Generac Power Systems 04758-2, 04759-2, 04760-2 Before Initial Start-Up, Electrical Checks

Page 12
2.1BEFORE INITIAL START-UP

Section 2 — Post Installation Start-up and Adjustments

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Remove watches, rings or other metal objects;

Use tools with insulated handles;

Wear rubber gloves and boots;

Do not lay tools or metal parts on top of the battery; and

Disconnect charging source prior to connecting or dis- connecting battery terminals.

Do not open or mutilate the battery. Released

!electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

!harmful to the skin and eyes. It is electrically conductive and corrosive.

The following procedures are to be observed:

Wear full eye protection and protective clothing;

Where electrolyte contacts the skin, wash it off immediately with water;

Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical attention; and

Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicar- bonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire because they generate hydrogen gas. The following procedures are to be followed:

DO NOT SMOKE when near the battery;

DO NOT cause flame or spark in battery area; and

Discharge static electricity from body before touch- ing the battery by first touching a grounded metal surface.

Be sure the AUTO/OFF/MANUAL switch is set to ! the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

2.1BEFORE INITIAL START-UP

Before starting, complete the following:

1.Set the generator’s main circuit breaker to its OFF (or open) position.

2.Set the generator's AUTO/OFF/MANUAL switch to the OFF position.

3.Turn OFF the utility power supply to the transfer switch using the means provided (such as the utility main line circuit breaker).

4.Check the engine crankcase oil level and, if nec- essary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark.

5.Check the fuel supply. Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel-gas codes. All fuel shutoff valves in the fuel supply lines must be open.

Never operate the engine with the oil level

!below the “Add” mark on the dipstick. Doing this could damage the engine.

2.2CHECK TRANSFER SWITCH

OPERATION

Refer to Section 3.5, of the owner’s manual for man- ual operation procedures.

2.2CHECK TRANSFER SWITCH2.3ELECTRICAL CHECKS DANGER

Do not attempt manual transfer switch opera- tion until all power voltage supplies to the transfer switch have been positively turned off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock.

2.3ELECTRICAL CHECKS

Complete electrical checks as follows:

1.Turn on the utility power supply to the transfer switch using the means provided (such as a utili- ty main line circuit breaker).

Manual backgroundManual background DANGER

The transfer switch is now electrically “hot.” Contact with “hot” parts will result in extreme- ly hazardous and possibly fatal electrical shock. Proceed with caution.

2.Use an accurate AC voltmeter to check utility power source voltage across terminals N1 and N2. Nominal line-to-line voltage should be 240 volts AC.

10 Generac® Power Systems, Inc.

Image 12
Contents Models 04758-2 6 kW NG, 7 kW LP 04759-2 12 kW NG, 12 kW LP 04760-2 13 kW NG, 15 kW LPThis manual should remain with the unit Installation and Owner’s Manual‹ CONTENTS ‹ OPERATION AND MAINTENANCE‹ HOW TO OBTAIN SERVICE INTRODUCTIONIntroduction GENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot during operation. Exercise care near running generatorsELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.1 UNPACKING/INSPECTION 1.2 PROTECTION SYSTEMS1.3 SYSTEM SET LED DANGER1.4 THE GENERATOR Figure 1.1 - 7 kW, Single Cylinder GH-410 EngineFigure 1.2 - 12 kW/15 kW, V-twin GT-990/760 Engine 1.5 SPECIFICATIONS ‹ 1.5.1 GENERATOR‹ 1.5.2 ENGINE 1.8 RECONFIGURING THE FUEL SYSTEM 1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS1.7 FUEL CONSUMPTION DANGER1.9 LOCATION 1.8.2 12KW AND 15KW, 990CC ENGINES1.9.1 GENERATOR Figure 1.4 - Demand Regulator1.10 BATTERY INSTALLATION 1.11 THE BATTERY1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW, 12 kW and 15 kW Units Figure 1.5 - Battery Cable Connections2.2 CHECK TRANSFER SWITCH OPERATION 2.1 BEFORE INITIAL START-UP2.3 ELECTRICAL CHECKS 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC OPERATION2.6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Figure 2.2 - Placement of RegulatorFigure 2.1 - Dual Fuel Regulators 2.7 ENGINE GOVERNOR ADJUSTMENT Figure 2.4 - V-twin Engine Governor AdjustmentFigure 2.3 - Single Cylinder Engine Governor Adjustment Figure 2.5 - V-twin Full Load Speed Adjust Screw2.8 VOLTAGE REGULATOR ADJUSTMENT 3.1 BREAK-IN PROCEDURE3.2 USING THE AUTO/OFF/MANUAL SWITCH FIGURE Figure 2.6 - Voltage Adjustment Potentiometer3.3 AUTOMATIC TRANSFER OPERATION 3.5 MANUAL TRANSFER OPERATION3.4 SEQUENCE OF AUTOMATIC OPERATION ‹ 3.5.1 TRANSFER TO GENERATOR POWER SOURCE‹ 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE ‹ 3.7.1 LOW OIL PRESSURE SWITCH‹ 3.7.2 HIGH TEMPERATURE SWITCH Figure 3.2 - Manual Transfer Switch OperationFigure 3.3 - Low Oil Pressure and High Temperature Switches 4.2 CHECKING THE ENGINE OIL LEVEL4.1 FUSE ‹ 3.7.3 OVERCRANK4.5 CHANGING THE ENGINE AIR CLEANER ‹ 4.3.2 OIL CHANGE PROCEDURE4.3 CHANGING THE ENGINE OIL 4.4 CHANGING THE OIL FILTER4.7 BATTERY MAINTENANCE Figure 4.6 - 7 kW, Engine Air Cleaner LocationFigure 4.7 - 12 kW and 15 kW Engine Air Cleaner Figure 4.8 - Setting the Spark Plug Gap4.8 ADJUSTING VALVE CLEARANCE Figure 4.10 - Valve Clearance Adjustment4.9 COOLING SYSTEM 4.12 OUT OF SERVICE PROCEDURE ‹ 4.12.2 RETURN TO SERVICE‹ 4.12.1 REMOVAL FROM SERVICE 4.10 ATTENTION AFTER SUBMERSION4.13 SERVICE SCHEDULE 5.1 TROUBLESHOOTING GUIDE PROBLEMCAUSE CORRECTION24 Generac Power Systems, Inc ENGINE WIRINGSection 6 - Electrical Data CONTROL PANEL BOX CUSTOMERCONNECTION Electrical Schematic - 12 & 15 kW - Drawing No. 0D8501-B 26 Generac Power Systems, IncGenerac Power Systems, Inc 28 Generac Power Systems, Inc Section 6 - Electrical DataGenerac Power Systems, Inc 30 Generac Power Systems, Inc 225A224A Electrical Schematic - 7 kW - Drawing No. 0D9014-C Section 7 - Exploded Views and Parts Lists 32 Generac Power Systems, IncPART NO. QTY. DESCRIPTION 34 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 36 Generac Power Systems, Inc 27, 2835, 36, 40 PART NO. QTY DESCRIPTION38 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 40 Generac Power Systems, Inc 14 201.8 FT 1.25 FT42 Generac Power Systems, Inc 2.6 FT 3 FT1.33 FT 44 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 46 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 48 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 50 Generac Power Systems, Inc ALL DIMENSIONS IN MILLIMETERS INCHESSection 8 - Mounting Guardian Air-cooled 7 kW, 12 Drawing No. 0D3739-BSection 9 - Notes YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGEPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGGENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORSWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING