Generac Power Systems 005040-2 Control Console Components, ‹ 3.2.2 Fault Indicator Leds

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Section 3 - Operation

Guardian Liquid-cooled 25 kW Generator

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 posi- tion.

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.

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.

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.

‹3.2.2 FAULT INDICATOR LEDS

(SEE CHART ON PAGE 14)

These LEDs turn ON when one or more of the follow- ing engine faults occurs and the engine shuts down.

Low Oil Pressure

Overcrank

Low Battery

3.2CONTROL CONSOLE

COMPONENTS

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

Overspeed/Engine Speed Signal Fault

High Coolant Temperature/Low Coolant Level

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

Figure 3.1 - Home Standby Generator Panel

‹3.2.3 15 AMP FUSE

AUTO

OFF

MANUAL

SYSTEM READY

LOW BATTERY

LOW OIL PRESSURE

LOW COOLANT LEVEL

HI COOLANT TEMPERATURE OVER SPEED

OVER CRANK

LED INDICATORS:

0F0653

OFF

ON

SET

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. 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.

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.

ATTENTION: POUR L'ALIMENTATION DE RESERVE, CONNECTER LA SORTIE DE LA ICE A UN COMMUTATEUR DE CALIBRE APPROPRIE, CONFO

CANADIEN DE L'ECTRICITE, PREMIERE PARTIE.

WARNING

N AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE. T

INJURY REMOVE NEGATIVE BATTERY CABLE PRIOR TO SE

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

‹3.2.4 5 AMP FUSE

This fuse protects the battery charger against electri- cal overload and is located inside the control panel. If

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 DETAILS)

USE OF SYNTHETIC OIL IS RECOMMENDED

WARNING

THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR

OUTDOOR INSTALLATION ONLY!

the fuse needs to be replaced, use only an identical 5- amp replacement fuse (type ATO).

NOTE:

‹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.

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

‹3.2.5 SET EXERCISE TIME SWITCH

This switch allows programming the generator to start and exercise automatically. “See Weekly Exercise Cycle.”

Generac® Power Systems, Inc. 13

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Contents This manual should remain with the unit Introduction Authorized Service Dealer Location‹ Operation and Maintenance ‹ HOW to Obtain ServiceTable of Contents General Hazards ‹ Standards Index Fire HazardsGenerator AC Connection Systems Transfer SwitchGenerator Automatic System OperationGenerator Fuel System ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.2 High Coolant Temperature Switch ‹ 1.7.3 LOW Coolant Level SwitchSpecifications UnpackingLifting the Generator Fuel Consumption Engine OIL Recommendations‹ 1.10.2 Generator Before Installation Coolant Recommendations‹ 2.1.1 Nfpa Standards Emergency Circuit Isolation Method Basic Standby Electric SystemGenerator Location Generator Mounting SupportGrounding the Generator Using AN Engineered GTS Transfer SwitchTotal Circuit Isolation Method Generator AC Neutral ConnectionsBattery Installation Preparation Before START-UP‹ 2.10.1 Vented Batteries Engineered GTS Transfer Switch Control Console Components ‹ 3.2.2 Fault Indicator Leds‹ 3.2.1 AUTO/OFF/MANUAL Switch ‹ 3.2.5 SET Exercise Time Switch‹ 3.2.6 System Ready LED Manual Transfer START-UP Engine Governor AdjustmentsAutomatic Operation Weekly Exercise CycleRetransfer and Shutdown Control Board DIP Switch Settings Cooling System Exhaust Manifold ProcedureIntake Manifold Procedure Cylinder Head ProcedureChecking Fluid Levels Overload Protection for Engine DC Electrical System‹ 4.8.10 Changing Engine OIL ‹ 4.8.11 Changing the Engine AIR Cleaner‹ 4.8.8 Check FAN Belt ‹ 4.8.9 Inspect Engine Governor‹ 4.9.4 Battery Replacement Miscellaneous Maintenance‹ 4.9.1 Cleaning the Generator ‹ 4.9.3 Battery MaintenanceService Maintenance Interval Information Scheduled MaintenanceLevel Maintenance Level Problem Cause Correction Troubleshooting PointsGuardian Liquid-cooled 25 kW Generator Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Mount Boot Battery Cable Hold Down Battery 2.5L FordBattery Post Cover Black Battery Post Cover REDPanel for Access Roof ACO & STD Encl 2.5L Assy Wire 14AWG 7.5 #0 GRN/YELAssembly Cover Access Cover Access GEN54 36 Screw Hhtt M5-0.8 X 12 BP Assy 2A 12V UL BatterySwitch ROC Dpst 125V SPD Assy Wire Fuse HolderGenerac Power Systems, Inc Ctrl PNL TOP 2.5L Ford STL Only Motor Units NUT HEX M10-1.5 G8 YEL CHR Tank Coolant RecoveryEngine 2.5L Ford STARTER, 12 VoltTo Engine Bracket Fuel Regulator Body Carburetor AssemblyCover AIR Cleaner GASKET, AIR Cleaner AdapterLocktight Rotor 39030AD1 HSB Tecum Rotor 390 15KW 1P Direct HSB 2.5L FordRotor 390 20KW 1P Direct HSB 2.5L Ford Rotor 390 25KW 1P Direct HSB 2.5L FordSaddle 2 Inch Pipe Muffler OUTPipe Exhaust 2.5L Ford Muffler 2.5L FordHarn GOV 2.5L Ford Housing Governor ConnectorCover Connector Housing ASM Motor StepperVENTURI, 16 FAN 2.5L Ford Radiator Support Radiator 2.5L AL TALRADIATOR, 2.5L Ford HOSE, 2.5L Ford LowerInstallation Diagram Your Warranty Rights and Obligations MANUFACTURER’S Emission Control System Warranty CoveragePURCHASER’S/OWNER’S Warranty Responsibilities Emission Related Parts Include the Following Emission Control System WarrantyWarranty Schedule