Generac 005031-2 3.2CONTROL CONSOLE COMPONENTS, GTS Mode Operation, ‹3.2.1 AUTO/OFF/MANUAL SWITCH

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Figure 3.1 - Generator Control Console

Section 3 - Operation

• After the engine starts and when the generator

AC output voltage and frequency have reached a

Liquid-cooled 25 kW Generators

Figure 3.1 - Generator Control Console

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 circuits signal

the switch main contacts to move back to their util-

ity power source side.

• Following re-transfer back to the utility power

source side, transfer switch circuit board action

signals the generator to stop. Engine then shuts

down.

GTS Mode Operation

OVER CRANK GTS Mode Operation

OVER SPEED ‹3.2.1 AUTO/OFF/MANUAL SWITCH

LOW COOL. LEVEL 3.2CONTROL CONSOLE

HI COOL. TEMP. ‹3.2.2 FAULT INDICATOR LEDS

LOW OIL PRESS. Manual background

LOW BATTERY Manual background

LED INDICATORS:

SYSTEM READY

FLASHING GREEN LED = NO UTILITY SENSE

 

5 FLASHING RED LED'S = EXERCISER NOT SET

 

(IN AUTO MODE ONLY)

 

SOLID GREEN LED = SYSTEM READY, UTILITY POWER ON

 

RED LED'S = INDIVIDUAL FAULT

 

(SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS)

 

 

AUTO

OFF

 

 

OFF

ON

 

SET

MANUAL

EXERCISE

 

TIME

 

TO SET EXERCISER TIME

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

2)HOLD "SET EXERCISE TIME" SWITCH IN "ON" POSITION FOR THREE SECONDS AND RELEASE. (SEE OWNER'S MANUAL FOR COMPLETE DETAILS)

THE EXERCISER IS NOW SET. ALL FIVE RED LED'S WILL FLASH FOR 10 SECONDS THEN THE UNIT WILL START, RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN.

0F2629

CAUTION

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

PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.

CAUTION

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

TENTION: POUR L'ALIMENTATION DE RESERVE, CONNECTER LA SORTIE DE ATRICE A UN COMMUTATEUR DE CALIBRE APPROPRIE, CONFORMENENT AU CANADIEN DE L'ECTRICITE, PREMIERE PARTIE.

WARNING

CAN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE.

Y REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATTE

SERVICING.

WARNING

THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR

OUTDOOR INSTALLATION ONLY!

USE OF SYNTHETIC OIL IS RECOMMENDED

0E7193

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

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

MANUAL — The 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 con- trol board will immediately start and run the genera- tor. When 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 oper- ating parameters and timing sequences.

For proper battery charger operation, it will be nec- essary to supply a fused 240VAC utility fed supply to terminals N1 and N2 in the control 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 3.6).

Set switch to MANUAL position to crank and start the generator engine.

Set switch to OFF position to shut down an operat- ing engine. With OFF selected, operation will not be possible.

Manual backgroundManual background DANGER

With switch set to AUTO, engine can crank and start suddenly without warning. Such automatic start up normally occurs when utility source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set AUTO/OFF/ MANUAL switch to OFF before working on or around the unit. Then, place a “DO NOT OPERATE” tag on control console.

3.2CONTROL CONSOLE

COMPONENTS

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

‹3.2.2 FAULT INDICATOR LEDS

(SEE CHART ON PAGE 14)

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

Low Oil Pressure

Overcrank

Low Battery

Overspeed/Engine Speed Signal Fault

High Coolant Temperature/Low Coolant Level

See Section 1.7 for further explanation of engine pro- tection functions.

13

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Contents This manual should remain with the unit SHOULD ATTEMPT INSTALLATIONLiquid-cooled,Prepackaged Standby Generators Model Number 005031-225kWINTRODUCTION AUTHORIZED SERVICE DEALER LOCATION‹OPERATION AND MAINTENANCE ‹HOW TO OBTAIN SERVICEINTRODUCTION  GENERAL HAZARDS ELECTRICAL HAZARDSWARNING  FIRE HAZARDS  EXPLOSION HAZARDS‹STANDARDS INDEX 1.4GENERATOR AC CONNECTION SYSTEMS 1.2TRANSFER SWITCH1.1GENERATOR 1.3ATS MODE AUTOMATIC OPERATIONFigure 1.4 - Low Oil Pressure Switch ‹1.7.1 LOW OIL PRESSURE SWITCH‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹1.7.3 LOW COOLANT LEVEL SWITCH1.8UNPACKING 1.10 SPECIFICATIONS‹1.7.6 LOW BATTERY ‹1.8.1 UNPACKING PRECAUTIONS1.13 ENGINE OIL RECOMMENDATIONS 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 - Reconfigure the Fuel System 1.11 FUEL CONSUMPTION‹2.1.1 NFPA STANDARDS 2.1STANDBY GENERATOR INSTALLATION1.15 BEFORE INSTALLATION 1.14 COOLANT RECOMMENDATIONS‹2.1.2 OTHER PUBLISHED STANDARDS 2.2GENERATOR LOCATION2.3GENERATOR MOUNTING AND SUPPORT 2.4BASIC STANDBY ELECTRIC SYSTEM2.7GROUNDING THE GENERATOR 2.9USING A “GTS” TRANSFER SWITCH2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.6TOTAL CIRCUIT ISOLATION METHOD2.10 BATTERY INSTALLATION Pos2 OFF — ATS Application‹2.10.1 VENTED BATTERIES ‹2.11.4 GENERATOR SET LUBRICATION 3.1GTS TRANSFER SWITCH‹2.11.2 TRANSFER SWITCH 2.11 PREPARATION BEFORE START-UPGTS Mode Operation ‹3.2.1 AUTO/OFF/MANUAL SWITCH‹3.2.2 FAULT INDICATOR LEDS 3.2CONTROL CONSOLE COMPONENTS‹3.2.6 SYSTEM READY LED ‹3.2.5 SET EXERCISE TIME SWITCH‹3.2.3 15 AMP FUSE ‹3.2.4 5 AMP FUSEFigure 3.2 - Engine Governor Adjustment 3.4ENGINE GOVERNOR GAIN ADJUSTMENTS3.3MANUAL TRANSFER AND START-UP 3.5MANUAL RETRANSFER AND SHUTDOWN3.7WEEKLY EXERCISE CYCLE 3.8CONTROL BOARD DIP SWITCH SETTINGSFigure 3.3 - “Set Exercise Time” Switch 3.6AUTOMATIC OPERATION‹ONCE ANNUALLY 3.9VOLTAGE REGULATOR ADJUSTMENT‹EVERY THREE MONTHS ‹ONCE EVERY SIX MONTHSFigure 4.1 - Intake Manifold Installation 4.2EXHAUST MANIFOLD PROCEDURE4.3INTAKE MANIFOLD PROCEDURE 4.4CYLINDER HEAD PROCEDURE4.6OVERLOAD PROTECTION FOR 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM‹4.7.2 BATTERY FLUID ‹4.8.2 CHECK BATTERY‹4.8.8 CHECK FAN BELT ‹4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 - Setting the Spark Plug Gap ‹4.8.7 INSPECT EXHAUST SYSTEM‹4.9.3 BATTERY MAINTENANCE 4.9MISCELLANEOUS MAINTENANCE‹4.9.1 CLEANING THE GENERATOR ‹4.9.2 BATTERYService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCETasks Level CORRECTION TROUBLESHOOTING POINTSPROBLEM CAUSESection 6 - Electrical Data Section 6 - Electrical Data Liquid-cooled25 kW Generators Section 6 - Electrical DataSection 6 - Electrical Data Liquid-cooled25 kW Generators Section 6 - Electrical DataSection 6 - Electrical Data Liquid-cooled25 kW Generators Section 6 - Electrical DataSection 6 - Electrical Data Section 7 - Exploded Views and Parts Lists Mounting Base - Drawing No. 0F0104-B DESCRIPTION38 3 45 39 32 18 LATCH DETAIL Enclosure - Drawing No. 0F1645-H Liquid-cooled25 kW Generators 0F0790 Control Panel 25kW - Drawing No. 0E7615-C 0F0790 RADIATOR FOR HARNESS GROUNDSTEPPER ONLYEngine - Drawing No. 0E9918-F COVER Fuel System - Drawing No. 0E9980-D LEADS LOCKTIGHT0F1659A Muffler - Drawing No. 0F2930-C Stepper Motor - Drawing No. 0E9979-C Radiator - Drawing No. 0E9965-F TO THERMOSTATADAPTER Section 8 - Installation Diagram YOUR WARRANTY RIGHTS AND OBLIGATIONS PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESCALIFORNIA EMISSION CONTROL WARRANTY STATEMENT EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING WARRANTY SCHEDULE