Generac Power Systems 005040-1 Manual Transfer And Start-Up, Engine Governor Adjustments

Page 16
‹3.2.6 SYSTEM READY LED

Section 3 - Operation

Guardian Liquid-cooled 25 kW Generator

 

Condition

System

Low

Low

High

Over

 

Over

Switch Position

 

 

 

Ready (Green)

Bat (Red)

Oil (Red)

Temp (Red)

Speed (Red)

 

Crank (Red)

Manual

Auto

Off

 

 

Generator Switch is

OFF

X

OFF

OFF

OFF

 

OFF

 

 

O

 

 

in the OFF Mode.

 

 

 

 

 

 

 

 

 

 

 

 

System Ready for

ON

X

OFF

OFF

OFF

 

OFF

 

O

 

 

 

Automatic Start

 

 

 

 

 

 

 

 

 

 

 

 

Generator Switch is

OFF

X

OFF

OFF

OFF

 

OFF

O

 

 

 

 

in the MANUAL Mode

 

 

 

 

 

 

 

 

 

 

 

 

Weekly Exerciser

X

Flashing

Flashing

Flashing

Flashing

 

Flashing

O

O

O

 

 

is not set

 

(-----------------------------------

1 sec rate

---------------------------------------

)

 

 

 

 

 

Battery Voltage <12V

X

ON

 

 

 

 

 

O

O

O

 

 

for >1 minute

 

(Non-latching)

 

 

 

 

 

 

 

 

 

 

Battery Voltage <6V

X

ON

 

 

 

 

 

O

O

 

 

 

Unit Shutdown due

OFF

X

ON

 

 

 

 

O

O

 

 

 

to Low Oil Pressure

 

 

 

 

 

 

 

 

 

 

 

 

Unit Shutdown due

OFF

X

 

ON

 

 

 

O

O

 

 

 

to High Temperature

 

 

 

 

 

 

 

 

 

 

 

 

Unit Shutdown due

OFF

X

 

 

ON

 

 

O

O

 

 

 

to Engine Overspeed

 

 

 

 

 

 

 

 

 

 

 

 

Unit Failed to Start

OFF

X

 

 

 

 

ON

O

O

 

 

 

during it’s Crank Cycle

 

 

 

 

 

 

 

 

 

 

 

 

Utility Voltage is

Flashing

X

 

 

 

 

 

O

O

 

 

 

<45% of Nominal

1 sec rate

 

 

 

 

 

 

 

 

 

 

 

Engine Speed Signal Fault

OFF

X

 

 

Flashing

 

 

O

O

 

 

 

Control Board is

OFF

X

The five RED LED’s will turn on one at a time

 

O

O

O

 

 

in GTS Mode

 

 

 

 

 

 

 

 

 

 

 

X = indicates that the LED can be ON or OFF depending on the operating conditions.

‹3.2.6 SYSTEM READY LED

The System Ready LED (green) has two main pro- 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).

14 Generac® Power Systems, Inc.

3.3MANUAL 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.

3.4ENGINE GOVERNOR

ADJUSTMENTS

Engine speed governing is also controlled by the engine control board. The engine governor has been set by the factory during final testing of the generator and should not be adjusted.

If, however, adjustments are necessary, the following procedure should be followed (Figure 3.2 and Section 3.8):

1.Move dip switch 8 to the test mode (OFF posi- tion).

2.Set all three potentiometers (pots) fully counter- clockwise.

Image 16
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 COMPONENTS3.3 MANUAL TRANSFER AND START-UP 3.4 ENGINE GOVERNOR ADJUSTMENTS‹ 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 Installation4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM 4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.7 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 cableLevel MaintenanceTasks Maintenance TROUBLESHOOTING POINTS PROBLEMCAUSE CORRECTIONGenerac Power Systems, Inc 26 Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F1411Section 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