Generac Power Systems 005053-1, 005054-0 Generator, Automatic System Operation, Transfer Switch

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1.1GENERATOR

Section 1 - General Information

Guardian Liquid-cooled 25 kW Generator

1.1GENERATOR

This equipment is a liquid-cooled, engine-driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. Use this generator as a source of electrical power for the oper- ation of 120 and/or 240VAC, single-phase loads.

These models are available. They are rated as fol- lows:

Model 005040-0:Provides 25,000 watts (25 kW) of single-phase power.

Model 005053-0:Provides 20,000 watts (20 kW) of single-phase power.

Model 005054-0:Provides 15,000 watts (15 kW) of single-phase power.

Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and cor- rosive vapors.

If a transfer switch is not included, one may be pur- chased separately from a Generac Authorized Dealer.

1.3AUTOMATIC SYSTEM OPERATION

When this generator, along with a transfer switch, has been installed and interconnected, a circuit board in the generator panel constantly monitors utility power source voltage. Should that voltage drop below a pre- set value, and remain at such a low state for a preset amount of time, the generator cranks and starts. After the generator starts, the transfer switch transfers load circuits so the generator can power them.

When utility source voltage has been restored, the switch re-transfers back to the utility source voltage and the generator then shuts down.

Please reference the transfer switch manual for spe- cific information.

If this generator is used to power electrical

!load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 701). Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power work- ers due to backfeed of electrical energy.

1.2TRANSFER SWITCH

This generator system is intended to be used with a matched automatic transfer. It may be supplied in either a NEMA 1 enclosure or a NEMA 3R enclosure. The NEMA 1 enclosure is intended for indoor use only. The NEMA 3R enclosure is weather proof and can be used indoors or outdoors. Follow these rules:

Install the transfer switch on a firm, sturdy sup- porting structure.

To prevent switch distortion, level the switch if nec- essary. This can be done by placing washers between the switch enclosure and the mounting surface.

Never install the switch where water or any corro- sive substance might drip onto the enclosure.

1.4GENERATOR AC CONNECTION

SYSTEMS

The generator was shipped from the factory with its stator AC output leads connected in a single-phase, 3-wire generator AC connection system (Figure 1.1). The stator assembly in this system consists of a pair of stationary windings, with two leads brought out of each winding. Each single winding can supply 120 VAC, 60 Hertz. When the two windings are connected in series, a 240 VAC, 60 Hertz AC output results. Typically the two “hot” leads in the circuit are Wires No. 11 and 44. The “Neutral” leads are the junction of Wires 22 and 33.

Figure 1.1 - Generator AC Connection System

0

NEUTRAL

Figure 1.2 - Main Circuit Breaker

Model

Rating

Phase

Actual Current

C/B Rating*

% over rating

Circuit Breaker

005040-0

25,000 W

1

104.2 A

125 A

120%

125A BQ2

005053-0

20,000 W

1

83.3 A

100 A

120%

100A BQ2

005054-0

15,000

1

62.5

70 A

120%

70A BQ2

 

 

 

* Amp Rating of C/B structured under model.

 

 

4 Generac® Power Systems, Inc.

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Contents Liquid-cooled, Prepackaged Standby Generators SHOULD ATTEMPT INSTALLATIONOwner’s Manual This manual should remain with the unit‹ HOW TO OBTAIN SERVICE AUTHORIZED SERVICE DEALER LOCATION‹ OPERATION AND MAINTENANCE INTRODUCTIONTable of Contents Guardian Liquid-cooled 25 kW GeneratorParts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator during operation. Exercise care near running gen- eratorsEXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS ‹ STANDARDS INDEX1.3 AUTOMATIC SYSTEM OPERATION 1.2 TRANSFER SWITCH1.1 GENERATOR 1.4 GENERATOR AC CONNECTION SYSTEMS‹ 1.7.3 LOW COOLANT LEVEL SWITCH ‹ 1.7.1 LOW OIL PRESSURE SWITCH‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH Figure 1.4 - Low Oil Pressure Switch‹ 1.8.1 UNPACKING PRECAUTIONS 1.10 SPECIFICATIONS‹ 1.7.6 LOW BATTERY 1.8 UNPACKING1.11 FUEL CONSUMPTION 1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 - Reconfigure the Fuel System ‹ 1.10.2 GENERATOR1.13 ENGINE OIL RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1 STANDBY GENERATOR INSTALLATION 1.14 COOLANT RECOMMENDATIONS2.2 GENERATOR LOCATION 2.3 GENERATOR MOUNTING AND SUPPORT2.4 BASIC STANDBY ELECTRIC SYSTEM ‹ 2.1.2 OTHER PUBLISHED STANDARDS2.6 TOTAL CIRCUIT ISOLATION METHOD 2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5 EMERGENCY CIRCUIT ISOLATION METHOD 2.7 GROUNDING THE GENERATOR‹ 2.10.1 VENTED BATTERIES 2.10 BATTERY INSTALLATIONPos2 OFF - Standard Prepackaged ATS Application Standby generators installed with automatic2.11 PREPARATION BEFORE START-UP 3.1 ENGINEERED GTS TRANSFER SWITCH‹ 2.11.2 TRANSFER SWITCH ‹ 2.11.1 PRIOR TO INITIAL START-UP‹ 3.2.5 SET EXERCISE TIME SWITCH ‹ 3.2.2 FAULT INDICATOR LEDS‹ 3.2.1 AUTO/OFF/MANUAL SWITCH 3.2 CONTROL CONSOLE COMPONENTS3.4 ENGINE GOVERNOR ADJUSTMENTS 3.3 MANUAL TRANSFER AND START-UP‹ 3.2.6 SYSTEM READY LED 3.6 AUTOMATIC OPERATION Figure 3.2 - Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.7 WEEKLY EXERCISE CYCLEA. EVERY THREE MONTHS 3.8 CONTROL BOARD DIP SWITCH SETTINGS4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES B. ONCE EVERY SIX MONTHS4.4 CYLINDER HEAD PROCEDURE 4.2 EXHAUST MANIFOLD PROCEDURE4.3 INTAKE MANIFOLD 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 ‹ 4.8.8 CHECK FAN BELT ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 - Setting the Spark Plug Gap ‹ 4.8.9 INSPECT ENGINE GOVERNOR‹ 4.9.2 BATTERY 4.9 MISCELLANEOUS MAINTENANCE‹ 4.9.1 CLEANING THE GENERATOR ‹ 4.9.3 BATTERY MAINTENANCETurn off the battery charger turn OFF utility supply to ATS 4.10 SCHEDULED MAINTENANCEService Maintenance Interval Information Remove the negative battery cableMaintenance LevelTasks Maintenance CAUSE TROUBLESHOOTING POINTSPROBLEM 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 MOUNT HARNESS WIRE34 Generac Power Systems, Inc BLOCK ENGINEDESCRIPTION COVER CABLE PANEL FOR ACCESSGROUND WIRE FASTENER TO SECUREEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc DESCRIPTION STEPPER MOTOR UNITS ONLY 42 Generac Power Systems, IncGuardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-E TO RADIATORSERPENTINE BELT - 41 3/8 LENGTH SOURCE GENERAC-BOSCH GOVGASKET, 2.5L FORD EXHAUST MAN BRKT,D.C. ALTERNATORMACHINEDCOVER 0E1028A I/NTO ENGINE 44 Generac Power Systems, IncGuardian Liquid-cooled 25 kW Generator 46 Generac Power Systems, Inc LOCKTIGHTLEADS Alternator - Drawing No. 0E8660-CSTR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD ROTOR REPLACEMENT PARTSROTOR 390 30KW 1P DIRECT HSB 3.0L 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 FTCOATING SECURE WIRE HARNESSITEM 13 NEOPRENE WITH TIE WRAP AS SHOWNSUPPORT,RADIATOR 2.5L FORD 50 Generac Power Systems, Inc1024 HOSE, UPPER RADIATOR 174MMSection 9 - Installation Diagram Installation Diagram - Drawing No. 0F1020-APURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANWARRANTY SCHEDULE GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI