Generac Power Systems 005054-1 Control Console Components, GTS Mode Operation, ‹ 3.2.4 5 AMP FUSE

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GTS Mode Operation

Section 3 - Operation

Guardian Liquid-cooled 25 kW Generator

GTS Mode Operation

When in GTS mode, the control board will respond as follows based on the generator AUTO/OFF/MANU- AL switch position.

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. Whe the two-wire start is removed the control board will immediately stop the generator.

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.

With switch set to AUTO, engine can crank‹3.2.2 FAULT INDICATOR LEDS DANGER

With switch set to AUTO, engine can crank

!and start suddenly without warning. Such automatic start up normally occurs when utili- ty 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 control console.

‹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

Overspeed/Engine Speed Signal Fault

High Coolant Temperature/Low Coolant Level

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

3.2CONTROL CONSOLE

COMPONENTS

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

Figure 3.1 - Home Standby Generator Panel

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

AUTO

OFF

MANUAL

SYSTEM READY

LOW BATTERY

LOW OIL PRESSURE

3.2CONTROL CONSOLELOW COOLANT LEVEL

Figure 3.1 - Home Standby Generator PanelHI COOLANT TEMPERATURE ‹3.2.3 15 AMP FUSE 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

‹3.2.4 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

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!

power from the PCB when it opens. This means the exercise timer will not be reset.

‹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.

‹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 SHOULD ATTEMPT INSTALLATIONOwner’s Manual Liquid-cooled, Prepackaged Standby GeneratorsINTRODUCTION AUTHORIZED SERVICE DEALER LOCATION‹ OPERATION AND MAINTENANCE ‹ HOW TO OBTAIN SERVICEGuardian Liquid-cooled 25 kW Generator Table of Contentsduring operation. Exercise care near running gen- erators GENERAL HAZARDSDespite the safe design of this generator Parts of the generator are rotating and/or hot‹ STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.4 GENERATOR AC CONNECTION SYSTEMS 1.2 TRANSFER SWITCH1.1 GENERATOR 1.3 AUTOMATIC SYSTEM OPERATIONFigure 1.4 - Low Oil Pressure Switch ‹ 1.7.1 LOW OIL PRESSURE SWITCH‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹ 1.7.3 LOW COOLANT LEVEL SWITCH1.8 UNPACKING 1.10 SPECIFICATIONS‹ 1.7.6 LOW BATTERY ‹ 1.8.1 UNPACKING PRECAUTIONS‹ 1.10.2 GENERATOR 1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 - Reconfigure the Fuel System 1.11 FUEL CONSUMPTION1.14 COOLANT RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1 STANDBY GENERATOR INSTALLATION 1.13 ENGINE OIL RECOMMENDATIONS‹ 2.1.2 OTHER PUBLISHED STANDARDS 2.3 GENERATOR MOUNTING AND SUPPORT2.4 BASIC STANDBY ELECTRIC SYSTEM 2.2 GENERATOR LOCATION2.7 GROUNDING THE GENERATOR 2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5 EMERGENCY CIRCUIT ISOLATION METHOD 2.6 TOTAL CIRCUIT ISOLATION METHODStandby generators installed with automatic 2.10 BATTERY INSTALLATIONPos2 OFF - Standard Prepackaged ATS Application ‹ 2.10.1 VENTED BATTERIES‹ 2.11.1 PRIOR TO INITIAL START-UP 3.1 ENGINEERED GTS TRANSFER SWITCH‹ 2.11.2 TRANSFER SWITCH 2.11 PREPARATION BEFORE START-UP3.2 CONTROL CONSOLE COMPONENTS ‹ 3.2.2 FAULT INDICATOR LEDS‹ 3.2.1 AUTO/OFF/MANUAL SWITCH ‹ 3.2.5 SET EXERCISE TIME SWITCH3.4 ENGINE GOVERNOR ADJUSTMENTS 3.3 MANUAL TRANSFER AND START-UP‹ 3.2.6 SYSTEM READY LED 3.7 WEEKLY EXERCISE CYCLE Figure 3.2 - Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.6 AUTOMATIC OPERATIONB. ONCE EVERY SIX MONTHS 3.8 CONTROL BOARD DIP SWITCH SETTINGS4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHSFigure 4.1 - Intake Manifold Installation 4.2 EXHAUST MANIFOLD PROCEDURE4.3 INTAKE MANIFOLD PROCEDURE 4.4 CYLINDER HEAD PROCEDURE4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM 4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM4.7 CHECKING FLUID LEVELS ‹ 4.8.9 INSPECT ENGINE GOVERNOR ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 - Setting the Spark Plug Gap ‹ 4.8.8 CHECK FAN BELT‹ 4.9.3 BATTERY MAINTENANCE 4.9 MISCELLANEOUS MAINTENANCE‹ 4.9.1 CLEANING THE GENERATOR ‹ 4.9.2 BATTERYRemove the negative battery cable 4.10 SCHEDULED MAINTENANCEService Maintenance Interval Information Turn off the battery charger turn OFF utility supply to ATSMaintenance LevelTasks Maintenance CORRECTION TROUBLESHOOTING POINTSPROBLEM CAUSEGuardian Liquid-cooled 25 kW Generator Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F1411 26 Generac Power Systems, IncSection 7 - Electrical Data Section 7 - Electrical Data 28 Generac Power Systems, Inc Section 7 - Electrical Data 30 Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0E9982-BSection 7 - Electrical Data 32 Generac Power Systems, Inc Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-BSection 7 - Electrical Data BLOCK ENGINE HARNESS WIRE34 Generac Power Systems, Inc MOUNTDESCRIPTION FASTENER TO SECURE PANEL FOR ACCESSGROUND WIRE COVER CABLEEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc DESCRIPTION TO RADIATOR 42 Generac Power Systems, IncGuardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-E STEPPER MOTOR UNITS ONLYBRKT,D.C. ALTERNATORMACHINED SOURCE GENERAC-BOSCH GOVGASKET, 2.5L FORD EXHAUST MAN SERPENTINE BELT - 41 3/8 LENGTH44 Generac Power Systems, Inc 0E1028A I/NTO ENGINE COVERFuel System - Drawing No. 0E9980-D Alternator - Drawing No. 0E8660-C LOCKTIGHTLEADS 46 Generac Power Systems, IncCONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER ROTOR REPLACEMENT PARTSROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD STR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORDSCREW HHC M8-1.25 X 60 G8.8 FT 48 Generac Power Systems, IncWITH TIE WRAP AS SHOWN SECURE WIRE HARNESSITEM 13 NEOPRENE COATINGHOSE, UPPER RADIATOR 174MM 50 Generac Power Systems, Inc1024 SUPPORT,RADIATOR 2.5L FORDInstallation Diagram - Drawing No. 0F1020-A Section 9 - Installation DiagramCALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYGENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING