.
3.2.2 FAULT INDICATOR LEDS
These LEDs turn ON when one of the following
engine faults occurs and the engine shuts down.
• Low Oil Pressure
• Overcrank
• Low Battery
• Overspeed/RPM Sensor Loss
• High Coolant Temperature/Low Coolant Level
See Section 1.7 for further explanation of engine protection functions.
!
F
(
)
5
T
SE
TO SET EXERCISER TIME
1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.
(
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Section 3 - Operation
40kW Liquid-cooled Generators
LED INDICATOR
FLASHING GREEN LED = NO UTILITY SEN
FLASHING RED LED'S = EXERCISER NOT SE
IN AUTO MODE ONLY) SOLID GREEN LED = SYSTEM READY, UTILITY POWER O
RED LED'S = INDIVIDUAL FAUL
SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS
EXECISE
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