Generac 04077-01, 04109-1, 04079-1, 00789-1, 00844
Contents
1. 3 10 SETTING THE EXERCISE TIMER 3 10 1 6 KW 8 KW AND 10 KW UNITS NON SA Your generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day you complete the following sequence During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 2 1 Page 18 allows you to select the day and time for system exercise To select the desired day and time of day proceed as follows 1 Verify that the Auto Off Manual switch is set to AUTO 2 Hold down the Set Exercise Timer switch until the generator starts approximately 10 seconds and then release 3 The generator will start and run for approximate ly 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is per formed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected The exerciser WILL NOT work if dip switch 2 Remote Not Auto is ON ee Generac Power Systems Inc e 3 10 2 SOUND ATTENUATED UNITS The generator will start and exercise once every seven days During this weekly exercise the unit runs for abo2. NOTE It is important that you DO NOT proceed until you are certain that generator AC voltage and frequen cy are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjust ment If frequency is correct but voltage is high or low the generator s voltage regulator requires adjustment 3 4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Set the generator s Auto Off Manual switch to OFF 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker Section 3 Post installation Start up Adjustments WARNING amp A Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positivelv turned off Failure to turn off all power voltage supplies will result in extremelv hazardous and possiblv fatal electrical shock 4 Manually set the transfer switch to the STANDBY position i e load terminals connected to the generator s E1 E2 terminals The transfer switch operating lever should be down 5 Set the generator s Auto Off Manual switch to MANUAL The engine should crank and start immediately 6 Let the engine stabilize and warm up for a few minutes 7 Setthe generator s main ci
3. 1 2 UNPACKING 1 2 1 PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack crates and cartons with the proper side up as noted on the shipping carton 1 2 2 INSPECTION After unpacking carefully inspect the contents for damage that may have occurred during shipment This standby generator set has been factory sup plied with a weather protective enclosure that is intended for outdoor installation only The 6 kW 8 kW and 10 kW standby generator sets are packaged with an automatic transfer switch This UL listed two pole switch is rated at 100 AC amperes at 250 volts maximum This transfer switch is for indoor use only All sound attenuated models have a built in trans fer switch WARNING A A If this generator is used to power electrical load circuits normally powered by a utility power source you are required by code to install a trans fer switch The transfer switch must effectively iso late the electrical system from the utility distribu tion system when the generator is operating NEC 701 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix
4. 13 1 Before Initial Start up EE 221 13 22 Check Transfer Switch Operation 221 13 9 Electrical CHECKS ete 221 3 1 Generator Tests Under Load ss 22 13 5 Checking Automatic Operation 231 3 6 m Adjusting the Load Block feme uou Me un ete ARA gal 23 1 13 7 Engine Governor Adjustment 24 3 7 1 6 kW Units Non Sai cee 241 3 7 2 8 kW and 10 kW Units Non SA 24 1 3 7 3 Sound Attenuated Units 251 3 8 Voltage Regulator Adjustment 25 9 9 Overspeed Calibration eni arena emen aaa 251 7789311 6 KW 8 KW and 1 10 kW Units Non SA 26 i 3 9 2 Sound Attenuated Units 261 3 10 Setting the Exercise Timer 26 3 10 1 6 kW 8 kW and 10 kW Units Non SAl 261i 3 10 2 Sound Attenuated Units 26 Section 4 Troubleshooting 27 14 1 Troubleshooting Guide nre 271 Aa malaio CHAOS corno oir 0 B res M LL cM c CEN CIC M MP CLE 1 Section 5 Notes mssnnananannnnnnannannnannnnnn 29 Generac Power Systems Inc 1 ee CES Important Safety Instructions Guardian Air cooled Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to A all operators and potential operators of this equipment A WAR
5. INSTALLATION START UP ADJUSTMENTS Guardian Air cooled Generators With the Auto Off Manual switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power sup ply to the transfer switch The following should occur After about six seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down 3 6 ADJUSTING THE LOAD BLOCK When the natural gas system is being used the load block is fitted with an adjustment screw that has been calibrated to provide maximum power However because of variations in the Btu content of natural gas across the country it may be necessary to readjust the load block Connect a frequency meter to the output of the generator Start the unit and apply full load according to the following chart Unit 120 Volts 240 Volts 6 kW Non SA 50 amps 25 amps 8 kW Non SA 66 7 amps 33 3 amps 10 kW Non SA 83 3 amps 41 6 amps Sound Attn 66 7 amps 33 3 amps Allow the unit to stabilize then turn the adjust ment screw slowly clockwise or counterclockwise and watch the frequency When the highest frequency is
6. Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored above 80 per cent of the nominal source voltage a retransfer time delay starts timing E Retransfer Time Delay This timer runs for about 15 SA six seconds At end of a 15 second SA six second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs F Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down Section 2 Operation OPERATION Guardian Air cooled Generators Ir NOTE Sound attenuated units have a control module assembly CMA board that reads frequency sig nals from the stator battery charge windings and relates them to engine speed or rpm When AC fre quency reaches about 30 Hertz cranking is termi nated and an engine warmup timer goes ON run ning for approximately 15 seconds 2 4 MANUAL TRANSFER OPERATION 2 4 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generator s Auto Off Manual swi
7. age regulator may require adjustment Figure 3 2 8 kW and 10 kW Engine Governor Adjustment Carburetor Spring Carburetor Governor Lever Spring Speed Adjust Nut Governor Shaft Bend Tab Governor spring Governor Clamp Bolt Front View NOTE If the engine continues to run fast use a pair of pliers to bend the bend tab clockwise to release tension on the lower governor spring Section 3 Post installation Start up Adjustments POST CD 3 7 3 SOUND ATTENUATED UNITS 1 Carefully inspect the governor anti lash spring Figure 3 3 Be sure it is not broken or disengaged 2 Loosen the governor clamp nut Then push the spring end of the governor lever all the way up wide open throttle 3 Hold the governor lever at wide open throttle and insert the tip of a screwdriver into the slotted end of the governor shaft Hold the governor lever at wide open throttle and rotate the governor shaft fully counterclockwise Hold the governor shaft fully counterclockwise and tighten the governor clamp nut to 70 inch pounds 8 N m torque Figure 3 3 Sound Attenuated Engine Governor Adjustment IDLE STOP gt SCREW CARBURETOR THROTTLE PLATE ADJUSTER NUT ANTI LASH SPRING GOVERNOR SPRING GOVERNOR SHAFT GOVERNOR CLAMP NUT GOVERNOR LEVER 3 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 61 62 Hertz slowly tu
8. cables were factory connected at the genera tor Figure 1 14 Connect cables to battery posts as follows 1 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 2 Connect the black battery cable from frame ground to the battery post indicated by a nega tive NEG or INSTALLATION P lili Section 1 Installation Guardian Air cooled Generators Figure 1 14 Batterv Cable Connections BLACK LEAD FROM FRAME e RED LEAD FROM STARTER CONTACTOR BEN BATTERY BLACK NOTE With the battery installed and utility power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charge feature cannot be used to recharge a dis charged battery 1 18 THE FUSE The generator panel s 15 amp fuse protects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open you cannot crank or start the engine You should replace the fuse using only an identical 15 amp replacement 1 19 POST INSTALLATION INSPECTION Before placing the home standby electrical system into service inspect the entire installation carefully Some areas may require that an inspection be per formed by a building or electrical inspector Figure 1 15 Typical Emerge
9. for parts needing repair or replacement Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc A ELECTRICAL HAZARDS A All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera tion Avoid contact with bare wires terminals con nections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If you must work around an operating unit stand on an insu lated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK WILL RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical
10. his or her signature under the consignor s memo of loss or damage If you note loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is discovered later 1 3 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Circuit Isolation Method and Total Circuit Isolation Method in Sections 1 8 and 1 9 Page 11 carefully The generators rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power You may have to group the criti cal essential electrical loads together and wire them into a separate emergency distribution panel NOTE In some areas you may need to acquire electrical permits for installing an emergency system build ing permits for installing gas lines and permits for noise allowances Check your local codes before installing the unit 1 4 LIFTING THE GENERATOR To lift a nonsound attenuated generator insert pipe having sufficient strength and diameter through the lift ing holes lifting brackets are provided with sound attenuated units which are located near the units base see Figure 1 1 You also may lift the unit using a hook and hoist method provided you use a spreader bar to ensure that the line
11. the life of your battery by maintaining the battery when the unit is not running A BINI A Do not dispose of the battery in a fire The A battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries 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 16 Generac Power Systems Inc WARNING A A Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A 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 flush thoroughly and immediately 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 e
12. when it continually attempts to start and another prob lem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED will light indi cating an overcrank failure The Auto Off Manual switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the overcrank feature will continue to activate 2 5 5 1 Approximate Crank Cycle Times e 15 seconds ON e 15 seconds OFF e 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 2 5 4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the pre set limit This protection also prevents the generator from supplying an output that could potentially damage appliances connected to the generator circuit The over speed feature will activate as follows 1 Ifthe generator runs at 72 Hertz for five seconds the generator will shut down 2 If the generator reaches 75 Hertz it will shut down instantly 2 6 ADDITIONAL GENERATOR FEATURES 2 6 1 6 KW 8 KW AND 10 KW UNITS NON SA The standard 6 kW 8 kW and 10 kW air cooled Guardians offer additional features that are not factory preset 1 Remote Start This allows for remote starting of the generator by means of the 183 common and 7178 normally open lines with the Auto Of
13. ED is 9 UTILITY 1 i WIRING Id UTILITY 2 Bes LOAD 1 l feel LOAD 2 Ka 23 fe e 194 e o GTS ES Ll AC GENERATOR CONNECTION PANEL Generac Power Systems Inc 13 INSTALLATION P LLD Section 1 Installation Guardian Air cooled Generators Figure 1 11 Interconnection With GTS Transfer Switch 100A y type UTILITY SUPPLY 22 NE NEUTRAL NEUTRAL TRANSFER LUG CONNECTION SWITCH N1 N2 di A 11 Ti T2 cel Hr44 E1 E2 CT ol l UTILITY 1 e lol urum2 coc ol lol 123 MO ol lol 1194 TIT 178 ol lol C REMOTE START OJOJOJO p 2 lo NO REMOTE START ol Q C REMOTE ALARM ojolojo ol lol NO REMOTE ALARM GTS CUSTOMER LOAD AC GENERATOR J CONTROL PANEL 1 12 GENERATORS AND GTS TRANSFER SWITCHES Guardian generators this DOES NOT APPLY to single phase sound attenuated units may be installed with either a prepackaged transfer switch or with a stan dard GTS type automatic transfer switch Figure 1 11 You can do this by connecting generator control console terminals 178 a
14. Full Load 1 2 Load Full Load 6 kW 74 1 105 3 0 86 31 30 1 08 39 30 8 kW 79 7 140 0 1 07 38 94 1 56 56 77 10 kW 100 8 177 9 1 16 42 21 2 15 78 24 Sound Attn 84 6 126 6 1 06 38 57 1 7 61 86 LP is in gallons per hour cubic feet per hour WARNING amp Gaseous fuels such as natural gas and liquid A propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 6 Generac Power Systems Inc 1 6 4 RECONFIGURING THE FUEL SYSTEM To reconfigure the fuel system from NG to LP follow these steps 1 Remove the carburetor fuel hose from the natural gas port of the fuel load block and the brass fit ting Figure 1 2 2 Remove the blanking plug from the LP port of the load block Figure 1 2 Figure 1 2 Natural Gas Setup BRASS E FITTING NG NATURAL GAS HOSE TO ADJUSTMENT CABURETOR SCREW FUEL LP LOAD BLOCK gh BLANKING PLUG DEMAND REGULATOR 3 Refit the fitting and hose to the LP port and the blanking plug to the natural gas port Figure 1 3 4 Reverse the procedure to convert back to natural gas NOTE The natural gas adjustment screw is preset during installation and should not need any further adjustment Figure 1 3 LP Gas Setup BLANKING Ta
15. GENERAG POW ER SYSTEMS INC Installation Start up and Adjustment Manual GUARDIAN by GENERAC POWER SYSTEMS Air cooled Prepackaged Standby Generators Models Nonsound Attenuated Non SA 04077 1 6 kW 04109 1 8 kW 04079 1 10 kW Sound Attenuated SA DOSE X T 00789 1 8 kW 00844 1 8 kW IDN DMI A iI A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION Thank you for purchasing a model of the Guardian product line by Generac Power Systems Inc These models are compact high performance air cooled engine driven generators designed to automatically supply electrical power to operate critical loads dur ing a utility power failure This unit is factory installed in an all weather metal enclosure that is intended exclusively for outdoor installation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG e READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact Generac or your nearest Generac Guardian Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert you to special instructions about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefu
16. Guardian Power Systems gen erator in most applications If you do need more information contact us directly at 262 544 4811 between the hours of 8 a m and 5 p m CST 1 1 2 STANDARDS INDEX In the absence of pertinent standards codes regula tions and laws the published information listed below may be used as installation guide for this equipment 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 2 NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES available same as Item 1 3 NFPA No 54 NATIONAL FUEL GAS CODE avail able same as Item 1 4 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 4 Generac Power Systems Inc 5 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 6 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 7 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 8 ASAE EP 3634 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRICAL SYS TEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 9 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1
17. LECTRICAL CONNECTIONS A Complies with local code requirements and all National Electrical Codes LJ Utility is connected and present Transfer switch is connected D All wires running outside of the generator are in NEC approved conduit Note Utility wires and transfer switch control wires must be in separate conduit Unit is grounded to an approved earth ground e COOLING AND VENTILATING A All inlets and outlets are free from obstruction See Figure 1 4 and Figure 1 5 e OTHER A Verify that the unit is filled to the proper level with the proper break in oil Adjust as required U Notify owner that the Break in Procedure should be performed Refer the owner to the Owner s Manual shipped with the unit OPTIONS AND ACCESSORIES Q Control board is configured properly See Section 1 15 A Remote alarm is installed if desired See Section 2 6 A Remote start is installed if desired See Section 2 6 Section 5 Notes NOTES Guardian Air cooled Generators Generac Power Systems inc 29 GENERAC POWER SYSTEMS INC P O BOX 8 WAUKESHA WI 531 87 Part No C4219 Revision 12 13 99 Printed in U S A
18. METHOD One effective way of preventing the generator from being overloaded is to use the Emergency Circuit Isolation Method Figure 1 6 Essential electrical loads are grouped together and wired into a separate emergency distribution panel Load circuits fed by the emergency distribution panel must be within the unit s rated wattage capacity The following apply to this type of isolation system The transfer switch is installed between the main and the emergency distribution panels as shown The transfer switch must have an ampere rating equal to the ampere rating of the emergency circuit Figure 1 6 Emergency Circuit Isolation Method TO POWER LINE MASTER SWITCH 1 WATT HOUR METER EE 77 MAIN DISTRIBUTION R TO RANGE i FUSE PANEL at i HA ud TO WATER es i TO AIR HEATER 773 CONDITIONER 240V inf i 1 St H 4 rosse Teese POWER RETURN SIGNAL LIGHT AND SWITCH SE 1 AH AUTOMATIC TRANSFER TO STANDBY Goen SWITCH IN NORMAL ALTERNATOR POSITION 1 1 I 4Q Hu D i TOLIGHTS 1 Af TO REFRIGERATOR i A oo 120V4 TO SUMP PUMP _ I At TO LIGHTS 120V H T IGHTS DE H b md TO FURNACE BLOWER 1 i i NEUTRAL EMERGENCY DISTRIBUTION PANEL Ampere rating must equal or exceed the ampere rating of the emergency distribution system Ampere capacity is not to
19. NING A The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefull before installing operating or servicing this equipment Become familiar with this Installation Start up and Adjustment Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible cir cumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a procedure work method or operating tech nique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that you choose does not render the generator unsafe A BINI A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work o
20. NING A A 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 preset 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 the fuse before working on or around the generator or transfer switch Then place a Do Not Operate tag on the generator panel and on the transfer switch Figure 2 1 Generator Control Panel 6 kW 8 kW 10 kW Non SA 18 Generac Power Systems Inc Figure 2 2 Generator Control Panel Sound Attenuated HOURS RUN METER SET EXERCISE ENGINE FAULT OFF je u sq e MANUAL yy 9 le JS MAIN BREAKER 2 2 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source Figure 2 3 Page 19 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generators Auto Off Manual switch to AUTO 4 Setthe generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatica
21. O INSTALLATION DANGER A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations NOTE Read the entire manual before starting the installa tion Ensure that the model number of the unit being installed matches a model on the front cover Generac cannot possibly know of and advise the home standby trade of all conceivable procedures and meth ods by which installation of this equipment might be achieved Neither can Generac know of possible hazards and or results of each method or procedure We have not undertaken any such wide evaluation 1 1 1 INSTALLATION ASSISTANCE 1 For the Homeowner or Business Owner You need to have a certified electrician or contractor to install this product To arrange for proper installa tion contact one of the following sources Generac Guardian Authorized Dealer Look for Generac or Guardian in your local Yellow Pages under the classification Generators Electric Heating and A C Contractors Look in your local Yellow Pages under the classifications Heating Contractors or Air Conditioning Contractors Call us direct at 262 544 4811 between the hours of 8 a m and 5 p m CST We will gladly assist you in finding a local qualified installer 2 For the Installing Dealer Contractor This manual contains all the information required to properly install and start a
22. PLUG BRASS NATURAL GAS ADJUSTMENT FITTING SCREW FUEL LOAD HOSE TO BLOCK CABURETOR DEMAND REGULATOR 1 7 LOCATION AND MOUNTING e 1 7 1 GENERATOR Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing you may need to consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow 3 feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE INSTALLATION P lili Section 1 Installation Guardian Air cooled Generators 1 7 1 1 6 kW 8 kW and 10 kW Units Non SA These Guardian units are supplied with their own mounting pads and DO NOT require a concrete pad Remove the packing material from the unit and unbolt the
23. R LOCATION To locate the GENERAC GUARDIAN AUTHORIZED DEALER nearest you please call this number 1 800 747 1530 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER 1 6 1 Fuel System Requirements and Recommendations Introduction Inside Front Cover Read This Manual Thoroughly IFC Operation and Matotenance IFC How to Obtain Service IFC Authorized Dealer Location Number IFC Safety Rules i teres 23 Section 1 Installation Eeer 4 1 1 Introduction to Installation 43 i 1 1 1 Installation Assistance 4 1 1 1 2 Standards Index nn 41 11 2 Unpacking eerte EE 4 f 1 2 1 Precautions nea na Naas akak agi 4 1 A Fo S l 2 2 Inspection Sets os ea setae s Tad num E a 1 3 Before nstallation resserre BT d 1 4 Lifting the Generator 5 1 5 Engine Oil Recommendations 51 1 6 Gaseous Fuel System cn 5 LG Fuel Consumption 1 6 3 Fuel Pipe Sizing eese E 1 6 4 Reconfiguring the Fuel System B 1 7 Location and Mounting eere eene eere 7a l 1 7 1 Generator eene 7 1 7 1 1 6 KW 8 kW and 10 kW Units Non SA Ta i 1 7 1 2 Sound Attenuated Units 7 1 1 7 2 E Ti 1 7 2 4 6 Kw 8 kW and i 10 kW Units Non SA 7 AP A QU 1 7 2 2 Sound Attenuated Units 7 1 8 Eme
24. Sound Attenuated Units All sound attenuated models have a transfer switch built into the enclosure and do not require a separate switch attachment Generac Power Systems Inc 7 Section 1 Installation Guardian Air cooled Generators INSTALLATION Figure 1 4 Generator and Transfer Switch Mounting Dimensions 6 kW 8 kW and 10 kW Non SA M3IA uv3d jHL Ad Lal LON Od SAJNADQI v SIAH 9NIL4 6110 WWTOEQ LFINI 1304 LAN Bin W E HOLIMS H34SNVUL L 0G 0 wu el d v2a 02 UWTpIG L v 261 wus Gs ii hip i o HOLIMS HIJSNVUL OVYINID 2101 WMD Ge S801 uu7 c 2 NANTDI MILYA dO pi ra L29 2 wus OS act v1 WWBESE H LOTZ Wuy es M dOL Ziel Ni HIV Ze UN HIV JL JINN GINDD3SV 119 V3elv N3d0 WNWINIW l d L 009 wut bi6 H il mi Jj 131100 Hie l qe L i sj Tec po IN tU E surdum reris petra trol Ak AL ER P 131400 HIV SHHINI 2 SAJLIWI TIIN INI SNUISN3WIG 1Ivxx Generac Power Systems Inc INSTALLATION k1W Section 1 Installation Guardian Air cooled Generators Figure 1 4 Continued JANSDIINA JHL HONOSHL LAd 38 AVW Sg 13 LINGNOS MJI 3GIS LHOIH MJM 3GIS 1471 yady SIHL NI Fees i i 1 1 LIES WWQ QGT Lee uer LE99I wG 22y C w
25. System 240 VOLTS CIRCUIT BREAKER 12 Generac Power Systems Inc 1 11 WIRING INTERCONNECTIONS caution A0 A This generator uses an UNGROUNDED neutral line consisting of the junction of stator leads 22 and 33 Figure 1 9 and Figure 1 10 Page 13 are interconnection diagrams of home standby electrical systems Power voltage leads and transfer switch signal leads must be run in separate conduit All wiring must be the proper size properly support ed of approved insulative qualities and protected by NEC approved conduit Use a length of flexible conduit between the generator and any rigid conduit NOTE See also Emergency Circuit Isolation Method Section 1 8 and Total Circuit Isolation Method Section 1 9 on Page 11 1 11 1 6 KW 8 KW AND 10 KW UNITS NON SA Complete the following AC power lead connections for single phase units Figure 1 9 Page 13 1 Connect utility power supply leads to transfer switch terminals N1 N2 and the neutral lug 2 Connect generator AC output leads from the gen erator s main circuit breaker CB1 and the gen erator neutral lug to transfer switch terminals El E2 and the neutral lug 3 Connect circuit load leads to customer load and to transfer switch terminals T1 T2 and the neutral lug 1 11 2 SOUND ATTENUATED UNITS The sound attenuated unit utilizes an internal 100 amp V type transfer switch The control and generator AC wires are
26. al relay closes when the 14 line is hot 3 Automatic Transfer Switch ATS in Emergency For this to be active a microswitch on the transfer switch sends a signal along the 231 line to close the volt free contact relay 4 Shutdown Fault This signal is controlled by the main printed circuit board along the 229 line When a common fault occurs low oil pressure high temperature overspeed overcrank the control board will send a signal along the 229 line to close the volt free contact relay Figure 2 6 Remote Alarms REMDTE ALARMS ENGINE RUN NC NU NC ND NC ND NC NU OOOOOOOO NC ND NC OOOOOOQQOQQOQQOQOOOQOQQO 70 a Zz D lt Generac Power Systems Inc 21 POST cD Section 3 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS Guardian Air cooled Generators 3 1 BEFORE INITIAL START UP Before starting complete the following 1 Set the generator s Auto Off Manual switch to the OFF position 2 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 3 Check the engine crankcase oil level and if neces sary fill to the dipstick FULL mark with the rec ommended oil Do not fill abov
27. ches see Figure 1 12 which may be set up differently during installation 1 Dip switch 1 When in the ON position the board requires 20 Vac from the step down transformer to the control board to determine if utility is present This switch is factory preset and should not need to be changed This switch should be set in the OFF position 2 Dip switch 2 When in the ON position it will disable the automatic starting of these units This should be set when utility is not present at the installation location This is the only switch that may need to be set to the ON position for these models 3 Dip switch 3 It will allow for 50 Hertz opera tion and is not applicable to these models This switch is factory preset and should not need to be changed This switch should be set in the OFF position 4 Dip switch 4 It has no function at this time INSTALLATION n lili Section 1 Installation Guardian Air cooled Generators Figure 1 12 Control Board Configuration J e 34 S Je JI 141312 CONTROL PRINTED CIRCUIT BOARD t ON INDICATES 20 Voc Sense Transformer Remote Not Auto 50 Hz Operation SPARE UU LED ALARM INDICATORS 17 16 15 14 13 18 11 10 9 8 7 6 1 4 1 16 GROUNDING THE GENERATOR Generally connecting a No 12 AWG stranded copper wire to the grounding lug Figure 1 13 and to an
28. ctions before using this equip ment We also strongly recommend instructing other users to properly start and operate the unit This pre pares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Guardian Authorized Dealer Normal main tenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for mainte nance service Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum See your Generac Guardian Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When your generator requires servicing or repairs simply contact a Generac Guardian Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting a Generac Guardian Authorized Dealer or the factory about parts and service always supply the complete model number and serial num ber of your unit as given on its data decal which is located on the generator s engine AUTHORIZED DEALE
29. e the FULL mark 4 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 caution Ak Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 3 2 CHECK TRANSFER SWITCH OPERATION Refer to Section 2 4 Page 19 for manual operation procedures A WARNING A Do not attempt manual transfer switch operation 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 3 3 ELECTRICAL 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 A EX A The transfer switch is now electrically hot Contact with hot parts will result in extremely 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 3 Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage sho
30. earth driven copper or brass grounding rod electrode will adequately ground the generator However local codes may vary widely Consult with a local electrician for grounding requirements in your area Figure 1 13 Grounding the Generator uv d GROUNDING LUG Generac Power Systems Inc 15 INSTALLATION P LLD Section 1 Installation Guardian Air cooled Generators 1 17 THE BATTERV Servicing of the batterv is to be performed or super vised bv personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel awav from batteries When replacing the batterv use the following tvpe of batterv Group 26 26R 12 volt batterv with a rating of 350 cold cranking amps at 17 8 C 0 F minimum When using a maintenance free battery it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Owner s Manual Service Schedule A negative ground system is used Battery connec tions are shown on the wiring diagrams Make sure the battery is correctly connected and terminals are tight Observe battery polarity when connecting the battery to the generator set NOTE Damage will result if the battery connections are made in reverse Your generator is equipped with a battery trickle charger that is active when your unit is set up for automatic operation The trickle charger is designed to help extend
31. ed SAE 10W 30 or SAE 30 Below 7 C 20 F SAE 5W 20 or 5W 30 All Seasons SAE 5W 30 Synthetic Organic break in oil is required before using synthetic oil A caution amp A Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 1 6 GASEOUS FUEL SYSTEM NOTE The following information pertaining to gaseous fuel systems is provided to assist gaseous fuel technicians in planning installations In no way should this information be interpreted to conflict with applicable fuel gas codes Consult with your local fuel supplier or fire marshall if questions or problems arise e 1 6 1 FUEL SYSTEM REQUIREMENTS AND RECOMMENDATIONS When installing the fuel system install a flexible length of line between the generator fuel connec tion and the rigid piping The flexible hose must be approved for use with gaseous fuels It is rec ommended that an emergency manual fuel shutoff valve be placed in line Generac Power Systems Inc 5 INSTALLATION P LED Section 1 Installation Guardian Air cooled Generators With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liq uid fuel in the storage tank The engine has been fitted with a fuel carburetion sys tem that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel sys tems T
32. eplace transfer relay source failure 3 Transfer relay circuit open 3 Close transfer relay circuit 4 Defective control logic board 4 Replace control logic board Unit starts automatically when 1 Utility not present 1 Switch dip switch 2 on control switched to the AUTO position board if utility is not available Check all connections if utility should be present 2 Defective Auto Off Manual 2 Replace switch switch System Set LED is not lit when 1 Failure present i e low oil l Correct failure switched to the AUTO position pressure 2 Dip switch 2 set to the ON 2 Switch to the OFF position if position desired Generac Power Systems Inc 27 TROUBLESHOOTING Section 4 Troubleshooting Guardian Air cooled Generators 4 2 INSTALLATION CHECKLIST e BATTERY INSTALLATION LI Battery is connected properly A Recommended battery is installed A Cables are clean and tight L1 Terminals are coated with anti corrosion grease and terminal covers are positioned e FUEL SYSTEM LI Complies with local and NFPA codes LI Fuel is connected and checked for leaks 1 Correct fuel pressure 11 14 inches of water 0 6 psi at all load ranges A Load block adjusted for maximum power for natural gas fuel e LOCATION LJ Unit is fastened to the appropriate mounting pad Louvers are free from obstruction LI Exhaust is clear of flammable objects and debris 28 Generac Power Systems Inc E
33. er as follows If droop is excessive move the governor spring down one slot on the lever For greater stability move the governor spring up one slot on the lever 6 After repositioning the spring on a lever slot recheck the frequency reading and if necessary readjust the adjuster nut to obtain 62 Hertz at no load 7 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the volt age regulator may require adjustment Figure 3 1 6 kW Engine Governor Adjustment GOVERNOR Jk GOVERNOR LEVER SPRING s CLAMP BOLT GOVERNOR ADJUSTOR SHAFT NUT ea Generac Power Systems Inc e 3 7 2 8 KW AND 10 KW UNITS NON SA l Loosen the governor clamp bolt Figure 3 2 2 Push the spring end of the governor lever clock wise to the wide open throttle position of the lever Hold the governor lever at wide open throttle and with a screwdriver rotate the governor shaft fully clockwise Before tightening verify that the governor lever is pushed all the way onto the governor shaft While holding the governor shaft fully clockwise and the governor lever at wide open throttle tighten the governor clamp bolt to 70 inch pounds 8 N m 3 Start the engine let it stabilize and warm up at no load 4 Turn the speed adjust nut to obtain a frequency reading of 62 Hertz 5 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the volt
34. exceed the alternator rating Only these items will be powered by the standby alternator If the electrician sizes the load properly the alternator cannot be overloaded All wiring must conform to the National Electrical Code and all state and local codes Consult a quali fied licensed electrician The above illustration assumes the utility is supply ing 120 240 volt single phase electrical service INSTALLATION P Iii Section 1 Installation Guardian Air cooled Generators 1 9 TOTAL CIRCUIT ISOLATION METHOD If essential electrical loads cannot be grouped togeth er and wired into an emergency distribution panel you will have to select load circuits that the generator will power during a utility power outage Be careful to avoid overloading the generator The fol lowing apply to the Total Circuit Isolation Method Figure 1 7 The transfer switch is installed between the utility service entrance and the distribution panel The transfer switch ampere rating must be equal to the main electrical service entrance rating Figure 1 7 Total Circuit Isolation Method To Power Line Master Switch Power Return Signal Light and Switch Watt Hour Meter i i Service Disconnect i i i Manual Transfer i Switch In Normal i Position To Standby _ Alternator To Range 240V 1 l Distribution Fuse Panel To Water n ph ME To Air Heater 240V g
35. f Manual switch set to AUTO Closure of the circuit starts the unit opening of the circuit stops the unit See Figure 2 5 NOTE This function will work ONLY with the unit in the AUTO mode Figure 2 5 Remote Start Alarm Options CUSTDMER g CONNECTION BOX L e REMOTE START OPTION e NORMALLY OPEN NA LAMP SPST SWITCH ETS TEN NA REMOTE ALARM DPTIUN 7 183 4 Tvpe 14 AWG wire is recommended These options should be wired to the unit by a qualified electrician or Generac Guardian Authorized Dealer Section 2 Operation OPERATION Guardian Air cooled Generators Ir 2 Remote Common Alarm This allows for an alarm light horn etc to activate when any fault has occurred Lines 210 common and 211 normally open provide a closure on common fault which can be used for 120 volts 10 amps maximum See Figure 2 5 3 Remote Not Auto The generator will not auto matically start during a utility failure e 2 6 2 SOUND ATTENUATED UNITS Model 00844 of the sound attenuated air cooled Guardians offers additional features that are not factory preset see Figure 2 6 1 Remote Start This allows for remote starting of the generator by means of the 183 and 178 lines with the Auto Off Manual switch set to AUTO 2 Engine Run Signal The engine run signal is con trolled by the 14 line The volt free engine run sign
36. h SS F SS SS JOOH FHL JOOH FHL ETA TE on L Mi L S06 MAER e el L S8 2 wug coo WAWANIW TIAVAHD Vad 00 WW2 94 NGIA INOUJ gw dai Cam e 2 wuug 0G EN EUER ee mE LEET WwO S8S JOOH FHL J004 FHL H NOYHL 6 e H NOYHL DIVINI HIV e 3WVANI Hie L L 961v WW8 G9OT Generac Power Systems Inc INSTALLATION Section 1 Installation Guardian Air cooled Generators Figure 1 5 Generator Mounting Dimensions Sound Attenuated ino alv MAIA QN3 HO MAIA LNOHH T o o o o a Oc ALO QL EI OO BIN SC DS AS CN e A sS IR E ei 82 d Le 222 Kk E SS ee H NM LUI mop EE o o in o o i Pats son it LJINI SY9 IWANLVN LAN ap 02 OS szzi GIE Do 00 o 00 8 9L 02 INS te a Ke EE 8 0 i i Ee z l Srel l T LS Loy T T T 2 ECHO S30W1d v 3SVE NI c62 SATOH ONILNNOW D Ste l l l l e gt 1 89 62 l OS er ESZ LT 21762 086 ove l 00 82 W i i l EE ND11v201 LINONDI Wi 400 30 3NTILID L A ir DEEG LES 21 aswa 40 3NI10D L sie 10 Generac Power Svstems Inc 1 8 EMERGENCY CIRCUIT ISOLATION
37. he manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher near the generator at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extin guisher properly charged and be familiar with its use If you have any question pertaining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applica ble fuel gas codes Before placing the home stand by electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation you must inspect the fuel system periodically for leaks No leakage is permitted Generac Power Systems Inc 3 INSTALLATION P LED Section 1 Installation Guardian Air cooled Generators 1 1 INTRODUCTION T
38. he unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel sys tem needs to be reconfigured See Section 1 6 4 Page 6 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask your fuel supplier for the Btu content of your fuel Fuel pressure for both natural gas and liquid propane LP vapor set ups MUST be 11 inches to 14 inches of water column 0 6 psi at all load ranges 1 6 2 FUEL CONSUMPTION See the following chart for fuel supply requirements at half and full load for both natural gas and LP vapor Natural gas is in cubic feet per hour 1 6 3 FUEL PIPE SIZING See the following chart for proper sizing of fuel supply piping Insufficient fuel pipe size can cause hard start ing poor engine performance and inability to carry load NG and LP Vapor Pipe Sizing Chart Length of Pipe Iron Pipe Size IPS Inches 2 480 850 43 99 19 435 700 38 i73 380 en 7 15 34 54 70 14 310 f 490 1000 65 i31 285 450 0 z 420 w9 24 380 w 225 9 25 30 Lo woj w Consumption in Cubic Feet Per Hour Model Nat Gas LP Vapor 1 2 Load
39. lly Their definitions are as follows A DIN A After this heading you can read instructions that if not strictly complied with will result in personal injury or property damage WARNING A After this heading you can read instructions that if not strictly complied with may result in personal injury or property damage caution Ak After this heading you can read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading you can read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows A This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of you and others This symbol points out potential explosion hazard Generac Power Systems Inc This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read the Owner s Manual and thoroughly understand all instru
40. lly when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Sequence of Automatic Operation 2 3 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors utili ty power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility source voltage above a preset level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 60 per cent of the nominal supply voltage the sensor energizes a 15 second SA six second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 SA 15 seconds before the load is transferred to a standby source C Standby
41. main contacts to activate and connect load circuits to generator output When utility source voltage is restored logic board opens leads 23 and 194 circuit Loads are then transferred back to utility circuit NOTE Recommended size of control circuit leads Utility l and 2 and 23 and 194 is No 14 AWG stranded copper wire 1 14 ADAPTING THREE PHASE TRANSFER SWITCH The generator you are installing may include a prepackaged transfer switch configured for three phase loads If you want to adapt this kind of transfer switch for single phase loads proceed as follows 1 Discard the three phase power monitor PM found inside the enclosure You will not use it with a single phase system 2 Locate the eight pin octal relay socket in the lower left corner of the transfer switch enclosure 3 Move Wire N1A from Terminal 8 to Terminal 1 by cutting the lug off of NIA stripping wire 5 16 from end and inserting the wire under screw of Terminal 1 NOTE Moving N1A from Terminal 8 to Terminal 1 takes the three phase voltage monitor out of the sensing circuit Now the control circuit board in the con trol module assembly CMA senses utility voltage 4 Now connect the control wires as follows Connect Utility Supply to lugs NI and N2 Connect the Customer Load lugs T1 and T2 Connect the Standby Supply to lugs El and E2 1 15 CONTROL BOARD CONFIGURATION The control board for the 6 kW 8 kW and 10 kw has four dip swit
42. n the generator f Parts of the generator are rotating and or hot during operation Exercise care near running generators 2 Generac Power Svstems Inc A GENERAL HAZARDS For safety reasons Generac recommends that the installation initial start up and mainte nance of this equipment is carried out by a Generac Guardian Authorized Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator The generator MUST be installed outdoors When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Inspect the generator regularly and contact your nearest Generac Guardian Authorized Dealer
43. ncy Power System SENSING amp TRANSFER SIGNAL CONECTRIONS STANDBY POWER CONNECTIONS GROUNDING l STANDBV GENERATOR MAIN EMERGENCV DISTRIBUTION DISTRIBUTION PANEL PANEL Jl wens III STANDBY POWER LEADS SENSING amp TRANSFER SIGNAL LEADS FUEL SUPPLY CONNECTRION Generac Power Systems Inc 17 OPERATION Section 2 Operation Ir Guardian Air cooled Generators NOTE Throughout the Operation section differences in procedures specific to sound attenuated units will be denoted as follows SA information 2 1 USING THE AUTO OFF MANUAL SWITCH FIGURE 2 1 2 2 e 2 1 1 AUTO POSITION Selecting this switch position activates fullv automat ic svstem operation It also allows vou to start and exercise the engine everv seven davs with the setting of the exercise timer see Section 3 10 Page 26 This position also is used for remote starting when it is set up 2 1 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 2 1 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 WAR
44. nd 183 to identically num bered terminals in the GTS switch Turn dip switch 2 Remote Not Auto to the ON position on the generator control printed circuit board NOTE The enclosure roof will need to be removed to gain access to the printed circuit board When a Guardian generator is installed with a stan dard GTS type switch solid state circuit boards in the transfer switch control automatic operation For automatic operating sequences parameters and timing refer to the appropriate GTS transfer switch manual Automatic operation for Guardian generators installed with prepackaged transfer switches is controlled by a control module circuit board in the control panel Refer to the Operation section of this manual 14 Generac Power Systems Inc 1 13 CONTROL CIRCUIT INTERCONNECTIONS For 6 kw 8 kW and 10 kW units not including sound attenuated these interconnections consist of Utility and leads 23 and 194 see Figure 1 9 Page 13 These four leads must be routed in con duit that is separate from the generator AC power leads Control lead functions may be briefly described as follows 1 Utility 1 and Utility 2 Deliver utility source power to the generator s logic circuit board 2 Leads 23 and 194 After the generator starts the logic circuit board in control panel delivers a transfer signal via these two leads When logic circuit board action closes this circuit it causes transfer switch
45. place starter contactor 4 Defective starter motor 4 Replace starter motor 5 Dead battery 5 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel solenoid FS 2 Replace fuel solenoid 3 Open 14 wire from 3 Check connections and engine control board insulation of 14 wires 4 Defective spark plug s 4 Clean re gap or replace plug s The engine starts hard l Air cleaner 1 Check clean or replace and runs rough plugged or damaged air cleaner 2 Defective spark plug s 2 Clean re gap or replace plug s The engine starts but shuts 1 Engine oil level low 1 Check oil and add oil as needed down immediately 2 Defective low oil 2 Replace pressure switch pressure switch 3 Defective high temperature 3 Replace temperature switch switch 4 Defective control board 4 Replace control board The Auto Off Manual switch 1 Defective Auto Off Manual 1 Replace switch is set to OFE but the engine switch continues to run 2 Auto Off Manual switch 2 Check wiring and connections wired incorrectly 3 Defective control board 3 Replace control board There is no AC output from 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON closed position 2 Generator internal failure 2 Contact an Authorized Dealer There is no transfer to 1 Defective transfer switch coil 1 Replace transfer switch coil standby after utility 2 Defective transfer relay 2 R
46. prewired from the factory Complete the following AC power lead connections for single phase units Figure 1 10 Page 13 1 Connect utility power supply leads to transfer switch terminals N1 N2 and the neutral lug 2 Connect circuit load leads to customer load and to transfer switch terminals T1 T2 and the neutral lug Section 1 Installation INSTALLATION e lili Guardian Air cooled Generators Figure 1 9 Interconnection Diagram for Single Phase Power Svstem 6 kW 8 kW and 10 kW Non SA UTILITY SUPPLY TRANSFER SWITCH NEUTRAL LUG NEUTRAL OJ UTILITY 1 OI UTILITY 2 ei S CONNECTION N UTILITY 1 e ojjojjo UTILITV 2 o o 23 194 7 NOTE POWER LEADS AND TRANSFER SWITCH LEADS MUST BE RUN IN TWO DIFFERENT CONDUITS ssssssessjs REMOTE TEST SWITCH OPTIONAL CUSTOMER SUPPLIED OPEN SWITCH TO TEST SWITCH TVPE SPST ELECTRICAL RATINGS 2A 250Vac MIN CUSTOMER LOAD AC GENERATOR CONTROL PANEL Figure 1 10 Interconnection Diagram for Single Phase Power System Sound Attenuated UTILITY SUPPLY 22 33 TRANSFER NEUTRAL SWITCH 1 T NEUTRAL CONNECTION N1 N2 LUG Q E1 E2 b ZR qM 44 EE 2 T1 T2 ojjojjojjojjojjojjojjojjo E d ER ollollollo TE FACTORY CONNECT
47. r has been restored you will want to transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Let the engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generator s Auto Off Manual switch to its OFF or open position The engine should shut down 4 Check that utility power supply to the transfer switch is turned OFF A DIE A A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 5 Use the manual transfer handle inside the trans fer switch to move the main contacts back to their Utility position i e loads connected to the util ity power source Figure 2 3 Page 19 6 Turn ON the utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 2 2 Page 18 2 5 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 1 Lo
48. rcuit breaker to its ON or closed position Loads are now powered by the standby generator 8 Turn ON electrical loads Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 9 Connect an accurate AC frequency meter across terminal lugs El and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 10 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 11 When testing under load is complete turn OFF electrical loads 12 Set the generator s main circuit breakers to their OFF or open positions 13 Let the engine run at no load for a few minutes 14 Set the Auto Off Manual switch to OFF The engine should shut down 3 5 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Check that the Auto Off Manual switch is set to OFF 2 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 3 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker 4 Setthe Auto Off Manual switch to AUTO The sys tem is now ready for automatic operation 5 Turn OFF the utility power supply to the transfer Switch 2 POST cE
49. reached turn the adjustment screw counterclockwise 1 4 turn The fuel system is now set For LP gas operations the hose and blanking plug must be reconfigured as shown in Figure 1 3 Page 7 The unit is set to provide maximum power using LP gas WARNING amp A Do not make any unnecessary adjustments Factory settings are correct for most applica tions However when making adjustments be careful to avoid overspeeding the engine Generac Power Systems Inc 23 S POST C Section 3 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS Guardian Air cooled Generators 3 7 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low adjust the engine governor as follows e 3 7 1 6 KW UNITS NON SA 1 Loosen the governor clamp bolt Figure 3 1 2 Push the spring end of the governor lever clock wise to the wide open throttle position of the lever Hold the governor lever at wide open throttle and with a pair of pliers rotate the governor shaft fully clockwise While holding the governor shaft fully clockwise and the governor lever at wide open throttle tighten the governor clamp bolt to 70 inch pounds 8 N m 3 Start the engine let it stabilize and warm up at no load 4 Turn the adjuster nut to obtain a frequency read ing of 62 Hertz 5 Determine if the governor spring is properly located in the slot of the governor lev
50. rgency Circuit Isolation Method 11 1 9 _ Total Circuit Isolation Method cl 1 10 Generator AC Connection System 12 det 12 1 11 1 6 kW 8 kW and i 10 kW Units Non SA EA Kee 1 11 2 Sound Attenuated Units 12 1 12 Generators and GTS Transfer Switches 14 1 1 13 Control Circuit Interconnections 14 11 14 Adapting Three phase Transfer Switch 1 15 Control Board Configuration Grounding the Generator Table of Contents ca Guardian Air cooled Generators CONTENTS Section 2 Operation 18 2 1 Using the Auto Off Manual Switch 18 i 2 1 1 Auto POSIDOIL coiere rani 18 l 2 1 2 Off POSILIOD ceret 18 2 1 8 Manual Position 18 22 _ Automatic Transfer Operation 2 3 Sequence of Automatic Operation 19 2 4 Manual Transfer Operation 19 2 5 Protection Systems eeeeeee 1 2 5 1 Low Oil Pressure Switch 2 5 2 High Temperature Switch A 2 5 8 OVvercrank aseene Cycle Times 2 5 4 Over speed is eet eS 2 6 Additional Generator Features 2 6 1 6 kW 8 kW and 1 10 kW Units Non SA i 2 6 2 Sound Attenuated Units Section 3 Post installation Start up i i Adjustments 22
51. rn the slotted potentiometer Figure 3 4 until line volt age reads 244 252 volts NOTE You must remove the roof to adjust the voltage regulator on nonsound attenuated units INSTALLATION START UP ADJUSTMENTS Guardian Air cooled Generators Figure 3 4 Voltage Adjustment Potentiometer pp prp gj 9 MD D NOTE The voltage regulator is housed in the generator s control panel The regulator maintains a voltage in direct proportion to frequency at a 2 to 1 ratio For example at 62 Hertz line to neu tral voltage will be 124 volts 3 9 OVERSPEED ADJUSTMENT 3 9 1 6 KW 8 KW AND 10 KW UNITS NON SA See item 3 of Section 1 15 on Page 15 for overspeed adjustment information for these units 3 9 2 SOUND ATTENUATED UNITS Use the following overspeed adjustment procedure l For initial setting turn the potentiometer fully clockwise 2 Start the engine and increase the governed speed setting to 72 Hertz 62 Hertz for 50 Hertz rated units NOTE If immediate shutdown occurs when the engine starts reverse the potentiometer setting done in item 1 3 Turn the adjustment potentiometer slowly until the engine shuts down 4 Readjust the governor to the rated speed Generac Power Systems Inc 25 S POST C Section 3 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS Guardian Air cooled Generators
52. s clear the roof Figure 1 1 Location of Lifting Holes Brackets OEE 4 e Cal 3 XN A d N H grae E 4 ANI se WE d etur Er EN n 6 kW 8 kW and 10 kW l N LIFTING HOLE LIFTING BRACKET Sound Attenuated INSTALLATION P lili Section 1 Installation Guardian Air cooled Generators WARNING A A When lifting or hoisting equipment is used be careful not to touch overhead power lines A The generator s weight of more than 300 pounds requires proper tools and equipment and qualified personnel to be used in all phases of handling and unpacking A Exercise caution when lifting the unit manually as it may shift on lifting pipes during transportation which may result in injury caution A01 A The generator was not designed to be lifted by its roof Use the lifting holes or brackets provided near the base of the unit If using a hook and hoist lifting method you must employ a spreader bar to prevent from crushing the roof 1 5 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Select the viscosity based on the air temperature at the time of operation See the fol lowing chart Temperature Above 7 C 20 F Oil Grade Recommend
53. sys tem After installing this home standby electrical sys tem the generator may crank and start at any time without warning When this occurs load circuits are transferred to the STANDBY generator power source To prevent possible injury if such a start and transfer occur always set the generator s Auto Off Manual switch to its OFF position before working on equipment and remove the fuse In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury Important Safety Instructions Ge ege Guardian Air cooled Generators FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with t
54. t Conditioner 240V FAL To Refrigerator FL To Lights 120V Fal To Furnace Blower i To Lights 120V 4 To Sump Pump Ampere rating is equal to or larger than main nor mal power source Use caution with this system to prevent overload of the alternator during utility power failure All load items in the distribution panel must be individual ly turned off Only certain items can be turned back on during alternator operation These items should be specified by your electrician so as not to overload the alternator All wiring must conform to the National Electrical Code and all state and local codes Consult a quali fied licensed electrician The above illustration assumes the utility is supply ing 120 240 volt single phase electrical service Generac Power Systems Inc 11 INSTALLATION e UD Section 1 Installation Guardian Air cooled Generators 1 10 GENERATOR AC CONNECTION SYSTEM Figure 1 8 represents a single phase three wire gen erator AC connection system The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each sin gle winding can supply a 120 volt 60 Hertz AC out put When the two windings are connected in series a 240 volt 60 Hertz AC output results Stator AC out put leads 11 and 44 are the two hot leads the junc tion of leads 22 and 33 forms the neutral lead Figure 1 8 Generator AC Connection
55. tch to OFF 2 Set the generator s main circuit breaker to its OFF or open position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A DI A A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock Figure 2 3 Manual Transfer Switch Operation LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 4 Use the manual transfer handle inside the trans fer switch to move the main contacts to their Standby position i e loads connected to the standby power source Figure 2 3 5 Turn ON the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker Generac Power Systems Inc 19 OPERATION Section 2 Operation Ir Guardian Air cooled Generators 6 To crank and start the engine set the Auto Off Manual switch to MANUAL 7 Let the engine stabilize and warm up for a few minutes 8 Set the generator s main circuit breaker to its ON or closed position The standby power source now powers the loads 2 4 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility powe
56. two 4 inch bv 4 inch wooden blocks from the underside of the mounting base Plug the holes with the plugs provided Prepare the installation site to accept the mounting base Provide adequate substrate to give sufficient drainage i e a 3 inch deep section of pea gravel scattered under the mounting base See Figure 1 4 Pages 8 9 for generator and transfer switch major dimensions 1 7 1 2 Sound Attenuated Units Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least 3 inches thick and should extend beyond the enclosure to a distance of at least 3 inches on all sides See Figure 1 5 Page 10 for generator major dimensions 1 7 2 TRANSFER SWITCH 1 72 1 6 kW 8 kW and 10 kW Units Non SA The transfer switch shipped with this generator is enclosed in a NEMA 1 enclosure This type of enclo sure is intended for indoor use only Follow these rules Install the transfer switch indoors on a firm stur dy supporting structure To prevent switch distortion level the switch if necessary This can be done by placing washers between the switch enclosure and mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and corrosive vapors 1 7 2 2
57. uld be 120 volts AC 22 Generac Power Systems Inc 4 When certain that utility supply voltage is com patible with transfer switch and load circuit rat ings turn OFF the utility power supply to the transfer switch 5 Set the generator s main circuit breaker to its OFF or open position Initial tests will be con ducted at no load condition 6 On the generator panel set the Auto Off Manual switch to MANUAL The engine should crank and start 7 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator s main circuit breaker to its ON or closed position A DI A A Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock 8 Connect an accurate AC voltmeter and an AC fre quency meter across transfer switch terminal lugs El and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz 9 Connect the AC voltmeter test leads across termi nal lug El and neutral then across E2 and neu tral In both cases voltage reading should be 121 126 volts AC 10 Set the generator s main circuit breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 11 Set the generator s Auto Off Manual switch to OFF The engine should shut down
58. ut 20 minutes and shuts down Transfer of loads to generator output does not occur during the exercise A switch on the control panel see Figure 2 2 Page 18 permits the day and time of day for system exer cise to be selected To select the desired day and time of day proceed as follows 1 Setthe Auto Off Manual switch to OFF 2 Set the generators main circuit breaker to its OFF or open position 3 On the control panel locate the rocker switch identified with the words Set Exercise Time 4 Hold the Set Exercise Time switch in the ON downward position for 20 to 30 seconds The switch springs back into its original position when released 5 Wait about 30 seconds before setting the Auto Off Manual switch to AUTO caution A If you reset the Auto Off Manual switch too soon the engine may start If engine does start it shuts off automatically in two minutes 6 Set the generator s main circuit breaker to its ON or closed position The generator will start and exercise every seven days thereafter on the day and at the time of day you pressed the switch Section 4 Troubleshooting TROUBLESHOOTING Guardian Air cooled Generators 4 1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank l Fuse blown 1 Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective starter contactor 3 Re
59. vidence 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 your body before touching the battery by first touching a grounded metal surface A 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 you attach the cables and cause an explosion 1 17 1 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if nec essary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Set the generator s Auto Off Manual switch to OFF 2 Turn off utility power supply to the transfer switch WARNING amp If the Auto Off Manual switch is not set to its gt OFF position the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off sparking can occur at the battery posts and cause an explosion Battery
60. w Oil Pressure Sensor 2 High Temperature Sensor 3 Overcrank 4 Overspeed 20 Generac Power Systems Inc On sound attenuated models there are LED read outs on the control panel to notify you that one of these faults has occurred There is also a System Set LED that is lit when all of the following condi tions are true 1 The Auto Off Manual switch is set to the AUTO position 2 The Not In Auto dip switch is set to the OFF position on the control board 3 No alarms are present e 2 5 1 LOW OIL PRESSURE SWITCH This switch Figure 2 4 has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the Auto Off Manual switch must be turned to OFF and then back to AUTO e 2 5 2 HIGH TEMPERATURE SWITCH This switch s Figure 2 4 contacts close if the tem perature should exceed approximately 140 C 284 F initiating an engine shutdown Your generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level Figure 2 4 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE p ENGINE OL OIL PRESSURE FILTER SWITCH D M n 2 5 3 OVERCRANK This feature prevents the generator from damaging itself
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