Generac 005031-2 owner manual Fire Hazards,  Explosion Hazards, ‹Standards Index

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FIRE HAZARDS 

Important Safety Instructions

Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

If personnel must stand on metal or concrete while install- ing, operating, servicing, adjusting or repairing this equip- ment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insula- tive 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 elec- tricity. 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 haz- ardous and possibly fatal electrical shock.

Connecting this unit to an electrical system normally sup- plied 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 genera- tor 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 pre- set 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 genera- tor 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 pos- sible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS

Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can deteriorate wiring insulation. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.

Liquid-cooled 25 kW Generators

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materi- als are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

These generator sets may operate using one of several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to applicable fuel-gas codes before placing this equipment into service.

Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air; install leak detectors accordingly.

‹STANDARDS INDEX

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

NOTE:

It is essential to use the latest version of any stan- dard to ensure correct and current information.

1.NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES, available from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

2.NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES, available same as Item 1.

3.NFPA No. 54, NATIONAL FUEL GAS CODE, available same as Item 1.

4.NFPA No. 58, AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same as Item 1.

5.NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC CODE, available same as Item 1.

6.Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038.

7.AGRICULTURAL WIRING HANDBOOK, available from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201.

8.ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.

9.NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE, available same as Item 1.

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Contents Liquid-cooled,Prepackaged Standby Generators SHOULD ATTEMPT INSTALLATIONModel Number 005031-225kW This manual should remain with the unit‹OPERATION AND MAINTENANCE AUTHORIZED SERVICE DEALER LOCATION‹HOW TO OBTAIN SERVICE INTRODUCTIONINTRODUCTION WARNING   GENERAL HAZARDSELECTRICAL HAZARDS ‹STANDARDS INDEX FIRE HAZARDS EXPLOSION HAZARDS 1.1GENERATOR 1.2TRANSFER SWITCH1.3ATS MODE AUTOMATIC OPERATION 1.4GENERATOR AC CONNECTION SYSTEMS‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹1.7.1 LOW OIL PRESSURE SWITCH‹1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch‹1.7.6 LOW BATTERY 1.10 SPECIFICATIONS‹1.8.1 UNPACKING PRECAUTIONS 1.8UNPACKINGFigure 1.8 - Reconfigure the Fuel System 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR1.11 FUEL CONSUMPTION 1.13 ENGINE OIL RECOMMENDATIONS1.15 BEFORE INSTALLATION 2.1STANDBY GENERATOR INSTALLATION1.14 COOLANT RECOMMENDATIONS ‹2.1.1 NFPA STANDARDS2.3GENERATOR MOUNTING AND SUPPORT 2.2GENERATOR LOCATION2.4BASIC STANDBY ELECTRIC SYSTEM ‹2.1.2 OTHER PUBLISHED STANDARDS2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.9USING A “GTS” TRANSFER SWITCH2.6TOTAL CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATOR‹2.10.1 VENTED BATTERIES 2.10 BATTERY INSTALLATIONPos2 OFF — ATS Application ‹2.11.2 TRANSFER SWITCH 3.1GTS TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹2.11.4 GENERATOR SET LUBRICATION‹3.2.2 FAULT INDICATOR LEDS ‹3.2.1 AUTO/OFF/MANUAL SWITCH3.2CONTROL CONSOLE COMPONENTS GTS Mode Operation‹3.2.3 15 AMP FUSE ‹3.2.5 SET EXERCISE TIME SWITCH‹3.2.4 5 AMP FUSE ‹3.2.6 SYSTEM READY LED3.3MANUAL TRANSFER AND START-UP 3.4ENGINE GOVERNOR GAIN ADJUSTMENTS3.5MANUAL RETRANSFER AND SHUTDOWN Figure 3.2 - Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.8CONTROL BOARD DIP SWITCH SETTINGS3.6AUTOMATIC OPERATION 3.7WEEKLY EXERCISE CYCLE‹EVERY THREE MONTHS 3.9VOLTAGE REGULATOR ADJUSTMENT‹ONCE EVERY SIX MONTHS ‹ONCE ANNUALLY4.3INTAKE MANIFOLD PROCEDURE 4.2EXHAUST MANIFOLD PROCEDURE4.4CYLINDER HEAD PROCEDURE Figure 4.1 - Intake Manifold Installation‹4.7.2 BATTERY FLUID 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM‹4.8.2 CHECK BATTERY 4.6OVERLOAD PROTECTION FORFigure 4.4 - Setting the Spark Plug Gap ‹4.8.11 CHANGING THE ENGINE AIR CLEANER‹4.8.7 INSPECT EXHAUST SYSTEM ‹4.8.8 CHECK FAN BELT‹4.9.1 CLEANING THE GENERATOR 4.9MISCELLANEOUS MAINTENANCE‹4.9.2 BATTERY ‹4.9.3 BATTERY MAINTENANCEService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCETasks Level PROBLEM TROUBLESHOOTING POINTSCAUSE CORRECTIONSection 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 Liquid-cooled25 kW Generators STEPPER FOR HARNESS GROUNDONLY RADIATOREngine - Drawing No. 0E9918-F COVER Fuel System - Drawing No. 0E9980-D LEADS LOCKTIGHT0F1659A Muffler - Drawing No. 0F2930-C Stepper Motor - Drawing No. 0E9979-C ADAPTER Radiator - Drawing No. 0E9965-FTO THERMOSTAT Section 8 - Installation Diagram CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING WARRANTY SCHEDULE