Generac 04675-3 BREAK-IN Procedure, Automatic Transfer Operation, Sequence of Automatic Operation

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Section 3 — Operation

Air-cooled 7 kW, 12 kW and 15 kW Generators

NOTE:

Figure 3.1 – Generator Control Panel

The voltage regulator is housed above the generator's control panel. The regulator maintains a voltage in direct proportion to frequency. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

3.1BREAK-IN PROCEDURE

Once the unit has been installed, with utility power connected to the transfer switch, and all electrical checks have been made, it is strongly recommended that the following “Break-in Procedure” be completed to ensure correct generator operation in the future.

FUSE

 

5A

OFF MAN.

AUTO

FUSE

 

15A

SET

 

EXERCISE

 

TIME

L o c a t e y o u r n e a r e s t d e a le r a t :

POWER SYSTEMS, INC.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

F L A S H IN G G R E E N L E D =

N O U T IL IT Y S E N S E 4 F L A S H IN G R E D L E D S =

E X E R C IS E R N O T S E T

1.Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

2.Turn OFF the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker).

3.The unit will start, and the transfer switch will transfer to standby.

4.Run the unit for one hour at 25 percent load.

5.Run the unit for one hour at 50 percent load.

6.Run the unit for one hour at 75 percent load.

7.Run the unit for one hour at 100 percent load.

8.Turn ON the utility power supply to the transfer switch, which will allow the transfer switch to transfer back to utility power. The unit will con- tinue to run for one minute and then shut down.

9.Allow the unit to cool.

10.Drain the oil and remove the oil filter. Replace the oil filter according to Section 4.4, “Changing the Oil Filter”. Replace the oil with synthetic oil as recommended in Section 4.3, “Changing the Engine Oil”.

11.The generator is now ready for service.

3.2USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1)

‹3.2.1 “AUTO” POSITION

Selecting this switch position activates fully automatic system operation. It also permits starting and exercising of the engine every seven days with the exercise timer (see Section 3.6). This position also is used for remote starting, when it is set up.

‹3.2.2 “OFF” POSITION

This switch position shuts down the engine. This position also prevents automatic operation.

‹3.2.3 “MANUAL” POSITION

Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure.

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With the switch set to AUTO, the engine may crank and start at any time without warning. Such automatic starting normally occurs when utility power source voltage drops below a pre- set level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove both fuses before working on or around the generator or transfer switch. Then, place a “Do Not Operate” tag on the generator panel and on the transfer switch.

3.3AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

1.Make sure the transfer switch main contacts are set to their “Utility” position, i.e., loads connected to the utility power source (Figure 3.2).

2.Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2.

3.Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

4.Set the generator’s main circuit breaker to its ON (or closed) position.

With the preceding steps complete, the generator will start automatically when utility source voltage drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to Section 3.4, “Sequence of Automatic Operation.”

3.4SEQUENCE OF AUTOMATIC

OPERATION

The generator’s control panel houses a control logic circuit board. This board constantly monitors util- ity power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start. After the engine starts, the circuit board signals the transfer switch to acti- vate and connect load circuits to the standby power supply (load terminal lugs T1/T2 connect to terminal lugs E1/E2).

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Contents Installation Introduction Authorized Dealer LocationPost Installation Start-up Adjustments MaintenanceTroubleshooting Introduction Inside Front CoverGeneral Hazards Fire Hazards ‹ Standards IndexProtection Systems UNPACKING/INSPECTIONSystem SET LED Generator Gfci‹ 1.5.1 Generator Specifications‹ 1.5.2 Engine Reconfiguring the Fuel System Fuel Requirements RecommendationsFuel Consumption ‹ 1.8.1 7 KW, 410CC‹ 1.9.2 Transfer Switch Location‹ 1.9.1 Generator 2.1 7 kW, 12 kW and 15 kW UnitsBattery Installation BatteryBefore Initial START-UP Check Transfer Switch OperationElectrical Checks Generator Tests Under Load Checking Automatic OperationEngine Governor Adjustment Adjusting the Regulator Natural GAS only‹ 2.7.1 7 KW Units Voltage Regulator Adjustment ‹ 2.7.2 12 KW and 15 KW UnitsBREAK-IN Procedure Automatic Transfer OperationSequence of Automatic Operation ‹ 3.2.1 Auto Position‹ 3.5.2 Transfer Back to Utility Power Source Manual Transfer OperationSetting the Exercise Timer ‹ 3.7.1 LOW OIL Pressure Switch‹ 3.7.2 High Temperature Switch ‹ 3.7.3 OvercrankApproximate Crank Cycle Times Checking the Engine OIL Level‹ 3.7.4 Overspeed ‹ 4.3.2 OIL Change Procedure Changing the Engine OILChanging the OIL Filter ‹ 4.3.1 Engine OIL RecommendationsBattery Maintenance Spark PlugsAdjusting Valve Clearance Cooling SystemOUT of Service Procedure ‹ 4.12.1 Removal from Service‹ 4.12.2 Return to Service Corrosion ProtectionService Schedule SYSTEM/COMPONENT Procedure FrequencyTroubleshooting Guide Problem Cause CorrectionElectrical Data Customer Battery Utility Battery Charger Utility Connection BCR RED Exploded Views and Parts Lists Part NO. QTY Description Exploded Views and Parts Lists Part NO. QTY. Description 16B Sleeve 122 124 125 138 139 136135 KNOB, AIR Cleaner 45 30 1016 1519 QTY Exploded Views and Parts Lists QTY Description Exploded Views and Parts Lists PIN, Piston D20 Exploded Views and Parts Lists SCREW, Taptite M6-1.0X8 Yellow Chrome 7KW CASTING, Twin Regulator Housing Mounting Dimensions Air-cooled 7 kW, 12 kW and 15 kW Generators MANUFACTURER’S Emission Control System Warranty Coverage Your Warranty Rights and ObligationsPURCHASER’S/OWNER’S Warranty Responsibilities Emission Control System Warranty Emission Related Parts Include the FollowingWarranty Schedule Errata Sheet PRE Packaged Units only ASSEMBLY, Enclosure Base
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04674-2, 04675-3, 04673-2 specifications

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