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Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Nos. 005040-0, 005040-1 (25kW)
005053-0, 005053-1 (20kW)
005054-0, 005054-1 (15kW)
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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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 this model of the Guardian the operator reads this Owner's Manual and thor- Elite standby generator series by Generac Power oughly understands all instructions before using this Systems, Inc.. equipment. Generac also strongly recommends Every effort was expended to make sure that the instructing other users to properly start and operate information and inst
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Table of Contents Guardian Liquid-cooled 25 kW Generator INTRODUCTION................................................IFC Section 3 — OPERATION ................................12 Read this Manual Thoroughly......................................IFC 3.1 Engineered GTS Transfer Switch........................12 Operation and Maintenance ........................................IFC 3.2 Control Console Components..............................13 How to Obtain Service .....................................
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Important Safety Instructions Guardian Liquid-cooled 25 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, 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 batteries. ! ! ! !
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Important Safety Instructions Guardian Liquid-cooled 25 kW Generator ELECTRICAL HAZARDS FIRE HAZARDS All generators covered by this manual produce dangerous Keep a fire extinguisher near the generator at all times. Do electrical voltages and can cause fatal electrical shock. NOT use any carbon tetra-chloride type extinguisher. Its Utility power delivers extremely high and dangerous volt- fumes are toxic, and the liquid can deteriorate wiring insu- ages to the transfer switch as well as the s
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Section 1 - General Information Guardian Liquid-cooled 25 kW Generator Protect the switch at all times against excessive 1.1 GENERATOR moisture, dust, dirt, lint, construction grit and cor- This equipment is a liquid-cooled, engine-driven gen- rosive vapors. erator set. The generator is designed to supply elec- If a transfer switch is not included, one may be pur- trical power that operates critical electrical loads chased separately from a Generac Authorized Dealer. during utility power failu
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Section 1 - General Information Guardian Liquid-cooled 25 kW Generator 1.7.1 LOW OIL PRESSURE SWITCH 1.5 MAIN CIRCUIT BREAKER The generator’s main circuit breaker is included with This switch is normally-closed (N.C.) but is held open the unit as shipped from the factory. The breaker for by engine oil pressure during engine running. Should each unit is described in Figure 1.2. operating oil pressure drop below about 8-10 psi (55-68 kPa), the switch contacts close and the engine 1.6 GENERATOR FU
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Section 1 — General Information Guardian Liquid-cooled 25 kW Generator Figure 1.6 - Low Coolant Level Sensor 1.8.2 INSPECTION Upon delivery, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consign- or’s memo of loss or damage. 1.9 LIFTING THE GENERATOR 1.7.4 OVERSPEED SHUTDOWN When lifting or hoistin
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Section 1 — General Information Guardian Liquid-cooled 25 kW Generator 1.10.2 GENERATOR Single-phase Single-phase Single-phase Model 005040-0 005053-0 005054-0 Rated Max. Cont. *25 20 15 AC Power Output (kW) Rated voltage (volts) 120/240 120/240 No. of Rotor Poles 4 4 4 Driven Speed of Rotor 1800 1800 1800 Rotor Excitation System Direct excited brush type Direct excited brush type Direct excited brush type Type of Stator 4 Wire 4 Wire 4 Wire Rotor Insulation Class F Class F Class F Stator Insul
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Section 2 — Installation Guardian Liquid-cooled 25 kW Generator The standard prepackaged transfer switch does not 1.13 ENGINE OIL RECOMMENDATIONS have sensing or controlling circuit boards. Instead, The unit has been filled with 15W-40 engine oil at the the generator control console houses a “Printed factory. Use a high-quality detergent oil classified “For Circuit Board Assembly”, which controls all phases Service CC, SD, SE, SF.” Detergent oils keep the of operation, including engine start up
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Section 2 — Installation Guardian Liquid-cooled 25 kW Generator NFPA No. 68, GUIDE FOR EXPLOSION VENTING 2.3 GENERATOR MOUNTING AND NFPA No. 70, NATIONAL ELECTRICAL CODE. SUPPORT NFPA No. 30, FLAMMABLE AND COMBUSTIBLE Retain the generator compartment to a concrete slab LIQUIDS CODE. with 1/4-inch masonry type anchor bolts. Be sure the NFPA No. 10, INSTALLATION, MAINTENANCE AND bolts are long enough to retain the compartment. The USE OF PORTABLE FIRE EXTINGUISHERS. slab should be at least
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Section 2 — Installation Guardian Liquid-cooled 25 kW Generator Figure 2.2 – Generator Grounding Lug (typical) 2.5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only crit- ical loads, within the wattage/amperage capacity, dur- ing utility power outages, consider using the emer- gency circuit isolation method. Critical electrical loads are grouped together an
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Section 2 — Installation Guardian Liquid-cooled 25 kW Generator The battery represents a risk of high short cir- Pos2 OFF — Standard Prepackaged ATS cuit current. When working on the battery, Application always remove watches, rings or other metal The control board will perform all of the automat- objects, and only use tools that have insulated ic features listed in this document. handles. The two-wire start connections, wires 178-183, should NOT be connected. 2.10.1 VENTED BATTERIES NOTE:
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Section 3 - Operation Guardian Liquid-cooled 25 kW Generator 2.11 PREPARATION BEFORE START-UP 2.11.5 ENGINE COOLANT The instructions in this section assume that the Have the engine cooling system properly filled with standby generator has been properly installed, serv- the recommended coolant mixture. Check the system iced, tested, adjusted and otherwise prepared for use for leaks and other problems. See “Specifications” by a competent, qualified installation contractor. Be and “Coolant”. sure
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Section 3 - Operation Guardian Liquid-cooled 25 kW Generator GTS Mode Operation DANGER When in GTS mode, the control board will respond With switch set to AUTO, engine can crank as follows based on the generator AUTO/OFF/MANU- and start suddenly without warning. Such AL switch position. ! automatic start up normally occurs when utili- OFF — The generator will not start and run in this ty source voltage drops below a pre-set level. position. To prevent possible injury that might be caused by such
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Section 3 - Operation Guardian Liquid-cooled 25 kW Generator Condition System Low Low High Over Over Switch Position Ready (Green) Bat (Red) Oil (Red) Temp (Red) Speed (Red) Crank (Red) Manual Auto Off Generator Switch is OFF X OFF OFF OFF OFF O in the OFF Mode. System Ready for ON X OFF OFF OFF OFF O Automatic Start Generator Switch is OFF X OFF OFF OFF OFF O in the MANUAL Mode Weekly Exerciser X Flashing Flashing Flashing Flashing Flashing O O O is not set (-----------------------------------1
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Section 3 - Operation Guardian Liquid-cooled 25 kW Generator 3. Under no load condition, increase the GAIN pot Let the generator engine run at no-load for a few as much as possible without causing instability. minutes, to stabilize internal unit temperatures. 4. Apply 1/4, 1/2, 3/4 and full load to the unit. On the generator console, set the Auto/Off/ Manual Decrease the GAIN pot if there is instability at any switch to Off. Wait for engine to come to a complete load point. stop. 5. Under fu
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Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator At this time all five red LEDs will flash for approxi- Switch Position 4 — Selects the type of fuel being mately 10 seconds, then the engine will start and run used and is factory pre-set for natural gas (NG). for it’s 12 minute exercise period, then shut down. Switch Position 5 — Selects the engine displacement The generator will now start and run each week at the and is factory pre-set for a 2.5 liter (2.5L) engine. same time. Swit
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Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator F. EVERY 800 OPERATING HOURS 4.4 CYLINDER HEAD PROCEDURE 1. Position head gasket on the block (Figure 4.2). 1. Retorque cylinder head (see torque specs). 2. Position cylinder head to cylinder block. 2. Retorque intake and exhaust manifold (see 3. Install 10 cylinder head bolts in numerical torque specs). sequence. Tighten to 70 N-m (52 lb-ft) in 3. Check engine compression. sequence. Retighten to 70 N-m (52 lb-ft) in 4. Check valve c
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Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator 4.7.3 ENGINE COOLANT 4.6 OVERLOAD PROTECTION FOR Check coolant level in coolant recovery bottle. See ENGINE DC ELECTRICAL SYSTEM Specifications. Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Add recommended coolant mixture as necessary. Battery voltage is delivered to that circuit board via a Periodically remove radiator pressure cap (only 15 amp fuse. These overcurrent pr
