Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 Danger

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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 SERVICEINTRODUCTION Table of ContentsGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot ‹STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.4GENERATOR AC CONNECTION SYSTEMS 1.2TRANSFER SWITCH1.1GENERATOR 1.3AUTOMATIC 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 SWITCH1.8UNPACKING 1.10 SPECIFICATIONS‹1.7.6 LOW BATTERY ‹1.8.1 UNPACKING PRECAUTIONS‹ 1.10.2 GENERATOR 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 — Reconfigure the Fuel System 1.11 FUEL CONSUMPTION1.14 COOLANT RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1STANDBY GENERATOR INSTALLATION 1.13 ENGINE OIL RECOMMENDATIONS‹2.1.2 OTHER PUBLISHED STANDARDS 2.3GENERATOR MOUNTING AND SUPPORT2.4BASIC STANDBY ELECTRIC SYSTEM 2.2GENERATOR LOCATION2.7GROUNDING THE GENERATOR 2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.6TOTAL CIRCUIT ISOLATION METHODStandby generators installed with automatic 2.10BATTERY INSTALLATIONPos2 OFF — Standard Prepackaged ATS Application ‹2.10.1 VENTED BATTERIES‹2.11.1 PRIOR TO INITIAL START-UP 3.1ENGINEERED GTS TRANSFER SWITCH‹2.11.2 TRANSFER SWITCH 2.11 PREPARATION BEFORE START-UP3.2CONTROL CONSOLE COMPONENTS ‹3.2.2 FAULT INDICATOR LEDS‹3.2.1 AUTO/OFF/MANUAL SWITCH ‹3.2.5 SET EXERCISE TIME SWITCH3.4ENGINE GOVERNOR ADJUSTMENTS 3.3MANUAL TRANSFER AND START-UP‹3.2.6 SYSTEM READY LED 3.7WEEKLY EXERCISE CYCLE Figure 3.2 — Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.6AUTOMATIC OPERATIONC. ONCE ANNUALLY 3.8CONTROL BOARD DIP SWITCH SETTINGSA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHSFigure 4.1 — Intake Manifold Installation 4.2EXHAUST MANIFOLD PROCEDURE4.3INTAKE MANIFOLD PROCEDURE 4.4CYLINDER HEAD PROCEDURE4.7CHECKING FLUID LEVELS 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.6OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM‹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 4.9MISCELLANEOUS MAINTENANCE‹4.9.1 CLEANING THE GENERATOR ‹4.9.2 BATTERYService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCEMaintenance LevelTasks Maintenance CORRECTION TROUBLESHOOTING POINTSPROBLEM CAUSESection 6 — Notes Section 7 - Electrical Data 26 Generac Power Systems, IncSection 7 - Electrical Data 28 Generac Power Systems, Inc Section 7 - Electrical Data 30 Generac Power Systems, Inc Section 7 - Electrical Data 32 Generac Power Systems, Inc Section 7 - Electrical Data MOUNT ITEM PART NODESCRIPTION 31 7 11 Enclosure — Drawing No. 0E9720-D 54 36 30 0C2267 40 Generac Power Systems, Inc 0C2267 Engine — Drawing No. 0E9918-E 42 Generac Power Systems, Inc0E9909 0E1028A I/N 0E8456 LOCKTIGHT 0F1659A Muffler — Drawing No. 0F2930-B Stepper Motor — Drawing No. 0E9979-C Radiator — Drawing No. 0E9965-D Installation Diagram — Drawing No. 0F1020-A Section 9 — Installation DiagramCALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES 1-800-333-1322EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYP.O. BOX 297 • WHITEWATER, WI WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC