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®
POWER SYSTEMS, INC.
Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
(Natural Gas)
004188-1
004370-2
004474-1
(Liquid Propane Vapor)
004189-1
004371-2
004475-1
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
*This manual should remain with the unit.*
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The operator is responsible for proper and safe use of INTRODUCTION the equipment. We strongly recommend that the opera- Thank you for purchasing this model of the standby gen- tor read this Owner's Manual and thoroughly under- erator set product line by Generac Power Systems. stand all instructions before using this equipment. We Every effort was expended to make sure that the infor- also strongly recommend instructing other users to mation and instructions in this manual were both accu- prope
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Table of Contents Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators INTRODUCTION ....................................IFC Section 3 OPERATION ..........................................11 SAFETY RULES..........................................2 Using a Standard “GTS” Transfer Switch ................11 Section 1 Control Console Components ..................................12 GENERAL INFORMATION ......................4 Manual Transfer and Startup ..................................13 Generator
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Important Safety Instructions Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 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, potential operators, and service and repair technicians for this equipment. SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and b
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Important Safety Instructions Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Inspect the generator regularly, and promptly repair Generators installed with an automatic 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 acceptable preset level. To prevent such automatic Before performing any maintenance on the generator, start-up and
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Section 1 - General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators GENERATOR AUTOMATIC SYSTEM OPERATION This equipment is a liquid-cooled, engine-driven gener- When this generator, along with its transfer switch, has ator set. The generator is designed to supply electrical been installed and interconnected, a circuit board in the power that operates critical electrical loads during util- generator panel constantly monitors utility power ity power failure. The unit has been
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Section 1 - General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 1.2 - Main Circuit Breaker Model Rating Phase Actual Current C/B Rating* % over rating Circuit Breaker 004188 15,000 1 62.5 70 112% 70A BQ2 004189 15,000 1 62.5 70 112% 70A BQ2 004370 20,000 1 83.3 90 108% 90A BQ2 004371 20,000 1 83.3 90 108% 90A BQ2 004474 25,000 1 104.2 125 120% 125A BQ2 004475 25,000 1 104.2 125 120% 125A BQ2 * Amp Rating of C/B structured under model. Figure 1.4 - Low Oil Pressure
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Section 1 — General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 1.6 - Low Coolant Level Sensor DC FUSE This clearly labeled fuse is located on the front panel of the control system. It protects the panel wiring and com- ponents from damaging overload. Always remove this fuse before commencing work on the generator. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. Generac normally uses an AGC fuse
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Section 1 — General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators ENGINE SPECIFICATIONS ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W-40 engine oil at the fac- Make ..................................................................................Mitsubishi tory. Use a high-quality detergent oil classified “For 3 Displacement ....................................................92 inches (1.5 liters) Service CC, SD, SE, SF.” Detergent oils keep the engine Cy
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Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 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, 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 result in injury or death to utility
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Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Critical electrical loads are grouped together and wired GENERATOR MOUNTING AND SUPPORT into a separate “Emergency Distribution Panel.” Load Retain the generator compartment to a concrete slab circuits powered by that panel are within the with 1/4-inch masonry type anchor bolts. Be sure the wattage/amperage capacity of the generator set. When bolts are long enough to retain the compartment. The this method is used,
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Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral. Do not dispose of the battery in a fire. The bat- Grounding is recommended only at the main service tery is capable of exploding. entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current Do not open or mutilate the battery. Released ! opens the load circuit breaker or collapses the genera- ele
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Section 3 - Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Engine Coolant PREPARATION BEFORE START-UP The instructions in this section assume that the stand- Have the engine cooling system properly filled with the by generator has been properly installed, serviced, test- recommended coolant mixture. Check the system for ed, adjusted and otherwise prepared for use by a com- leaks and other problems. See “Specifications” and petent, qualified installation contractor. Be sure to
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Section 3 — Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators CONTROL CONSOLE COMPONENTS HOURMETER The components of a liquid-cooled generator control Indicates time the engine-generator has operated, in console (Figure 3.1) are as follows: hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for the genera- Figure 3.1 - Liquid-Cooled Generator Panel tor set. AUTO/OFF/MANUAL SWITCH Use this 3-position switch as follows: Set the switch to
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Section 3 - Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators NOTE: WEEKLY EXERCISE CYCLE This fuse will not remove the + battery input power The generator will start and exercise once every 7 days. from the PCB when it opens. This means the exercise During this weekly exercise, the unit runs for about 20 timer will not be reset. If this fuse does open, care- minutes and shuts down. Transfer of loads to generator fully check the wiring to the start, fuel, field boost output does
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Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators E. EVERY 500 OPERATING HOURS ENGINE HEATER The Generac standby generator comes equipped with a 1.Service air cleaner. block heater (Figure 4.1), similar to the block heaters 2.Check starter. used in automotive applications. The block heater is 3.Check engine DC alternator. wired to a grounded plug. F. EVERY 800 OPERATING HOURS Figure 4.1 - Engine Block Heater 1.Retorque cylinder head. (See Torque Specs.) 2.Retorque
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Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators If oil level is below the dipstick ADD mark, remove oil EXERCISE SYSTEM fill cap. Add the recommended oil to bring oil level up Start the generator engine at least once every seven days to the FULL mark. DO NOT FILL ABOVE THE and let it run at least 20 minutes. See “Weekly Exercise “FULL” MARK. (See Engine Oil Recommenations.) Cycle”. Figure 4.2 - Oil Dipstick and Oil Fill Cap INSPECT COOLING SYSTEM OIL DIPSTICK
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Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 4.4 – Engine Air Cleaner CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning. This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into
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Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 1. Inspect the battery posts and cables for tightness MISCELLANEOUS MAINTENANCE and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries CLEANING THE GENERATOR and, if necessary, fill with DISTILLED WATER Keep the generator as clean and as dry as possible. Dirt ONLY. DO NOT USE TAP WATER IN BATTERIES. and moisture that accumulates on internal generator 3. Have the state
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Section 5 — Troubleshooting Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators PERIODIC REPLACEMENT PARTS Part Name Generac’s Part Number Oil Filter # 0A45310244 Radiator Cap # 046627 Air Cleaner # 059402 Spark Plug # 0A45310275 TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 30 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3. Replace contact
