Generac Power Systems 005053-1 Emergency Circuit Isolation Method, Total Circuit Isolation Method

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2.5EMERGENCY CIRCUIT ISOLATION

Section 2 — Installation

Guardian Liquid-cooled 25 kW Generator

2.5EMERGENCY CIRCUIT ISOLATION

METHOD

This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only crit- ical loads, within the wattage/amperage capacity, dur- ing utility power outages, consider using the emer- gency circuit isolation method.

Critical electrical loads are grouped together and wired into a separate “Emergency Distribution Panel.” Load circuits powered by that panel are with- in the wattage/amperage capacity of the generator set. The transfer switch must meet the following require- ments:

It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit.

It must be installed between the building’s main distribution panel and the emergency distribution panel.

2.6TOTAL CIRCUIT ISOLATION

METHOD

When a generator capable of powering all electrical loads in the circuit is to be installed, the “Total Circuit Isolation Method” may be used. The following apply to the transfer switch in this type of system.

Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service.

The transfer switch is installed between the utility service entrance and the building distribution panel.

2.7GROUNDING THE GENERATOR

The National Electrical Code requires the frame and external electrically conductive parts of this equip- ment to be properly connected to an approved earth ground and/or grounding rods. For that purpose, a GROUND LUG (Figure 2.2) is provided on the gener- ator mounting base. Consult a qualified electrician for grounding requirements in the area. Grounding procedures must meet local regulations.

2.6TOTAL CIRCUIT ISOLATION2.7GROUNDING THE GENERATOR DANGER

Do not connect the ground wire to any pipe that carries a flammable or explosive substance

– FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi- tion in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.

Figure 2.2 – Generator Grounding Lug (typical)

2.8GENERATOR AC NEUTRAL

CONNECTIONS

Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. The actual result depends on the electrical characteristics of the particular installed generator.

2.9USING AN ENGINEERED “GTS”

TRANSFER SWITCH

When required, the pre-packaged standby generator can be installed with an engineered Generac “GTS” type automatic transfer switch.

In this application, the engineered GTS is responsi- ble for utility sensing, weekly exercising, and load transferring.

Position two of the eight-position dip switch is used to turn over this control to the engineered GTS.

In order for the battery charger to work, it is neces- sary to provide a fused 240 VAC utility source to the N1 and N2 terminals in the control panel.

Pos2 ON — Engineered GTS Application

The control board will NOT monitor utility.

The control board will NOT perform a weekly exer- cise. (The five red LEDs will flash one at a time in this mode.)

The control board will NOT activate the transfer output.

The control board WILL monitor all engine condi- tions and shut down on all the faults listed in this document.

10 Generac® Power Systems, Inc.

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Contents SHOULD ATTEMPT INSTALLATION Owner’s ManualLiquid-cooled, Prepackaged Standby Generators This manual should remain with the unitAUTHORIZED SERVICE DEALER LOCATION ‹ OPERATION AND MAINTENANCE‹ HOW TO OBTAIN SERVICE INTRODUCTIONTable of Contents Guardian Liquid-cooled 25 kW GeneratorGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot during operation. Exercise care near running gen- eratorsELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.2 TRANSFER SWITCH 1.1 GENERATOR1.3 AUTOMATIC SYSTEM OPERATION 1.4 GENERATOR AC CONNECTION SYSTEMS‹ 1.7.1 LOW OIL PRESSURE SWITCH ‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH‹ 1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch1.10 SPECIFICATIONS ‹ 1.7.6 LOW BATTERY‹ 1.8.1 UNPACKING PRECAUTIONS 1.8 UNPACKING1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR Figure 1.8 - Reconfigure the Fuel System1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR1.15 BEFORE INSTALLATION 2.1 STANDBY GENERATOR INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.3 GENERATOR MOUNTING AND SUPPORT 2.4 BASIC STANDBY ELECTRIC SYSTEM2.2 GENERATOR LOCATION ‹ 2.1.2 OTHER PUBLISHED STANDARDS2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH 2.5 EMERGENCY CIRCUIT ISOLATION METHOD2.6 TOTAL CIRCUIT ISOLATION METHOD 2.7 GROUNDING THE GENERATOR2.10 BATTERY INSTALLATION Pos2 OFF - Standard Prepackaged ATS Application‹ 2.10.1 VENTED BATTERIES Standby generators installed with automatic3.1 ENGINEERED GTS TRANSFER SWITCH ‹ 2.11.2 TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹ 2.11.1 PRIOR TO INITIAL START-UP‹ 3.2.2 FAULT INDICATOR LEDS ‹ 3.2.1 AUTO/OFF/MANUAL SWITCH‹ 3.2.5 SET EXERCISE TIME SWITCH 3.2 CONTROL CONSOLE COMPONENTS3.4 ENGINE GOVERNOR ADJUSTMENTS 3.3 MANUAL TRANSFER AND START-UP‹ 3.2.6 SYSTEM READY LED Figure 3.2 - Engine Governor Adjustment Figure 3.3 - “Set Exercise Time” Switch3.6 AUTOMATIC OPERATION 3.7 WEEKLY EXERCISE CYCLE3.8 CONTROL BOARD DIP SWITCH SETTINGS 4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIESA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHS4.2 EXHAUST MANIFOLD PROCEDURE 4.3 INTAKE MANIFOLD PROCEDURE4.4 CYLINDER HEAD PROCEDURE Figure 4.1 - Intake Manifold Installation4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM 4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM4.7 CHECKING FLUID LEVELS ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANER Figure 4.4 - Setting the Spark Plug Gap‹ 4.8.8 CHECK FAN BELT ‹ 4.8.9 INSPECT ENGINE GOVERNOR4.9 MISCELLANEOUS MAINTENANCE ‹ 4.9.1 CLEANING THE GENERATOR‹ 4.9.2 BATTERY ‹ 4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationTurn off the battery charger turn OFF utility supply to ATS Remove the negative battery cableMaintenance LevelTasks Maintenance TROUBLESHOOTING POINTS PROBLEMCAUSE CORRECTIONGenerac Power Systems, Inc Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F1411 26 Generac Power Systems, IncSection 7 - Electrical Data Generac Power Systems, Inc 28 Generac Power Systems, Inc Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0E9982-B 30 Generac Power Systems, IncGenerac Power Systems, Inc Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-B 32 Generac Power Systems, IncGenerac Power Systems, Inc HARNESS WIRE 34 Generac Power Systems, IncMOUNT BLOCK ENGINEDESCRIPTION PANEL FOR ACCESS GROUND WIRECOVER CABLE FASTENER TO SECUREEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc DESCRIPTION 42 Generac Power Systems, Inc Guardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-ESTEPPER MOTOR UNITS ONLY TO RADIATORSOURCE GENERAC-BOSCH GOV GASKET, 2.5L FORD EXHAUST MANSERPENTINE BELT - 41 3/8 LENGTH BRKT,D.C. ALTERNATORMACHINED0E1028A I/N TO ENGINECOVER 44 Generac Power Systems, IncDESCRIPTION LOCKTIGHT LEADS46 Generac Power Systems, Inc Alternator - Drawing No. 0E8660-CROTOR REPLACEMENT PARTS ROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORDSTR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD CONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER48 Generac Power Systems, Inc SCREW HHC M8-1.25 X 60 G8.8 FTSECURE WIRE HARNESS ITEM 13 NEOPRENECOATING WITH TIE WRAP AS SHOWN50 Generac Power Systems, Inc 1024SUPPORT,RADIATOR 2.5L FORD HOSE, UPPER RADIATOR 174MMSection 9 - Installation Diagram Installation Diagram - Drawing No. 0F1020-AYOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGEPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGGENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI