Generac Power Systems 04758-2, 04759-2, 04760-2 Voltage Regulator Adjustment, Break-In Procedure

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◆2.7.3 ADDITIONAL CORROSION PROTECTION

Section 3 — Operation

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

2.7.3 ADDITIONAL CORROSION PROTECTION

Periodically spray all engine linkage parts and brack- ets with corrosion inhibiting spray such as WD-40 or a comparable product.

2.8VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 62-63.5 Hertz, slowly turn the slotted potentiometer (Figure 2.6) until line voltage reads 244-252 volts.

NOTE:

Remove the access panel on top of the control panel to adjust the voltage regulator.

Figure 2.6 – Voltage Adjustment Potentiometer

7.Run the unit for one hour at 100 percent load.

8.Turn ON the utility power supply to the transfer switch, which will allow the transfer switch to transfer back to utility power. The unit will con- tinue to run for one minute and then shut down.

9.Allow the unit to cool.

10.Drain the oil and remove the oil filter. Replace the oil filter according to Section 4.4, “Changing the Oil Filter”. Replace the oil with synthetic oil as recommended in Section 4.3, “Changing the Engine Oil”.

11.The generator is now ready for service.

3.2USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1)

‹3.2.1 “AUTO” POSITION

NOTE:

Selecting this switch position activates fully automatic system operation. It also permits starting and exercising the engine every seven days with the setting of the exer- cise timer (see Section 3.6). This position also is used for remote starting, when it is set up.

‹3.2.2 “OFF” POSITION

This switch position shuts down the engine. This position also prevents automatic operation.

‹3.2.3 “MANUAL” POSITION

Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure.

Figure 3.1 – Generator Control Panel

The voltage regulator is housed above the genera- tor's control panel. The regulator maintains a volt- age in direct proportion to frequency. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

3.1BREAK-IN PROCEDURE

Once the unit has been installed, with utility power connected to the transfer switch, and all electrical checks have been made, it is strongly recommended that the following “Break-in Procedure” be completed to ensure correct generator operation in the future.

FUSE

5A

AUTO OFF MAN.

FUSE

15ASET EXERCISE

TIME

L o c a t e y o u r n e a r e s t 2.8VOLTAGE REGULATORFigure 2.6 – Voltage Adjustment Potentiometer3.2USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1) d e a le r a t :

‹3.2.1 “AUTO” POSITIONPOWER SYSTEMS, INC.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

F L A S H IN G G R E E N L E D =

N O U T IL IT Y S E N S E 4 F L A S H IN G R E D L E D S =

E X E R C IS E R N O T S E T

1.Set the generator’s AUTO/OFF/MANUAL switch to AUTO.

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

3.The unit will start, and the transfer switch will transfer to standby.

4.Run the unit for one hour at 25 percent load.

5.Run the unit for one hour at 50 percent load.

6.Run the unit for one hour at 75 percent load.

14 Generac® Power Systems, Inc.

With the switch set to AUTO, the engine may

!crank and start at any time without warning. Such automatic starting normally occurs when utility power source voltage drops below a pre- set level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove both fuses before working on or around the generator or transfer switch. Then, place a “Do Not Operate” tag on the gen- erator panel and on the transfer switch.

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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 DANGERFigure 1.1 - 7 kW, Single Cylinder GH-410 Engine 1.4 THE GENERATORFigure 1.2 - 12 kW/15 kW, V-twin GT-990/760 Engine ‹ 1.5.1 GENERATOR 1.5 SPECIFICATIONS‹ 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 Connections2.1 BEFORE INITIAL START-UP 2.2 CHECK TRANSFER SWITCH OPERATION2.3 ELECTRICAL CHECKS 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC OPERATIONFigure 2.2 - Placement of Regulator 2.6 ADJUSTING THE REGULATOR NATURAL GAS ONLYFigure 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 GapFigure 4.10 - Valve Clearance Adjustment 4.8 ADJUSTING VALVE CLEARANCE4.9 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 CORRECTIONENGINE WIRING 24 Generac Power Systems, IncSection 6 - Electrical Data CUSTOMER CONTROL PANEL BOXCONNECTION 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 225A 30 Generac Power Systems, Inc224A 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 PART NO. QTY. DESCRIPTION 27, 28 36 Generac Power Systems, Inc35, 36, 40 PART NO. QTY DESCRIPTION38 Generac Power Systems, Inc DESCRIPTION 40 Generac Power Systems, Inc 14 201.8 FT 1.25 FT42 Generac Power Systems, Inc 3 FT 2.6 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