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®
POWER SYSTEMS, INC.
Installation and
Owner’s Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
04389-1 (6 kW NG, 7 kW LP)
04456-1 (12 kW NG, 12 kW LP)
04390-1 (13 kW NG, 15 kW LP)
R
GENERAC
POWER SYSTEMS, INC.
R
Not intended for use as Primary Power in place of utility or in
!
!
life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
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This symbol points out potential electrical shock INTRODUCTION hazard. Thank you for purchasing this model of the Guardian The operator is responsible for proper and safe use product line by Generac Power Systems Inc. This of the equipment. We strongly recommend that the model is a compact, high performance, air-cooled, operator read this Owner's Manual and thoroughly engine-driven generator designed to automatically understand all instructions before using this equip- supply electrical power t
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Table of Contents Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 3.2.2 “Off” Position....................................14 Introduction ........................Inside Front Cover Read This Manual Thoroughly ........................IFC 3.2.3 “Manual” Position ............................14 Contents ..........................................................IFC 3.3 Automatic Transfer Operation ....................14 Operation and Maintenance ............................IFC 3.4 Sequence of Au
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IMPORTANT SAFETY INSTRUCTIONS Guardian Air-cooled 7 kW, 12 kW and 15 kW 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 ! ! all operators and potential operators of this equipment. ! ! ! ! WARNING: GENERAL HAZARDS The engine exhaust from this product For safety reasons, Generac recommends contains chemicals known to the state of California to cause cancer, bi
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IMPORTANT SAFETY INSTRUCTIONS Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National ELECTRICAL HAZARDS Fire Protection Association are appropriate for use on the standby electric system. Keep the extin- All generators covered by this manual produce dangerous electrical voltages and can cause fatal guisher properly charged and be familiar with its use. If you have any question pertaining to fire
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Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1.2 PROTECTION SYSTEMS DANGER Unlike an automobile engine, the generator may have to run for long periods of time with no operator present to Only qualified electricians or contractors should attempt such installations, which must comply strictly monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it with applicable codes, standards and regulations. against
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Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1.4 YOUR GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Control Panel Data Decal Exhaust Enclosure Air Filter Fuel Regulator Battery Compartment Oil Filter Figure 1.2 – 12 kW and 15 kW, V-twin GT-990 Engine Data Control Decal Panel Oil Dipstick Air Filter Exhaust Enclosure Fuel Regulator Battery Compartment Oil Filter ® Generac Power Systems, Inc. 5
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Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1.5 SPECIFICATIONS 1.5.1 GENERATOR Model 04389-1 Model 04456-1 Model 04390-1 Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP† Rated Voltage 120/240 120/240 120/240 Rated Max. Continuous Load Current (Amps) 120 Volts** 50.0 NG/58.3 LP 100.0 NG/100.0 LP 108.3 NG/125.0 LP 240 Volts 25.0 NG/29.2 LP 50.0 NG/50.0 LP 54.2 NG/62.5 LP Main Line Circuit Breaker 30 A
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Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 3. Disconnect wire #0 and wire #14 from the gas 1.6 FUEL REQUIREMENTS solenoid located on the top of the demand regu- AND RECOMMENDATIONS lator. With LP gas, use only the vapor withdrawal 4. Remove the demand regulator by rotating coun- system. This type of system uses the vapors formed terclockwise. above the liquid fuel in the storage tank. 5. Remove the brass hose fitting from the outlet port of the demand r
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Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 5. Remove the small brass hose fitting from the idle Install the generator on high ground where water circuit port of the regulator housing. levels will not rise and endanger it. 6. Remove the small jet (0D5698A) located in the Allow sufficient room on all sides of the generator side of the regulator housing and install it into the for maintenance and servicing. A good rule is to small threaded hole in the i
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Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Battery cables were factory connected at the genera- DANGER tor (Figure 1.5). Connect cables to battery posts as follows: Do not dispose of the battery in a fire. The 4. Connect the red battery cable (from starter con- battery is capable of exploding. tactor) to the battery post indicated by a positive, A battery presents a risk of electrical shock POS or (+). and high short circuit current. The following 5. C
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Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Be sure the utility power supply is turned off DANGER and the 5A and 15A fuses are removed from the generator control panel, or sparking may The transfer switch is now electrically “hot.” occur at the battery posts as you attach the Contact with “hot” parts will result in extreme- cables and cause an explosion. ly hazardous and possibly fatal electrical shock. Proceed with caution. 2.1 BEF
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Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC To test the generator set with electrical loads applied, OPERATION proceed as follows: To check the system for proper automatic operation, 1. Set generator’s main circuit breaker to its OFF proceed as follows: (or open) position. 1. Set generator’s main circuit breaker to its OFF 2. Turn OFFall loads connected to the transfer (or open)
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Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 3. Turn on appliances, lights, pumps, etc., that are 7. Turn utility power to the main distribution panel on the emergency circuits in an attempt to fully back on. This can be done by switching the serv- load the generator. Be cautious not to overload ice main breaker to the on or closed position. the generator. Use the following chart as a guide: Allow the generator to shut down. Unit 120
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Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Figure 2.5 – Voltage Adjustment Potentiometer 2.7.2 12 KW AND 15 KW UNITS ◆ 1. Loosen governor clamp bolt (See Figure 2.3). 2. Completely remove the idle spring. 3. With governor arm at wide open throttle position, rotate governor shaft fully clockwise. Tighten clamp bolt to 84 inch-pounds. 4. Start unit and apply full load. Use full load speed adjust screw (Figure 2.4) to adjust frequency to 58 Hz. 5. Remove load, stop e
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Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 11. Drain the oil and remove the oil filter. Replace the 3.3 AUTOMATIC TRANSFER oil filter according to Section 4.4, “Changing the OPERATION Oil Filter” (Page 18). Replace the oil with synthet- To select automatic operation, do the following: ic oil as recommended in Section 4.3, “Changing the Engine Oil” (Page 17). 1. Make sure the transfer switch main contacts are 12.Reconnect the battery cables as outlined in set to t
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Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators D.Utility Voltage Pickup Sensor 5. To crank and start the engine, set the This sensor monitors utility power supply volt- Auto/Off/Manual switch to MANUAL. age. When that voltage is restored above 70 per- 6. Let the engine stabilize and warm up for a few cent of the nominal source voltage, a retransfer minutes. time delay starts timing. 7. Set the generator’s main circuit breaker to its ON E.Retransfer Time Delay (or c
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n e s o o L Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1. Verify that the Auto/Off/Manual switch is set 3.7.3 OVERCRANK to AUTO. This feature prevents the generator from damaging 2. Hold down the “Set Exercise Time” switch until itself when it continually attempts to start and anoth- the generator starts (approximately 10 seconds) er problem, such as no fuel supply, prevents it from and then release. starting. The unit will crank and rest for a preset time 3.
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Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Figure 4.1 – Generator Control Panel Figure 4.3 — Oil Dipstick and Fill, 12 kW and 15 kW FUSE R Loc at e y our near es t dealer at : Oil Dipstick R POWER SYSTEMS, INC. 5A AUTO OFF MAN. SYSTEM SET LOW OIL HIGH TEMP. FUSE OVER SPEED OVER CRANK Oil Fill SET F L A S H IN G G R EEN L ED = 15A N O U T IL IT Y S E N S E EXERCISE 4FLASHING RED LEDS= EX ER C IS ER N O T S ET TIME 4.2 CHECKING THE ENGINE OIL LEVEL For oil capaci
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n e s o o L Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Figure 4.4 – Oil Drain Hose and Filter Figure 4.6 — 7 kW, Engine Air Cleaner Location Low Oil Switch High Temp Switch Fuel Air Cleaner Regulator Oil Drain Hose Oil Filter Figure 4.7 — 12 kW and 15 kW Engine 4.4 CHANGING THE OIL FILTER Air Cleaner Change the engine oil filter as follows: 1. With the oil drained, remove the old oil filter by Screw turning it counterclockwise. 2. Apply a light coating of clean
