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Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Models: 0043733, 0043734
& 0043735
(40 kW/Single-phase w/
200 Amp Transfer
Switch)
0046262, 0046263
& 0046264
®
POWER SYSTEMS, INC.
®
(40 kW/Single-phase w/
200 Amp Transfer
Switch California
Emissions)
Not intended for use in critical life support applications.
! !
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION!!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
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The operator is responsible for proper and safe use INTRODUCTION of the equipment. Generac strongly recommends that Thank you for purchasing the Guardian product line the operator read this Owner's Manual and thor- by Generac Power Systems. This model is a compact, oughly understand all instructions before using this high performance, liquid-cooled, engine-driven gen- equipment. Generac also strongly recommends erator designed to automatically supply electrical instructing other users to properl
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Table of Contents Guardian Liquid-cooled 40 kW Generator Introduction ......................Inside Front Cover Section 3 – Operation ..................................12 Read This Manual Thoroughly ......................IFC 3.1 Control Console Components ......................12 Contents ........................................................IFC 3.1.1 AC Voltmeter ..................................12 Operation and Maintenance............................IFC 3.1.2 AC Ammeter ....................
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Important Safety Instructions Guardian Liquid-cooled 40 kW Generator SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all ! ! operators and potential operators of this equipment. SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. ! ! ! ! ! ! GENERAL HAZARDS WARNING: The e
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Important Safety Instructions Guardian Liquid-cooled 40 kW Generator Inspect the generator regularly, and promptly repair Generators installed with an automatically transfer or replace all worn, damaged or defective parts using switch will crank and start automatically when nor- only factory-approved parts. mal (utility) source voltage is removed or is below an Before performing any maintenance on the generator, acceptable preset level. To prevent such automatic disconnect its battery cabl
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Section 1 — General Information Guardian Liquid-cooled 40 kW Generator When the two windings are connected in series, a 240- 1.1 UNPACKING/INSPECTION volt, 60-Hertz AC output results. Typically, the two “hot” After unpacking, carefully inspect the contents for dam- leads in the circuit are Wires 11 and 44. The neutral age. leads are the junction of Wires 22 and 33. This standby generator set has been factory installed in an all-weather, metal enclosure that is intended Figure 1.1 – Single-pha
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Section 1 — General Information Guardian Liquid-cooled 40 kW Generator 1.7.3 LOW COOLANT LEVEL SWITCH 1.6 MAIN CIRCUIT BREAKER The generator’s main circuit breaker is included with the Should the engine coolant level drop below the level of the unit as shipped from the factory. The breaker for each high coolant temperature switch, it is possible for the unit is described as follows: engine to overheat without automatic shut down. To pre- vent such overheating without automatic shut down, the Mo
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Section 1 — General Information Guardian Liquid-cooled 40 kW Generator 1.8.2 GENERATOR AND LOAD COMPATIBILITY 1.9 FUEL REQUIREMENTS The generator must be fully compatible with the rated AND RECOMMENDATIONS voltage, number of phases and frequency of the con- With LP gas, use only the vapor withdrawal system. This nected electrical loads. The generator, connected elec- type of system uses the vapors formed above the liquid fuel in the storage tank. trical devices, or both, can be damaged if volt
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Section 1 — General Information Guardian Liquid-cooled 40 kW Generator 1.10 ENGINE OIL RECOMMENDATIONS 1.12 EMISSIONS CONTROL SYSTEM The unit has been filled with 15W-40 engine oil at the (MODELS 0046262, 0046263 & 0046264) factory. Use a high-quality detergent oil classified “For This model is equipped with an active exhaust emis- Service CC, SD, SE or SF.” Detergent oils keep the sions control system to comply with certain California engine cleaner and reduce carbon deposits. Use oil hav- air
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Section 2 — Installation Guardian Liquid-cooled 40 kW Generator STANDBY GENERATOR INSTALLATION DANGER Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch (such as the Generac “GTS” type transfer switch), so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also resul
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Section 2 — Installation Guardian Liquid-cooled 40 kW Generator Figure 2.1 – Basic Standby Electric System DANGER Do not connect the ground wire to any pipe that carries a flammable or explosive substance – FIRE or an EXPLOSION may result. Proper grounding helps protect personnel against electri- cal shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devic
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Section 2 — Installation Guardian Liquid-cooled 40 kW Generator NOTE: 2.7.1 VENTED BATTERIES When using a GTS switch, it is necessary to connect a 240V AC supply to N1 and N2 terminals of the generator to provide for battery charging. Wires T1, T2, 23 and 194 should not be The electrolyte is a dilute sulfuric acid that is ! connected. harmful to the skin and eyes. It is electrically con- ductive and corrosive. The following procedures are to be observed: 2.7 BATTERY INSTALLATION Wear full e
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Section 2 — Installation Guardian Liquid-cooled 40 kW Generator 2.8.1 PRIOR TO INITIAL START-UP 2.8.6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of approx- Prior to initially starting the generator, it must be imately 22 pounds (10 kg), applied midway between ! properly prepared for use. Any attempt to crank pulleys, deflects the belt about 3/8- to 5/8-inch (10 to 16 or
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Section 3 — Operation Guardian Liquid-cooled 40 kW Generator 3.1.6 AUTO/OFF/MANUAL SWITCH 3.1 CONTROL CONSOLE COMPONENTS The components of a liquid-cooled generator control See Section 3.2. console (Figure 3.1) are as follows: 3.1.7 FAULT INDICATOR LAMP Figure 3.1 – Control Console This lamp goes ON when one or more of the following engine faults occurs and when engine shuts down. Low oil pressure High coolant temperature Low coolant level Overcrank Overspeed 3.1.8 15-AMP FUSE This
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Section 3 — Operation Guardian Liquid-cooled 40 kW Generator Upon restoration of utility source voltage above a preset 3.2.2 “OFF” POSITION level, generator circuit board action signals the transfer This switch position shuts down the engine. This posi- switch to transfer loads back to that power supply. After tion also prevents operation. retransfer, the engine is signalled to shut down. The actual sequence of operation is controlled by 3.2.3 “MANUAL” POSITION sensors and timers on a control
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Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator Place a sign on the generator’s control panel and on Figure 3.2 – Engine Block Heater the transfer switch that indicates the day and time the generator will be exercising. OUTLET NOTE: If the battery terminals are disconnected or the con- trol panel fuse is removed, the exercise timer needs to be reset for automatic exercise operation. Figure 3.3 – “Set Exercise” Switch on Control Panel INLET Refer to applicable wiring diagram(s) a
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Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator Figure 4.1 – Oil Dipstick and Fill Figure 4.2 – Oil Filter
4.2 CHANGING THE ENGINE OIL AND 5. Apply a light coating of engine oil to the seal of new oil filter. Install the filter and tighten by hand FILTER only. DO NOT OVERTIGHTEN. 6. Remove the oil fill cap (Figure 4.1). Add the recom- 4.2.1 ENGINE OIL RECOMMENDATIONS mended oil (see Section 4.2.1). DO NOT FILL Use oil of
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Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator Figure 4.3 – Engine Air Cleaner DANGER Air Cleaner Standby generators installed with automatic transfer switches will crank and start automatical- ly when normal (utility) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to per- sonnel, do not connect battery cables until the normal source voltage at the transfer switch is correct and the system is ready to be pl
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Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator 4.6 COOLING SYSTEM 4.9 ENGINE COOLANT Air intake and outlet openings in the generator compart- Check the coolant level in the coolant recovery bottle. ment must be open and unobstructed for continued prop- Add the recommended coolant mixture as necessary, er operation. This includes such obstructions as high see Section 1.10. grass, weeds, brush, leaves and snow. Periodically remove the radiator pressure cap to make Without suffi
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Section 4 — Maintenance Guardian Liquid-cooled 40 kW Generator 2. Inside the generator set, the chance of rodent entry 4.11.2 RETURN TO SERVICE into the control panel is greatly reduced by the To return the unit to service after storage, proceed inclusion of adjustable wire connectors. Check that as follows: the wire connector screws are tight, thus closing off any gap between the access holes and the wires. 1. Verify that utility power is turned off to the transfer switch and that the Auto/Of
