Generac 005030-0 (15kW), 005031-0 (25kW) Control Console Components, Manual Transfer START-UP

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Section 3 - Operation

Liquid-cooled 15, 20 and 25 kW Generators

3.1CONTROL CONSOLE

COMPONENTS

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

Figure 3.1 - Generator Control Console

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

‹3.1.3 15 AMP FUSE

This fuse protects the control console’s DC control circuit against electrical overload and is located inside the control panel. If the fuse has melted open because of an overload, engine cranking and startup

OVER CRANK

OVER SPEED

LOW COOL. LEVEL

HI COOL. TEMP.

LOW OIL PRESS.

LOW BATTERY

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

cannot occur. If the fuse needs to be replaced, use only an identical 15-amp replacement fuse (type ATO).

‹3.1.4 5 AMP FUSE

This fuse protects the battery charger against electri- cal overload and is located inside the control panel. If the fuse needs to be replaced, use only an identical 5- amp replacement fuse (type ATO).

NOTE:

This fuse will not remove the + battery input power from the PCB when it opens. This means the exercise timer will not be reset.

‹3.1.1 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 oper- ating engine. With OFF selected, operation will not be possible.

DANGER

With switch set to AUTO, engine can crank and

!start suddenly without warning. Such automat- ic 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 con- trol console.

‹3.1.2 FAULT INDICATOR LEDS

(SEE CHART ON PAGE 16)

These red LEDs turn ON when one or more of the fol- lowing 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

‹3.1.5 SET EXERCISE TIME SWITCH

This switch allows programming the generator to start and exercise automatically. “See Weekly Exercise Cycle” (see Figure 3.3 and Section 3.6).

‹3.1.6 SYSTEM READY LED

The System Ready LED (green) has two main pur- poses. First, the LED will be ON when the AUTO/OFF/MANUAL switch is in the AUTO position, utility is present, and there are no system alarms. This ON state indicates the system is fully ready for automatic operation.

The system ready LED will be OFF when the switch is in the MANUAL or OFF positions.

The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes. The LED will flash at the rate of 1/2 second on, 1/2 second off if the utility sensing level is below the transfer back threshold.

This secondary function is only available with DIP switch two in the OFF position (ATS - automatic transfer switch application).

3.2MANUAL TRANSFER AND

START-UP

To transfer electrical loads to the Standby (EMER- GENCY) power source side and start the engine man- ually, refer to the Owner’s Manual of the particular transfer switch.

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Contents This manual should remain with the unit ‹ Operation and Maintenance Authorized Service Dealer Location‹ HOW to Obtain Service IntroductionTable of Contents General Hazards ‹ Standards Index Electrical HazardsAutomatic Transfer Switch ATS Mode Transfer SwitchEngineered Transfer Switch Wire Start GTS Mode Generator‹ 1.8.2 High Coolant Temperature Switch ‹ 1.8.1 LOW OIL Pressure SwitchMain Circuit Breaker Generator Fuel SystemLifting the Generator UnpackingAWSF-52-C SpecificationsFuel Consumption Engine OIL Recommendations Before InstallationCoolant Recommendations Generator Mounting Support Generator Location‹ 2.1.1 Nfpa Standards ‹ 2.1.2 Other Published StandardsTotal Circuit Isolation Method Basic Standby Electric SystemGrounding the Generator Emergency Circuit Isolation MethodGenerator AC Neutral Connections Connection Diagram ATS Mode Connection Diagram GTS Mode ‹ 2.11.1 Vented Batteries Battery InstallationPreparation Before START-UP Manual Transfer START-UP Control Console ComponentsBat Red Oil Red Temp Red Speed Red Crank Red Engine Governor Gain AdjustmentsWeekly Exercise Cycle Manual Retransfer ShutdownAutomatic Operation Voltage Regulator Adjustment Control Board DIP Switch SettingsIntake Manifold Procedure Exhaust Manifold ProcedureCooling System Cylinder Head ProcedureOverload Protection for Engine DC Electrical System Checking Fluid Levels‹ 4.8.2 Check Battery ‹ 4.7.2 Battery Fluid ‹ 4.8.6 Perform Visual Inspection‹ 4.7.3 Engine Coolant ‹ 4.8.1 Check Engine OIL Level‹ 4.8.11 Changing the Engine AIR Cleaner Miscellaneous Maintenance‹ 4.9.1 Cleaning the Generator ‹ 4.8.13 Coolant ChangePeriodic Replacement Parts ‹ 4.9.3 Battery Maintenance‹ 4.9.4 Battery Replacement Service Maintenance Interval Information Scheduled MaintenanceLevel Maintenance Level Problem Cause Correction Troubleshooting PointsLiquid-cooled 15, 20 and 25 kW Generators Liquid-cooled 15, 20 and 25 kW Generators Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Page Hold Down Battery Support Battery TrayAssembly Battery Tray Battery Post Cover BlackTo B Door Battery Compartment Assy Wire 14AWG 7.5 #0 GRN/YELDuct Intake MID AL 2.5L Duct Discharge RH AL 2.5LPage Switch ROC Dpdt ON-OFF-ON Switch ROC Dpst 125V SPDHang TAG 2 Wire Start not Shown TOP, Control PanelPage Harness Ctrl PNL 2.5L Ford AL not Shown 13 17 Engine 2.5L Ford Tank Coolant RecoverySTARTER, 12 Volt NUT HEX M10-1.5 G8 YEL CHRTo Engine Cover AIR Cleaner Body Carburetor AssemblyGASKET, AIR Cleaner Adapter Bracket Fuel RegulatorLocktight Rotor 390 20KW 1P Direct HSB 2.5L Ford Rotor 390 15KW 1P Direct HSB 2.5L FordRotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 390 40KW 1P Direct HSB 3.9L ChryslerPipe Exhaust 2.5L Ford Pipe Muffler OUTMuffler 2.5L Ford Saddle 2 InchCover Connector Housing Housing Governor ConnectorASM Motor Stepper Harn GOV 2.5L FordBarbed STR 1/4 NPT X 3/8 HOSE, 2.5L Ford LowerALM Radiator 2.5L FordInstallation Diagram PURCHASER’S/OWNER’S Warranty Responsibilities Your Warranty Rights and ObligationsMANUFACTURER’S Emission Control System Warranty Coverage Emission Related Parts Include the Following Emission Control System WarrantyThis Warranty Shall not Apply to the Following

005030-0 (15kW), 005031-0 (25kW) specifications

Generac has long been recognized as a leader in backup power solutions, and its 005031-0 (25kW) and 005030-0 (15kW) home standby generators exemplify the brand's commitment to reliability and performance. Designed for residential use, these generators provide peace of mind during outages, ensuring that homes remain powered even in the most challenging conditions.

One of the standout features of both models is their advanced Generac G-Force engine, which is engineered for longevity and impressive power output. The G-Force engine is built from the ground up for generator use, refined to handle the unique demands of continuous operation. This results in a highly durable system that requires little to no maintenance, making it a favored choice for homeowners looking for a reliable energy solution.

Another important characteristic is the True Power technology featured in both generators. This technology delivers clean, stable power that is safe for sensitive electronics and appliances. It ensures that devices such as computers and medical equipment operate smoothly without the risk of damage from power fluctuations. Additionally, the Generac 005031-0 and 005030-0 generators are equipped with the Quiet-Test mode, allowing them to run at lower RPMs during routine weekly self-tests. This innovation significantly reduces the noise produced during tests, making it less disruptive for residents.

Furthermore, these generators come with a user-friendly interface and a mobile link app, enabling homeowners to monitor their generator's performance remotely via a smartphone. This feature enhances convenience, allowing users to receive alerts and notifications about their generator's status, maintenance needs, and operation conditions right from their devices.

Both the 25kW and 15kW models are also designed with a robust transfer switch, which seamlessly shifts power from the grid to the generator in case of any outages. This automatic transfer feature ensures that homes maintain power without needing manual intervention, making them ideal for those who want uninterrupted electricity.

In terms of fuel source, both models operate on natural gas or propane, providing flexibility to homeowners regarding fuel availability and preferences. With excellent warranty options and Generac's reputation for quality, both the 005031-0 (25kW) and 005030-0 (15kW) generators stand as dependable choices for safeguarding homes from the unpredictability of power outages.
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