Generac Power Systems 005054-1 Fuel Consumption, Reconfiguring The Fuel System For Lp Vapor

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‹ 1.10.2 GENERATOR

Section 1 — General Information

Guardian Liquid-cooled 25 kW Generator

‹ 1.10.2 GENERATOR

 

 

Single-phase

Single-phase

Single-phase

 

 

Model

005040-0

005053-0

005054-0

 

 

Rated Max. Cont.

*25

20

15

 

 

AC Power Output (kW)

 

 

 

 

 

Rated voltage (volts)

 

120/240

120/240

 

 

No. of Rotor Poles

4

4

4

 

 

Driven Speed of Rotor

1800

1800

1800

 

 

Rotor Excitation System

Direct excited brush type

Direct excited brush type

Direct excited brush type

 

 

Type of Stator

4 Wire

4 Wire

4 Wire

 

 

Rotor Insulation

Class F

Class F

Class F

 

 

Stator Insulation

Class H

Class H

Class H

 

 

 

 

 

 

 

*Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an addi- tional 1% for each 10°F above 60°F. Maximum output power of the generator is limited by maximum engine power.

1.11 FUEL CONSUMPTION

25 kW Models

Using Natural Gas

........................................441 cu. ft. per hour

Using LP Gas

175 cubic ft.(4.8 gal.) per hour

Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

Fuel consumption is given at rated maximum con- tinuous power output when using natural gas rated at 1000 Btu per cubic foot; or LP gas rated 2520 Btu per cubic foot. Actual fuel consumption obtained may vary depending on such variables as applied load, ambient temperature, engine condi- tions and other environmental factors.

5.Install brass hose fitting into Port 2.

6.Install pipe plug into Port 1.

7.Connect carburetor gas hose to brass fitting.

8.Tighten all clamps and plugs.

9.Make sure fuel supply is of the proper pressure and type for configuration.

10.Move dip switch position 4 on the control board to the off position (LP vapor, see Figure 3.2 and Section 3.8).

11.Reverse the procedure to convert back to natural gas.

Figure 1.8 — Reconfigure the Fuel System

 

Port 1

 

Port 2

 

FUEL HOSE

FUEL HOSE

 

PLUG

BRASS HOSE

BRASS HOSE

PLUG

FITTING

FITTING

 

 

OUT

OUT

 

 

PORT 1

PORT 2

 

FUEL INLET

1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR

NOTE:

All models are configured for natural gas from the factory.

To reconfigure the fuel system from NG to LP vapor, follow these steps:

1.Turn the main gas supply off.

2.Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure 1.8).

3.Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator.

4.Remove pipe plug from Port 2.

NG FUEL SYSTEM

LP FUEL SYSTEM

NOTE:

Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made.

1.11 FUEL CONSUMPTIONFigure 1.8 — Reconfigure the Fuel System DANGER

Serious injury or damage may occur if not

!configured properly. Please consult an author- ized Generac Service Dealer with any ques- tions.

Generac® Power Systems, Inc. 7

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Contents Owner’s Manual SHOULD ATTEMPT INSTALLATIONLiquid-cooled, Prepackaged Standby Generators This manual should remain with the unit‹ OPERATION AND MAINTENANCE AUTHORIZED SERVICE DEALER LOCATION‹ HOW TO OBTAIN SERVICE INTRODUCTIONGuardian Liquid-cooled 25 kW Generator Table of ContentsDespite the safe design of this generator GENERAL HAZARDSParts of the generator are rotating and/or hot during operation. Exercise care near running gen- eratorsFIRE HAZARDS ELECTRICAL HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.1 GENERATOR 1.2 TRANSFER SWITCH1.3 AUTOMATIC SYSTEM OPERATION 1.4 GENERATOR AC CONNECTION SYSTEMS‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹ 1.7.1 LOW OIL PRESSURE SWITCH‹ 1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch‹ 1.7.6 LOW BATTERY 1.10 SPECIFICATIONS‹ 1.8.1 UNPACKING PRECAUTIONS 1.8 UNPACKINGFigure 1.8 - Reconfigure the Fuel System 1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR2.1 STANDBY GENERATOR INSTALLATION 1.15 BEFORE INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.4 BASIC STANDBY ELECTRIC SYSTEM 2.3 GENERATOR MOUNTING AND SUPPORT2.2 GENERATOR LOCATION ‹ 2.1.2 OTHER PUBLISHED STANDARDS2.5 EMERGENCY CIRCUIT ISOLATION METHOD 2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH2.6 TOTAL CIRCUIT ISOLATION METHOD 2.7 GROUNDING THE GENERATORPos2 OFF - Standard Prepackaged ATS Application 2.10 BATTERY INSTALLATION‹ 2.10.1 VENTED BATTERIES Standby generators installed with automatic‹ 2.11.2 TRANSFER SWITCH 3.1 ENGINEERED GTS TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹ 2.11.1 PRIOR TO INITIAL START-UP‹ 3.2.1 AUTO/OFF/MANUAL SWITCH ‹ 3.2.2 FAULT INDICATOR LEDS‹ 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 3.3 - “Set Exercise Time” Switch Figure 3.2 - Engine Governor Adjustment3.6 AUTOMATIC OPERATION 3.7 WEEKLY EXERCISE CYCLE4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES 3.8 CONTROL BOARD DIP SWITCH SETTINGSA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHS4.3 INTAKE MANIFOLD PROCEDURE 4.2 EXHAUST 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 Figure 4.4 - Setting the Spark Plug Gap ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANER‹ 4.8.8 CHECK FAN BELT ‹ 4.8.9 INSPECT ENGINE GOVERNOR‹ 4.9.1 CLEANING THE GENERATOR 4.9 MISCELLANEOUS MAINTENANCE‹ 4.9.2 BATTERY ‹ 4.9.3 BATTERY MAINTENANCEService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCETurn off the battery charger turn OFF utility supply to ATS Remove the negative battery cableMaintenance LevelTasks Maintenance PROBLEM TROUBLESHOOTING POINTSCAUSE CORRECTIONGuardian 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 34 Generac Power Systems, Inc HARNESS WIREMOUNT BLOCK ENGINEDESCRIPTION GROUND WIRE PANEL FOR ACCESSCOVER 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 Guardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-E 42 Generac Power Systems, IncSTEPPER MOTOR UNITS ONLY TO RADIATORGASKET, 2.5L FORD EXHAUST MAN SOURCE GENERAC-BOSCH GOVSERPENTINE BELT - 41 3/8 LENGTH BRKT,D.C. ALTERNATORMACHINEDTO ENGINE 0E1028A I/NCOVER 44 Generac Power Systems, IncSection 8 - Exploded Views and Parts LEADS LOCKTIGHT46 Generac Power Systems, Inc Alternator - Drawing No. 0E8660-CROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD ROTOR REPLACEMENT PARTSSTR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD CONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLERSCREW HHC M8-1.25 X 60 G8.8 FT 48 Generac Power Systems, IncITEM 13 NEOPRENE SECURE WIRE HARNESSCOATING WITH TIE WRAP AS SHOWN1024 50 Generac Power Systems, IncSUPPORT,RADIATOR 2.5L FORD HOSE, UPPER RADIATOR 174MMInstallation Diagram - Drawing No. 0F1020-A Section 9 - Installation DiagramMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYWARRANTY SCHEDULE GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI