Generac Power Systems 04077-01, 04109-1, 04079-1, 00789-1, 00844-1 manual

PO WER SY STEMS, INC. ® Installation, Start-up and Adjustment Manual 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) 00789-1 (8 kW) 00844-1 (8 kW) ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!![...]

Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing a model of the Guardian product line by Generac P ower 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 fac[...]

T able of Contents Guardian Air-cooled Generators Generac® Pow er Systems, Inc. 1 Introduction ......................Inside Front Cover Read This Manual Thoroughly ......................IFC Operation and Maintenance ............................IFC How to Obtain Service ....................................IFC Authorized Dealer Location Number......[...]

2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully 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 accident[...]

Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • 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. A void contact with bare wires, t[...]

1.1 I NTRODUCTION T O I NST ALL A TION 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 mi[...]

1.3 B EFOR E I NS T ALLA TION Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Circuit Isolation Method” and “T otal Circuit Isolation Method” in Sections 1.8 and 1.9 (P age 11) carefully . The generator's rated wattage/amperage capacity must be adequate to handle all el[...]

6 Generac ® Pow er Systems, Inc. W ith 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. The [...]

Generac ® Pow er Systems, Inc. 7 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 1.7 L OCA TIO[...]

8 Generac ® Pow er Systems, Inc. Figure 1.4 – Generator and Transfer Switch Mounting Dimensions (6 kW, 8 kW and 10 kW Non-SA) Section 1 — Installation Guardian Air-cooled Generators[...]

Generac ® Pow er Systems, Inc. 9 Figure 1.4 (Continued) Section 1 — Installation Guardian Air-cooled Generators[...]

10 Generac ® Pow er Systems, Inc. Figure 1.5 – Generator Mounting Dimensions (Sound Attenuated) Section 1 — Installation Guardian Air-cooled Generators[...]

Generac ® Pow er Systems, Inc. 11 1.8 EM ERGENCY CI RCU IT IS OL A TION 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 emer[...]

12 Generac ® Pow er Systems, Inc. 1.1 0 GEN ER A T OR A C C ON N E CTION S Y S TEM 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[...]

Generac ® Pow er Systems, Inc. 13 Section 1 — Installation Guardian Air-cooled Generators Figure 1.10 – Interconnection Diagram for Single-Phase Power System (Sound Attenuated) Figure 1.9 – Interconnection Diagram for Single-Phase Power System (6 kW, 8 kW and 10 kW Non-SA)[...]

14 Generac ® Pow er Systems, Inc. 1.1 2 GEN ER A T ORS AND GT S TR ANSF ER SWIT CH ES Guardian generators (this DOES NOT APPL Y 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). Y ou can do this by connecting generator control[...]

Generac ® Pow er Systems, Inc. 15 1.1 4 AD APTING TH R EE-P HA SE TR ANSF ER SWIT CH 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[...]

16 Generac ® Pow er Systems, Inc. 1.1 7 TH E B A TTER Y Servicing of the battery is to be performed or super- vised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized person- nel away from batteries. When replacing the battery , use the following type of battery: Group 26/26R 12-volt battery with a rating of 35[...]

Generac ® Pow er Systems, Inc. 17 1.1 7 .1 BA TTERY INST ALLA TION 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 A uto/Off/Manual switch to OFF . 2. T urn off utility [...]

18 Generac ® Pow er Systems, Inc. NOTE: Throughout the “Operation ” section, differences in procedures specific to sound attenuated units will be denoted as follows: (SA = information). 2.1 USI NG TH E AUT O/OF F/MAN UAL SWIT CH (FIGURE 2.1/2.2) 2.1.1 “ AUT O” POSITION Selecting this switch position activates fully automat- ic system opera[...]

Generac ® Pow er Systems, Inc. 19 2.3 SE QU ENCE OF AUT OMA TIC OP ER A TION 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[...]

20 Generac ® Pow er Systems, Inc. 6. T o crank and start the engine, set the Auto/Off/Manual switch to MANU AL. 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 TR ANSFER BA CK T O UTI LITY POWER S OURCE When[...]

2.5.3.1 Approximat e Crank Cycle T imes • 15 seconds ON • 15 seconds OFF • 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 [...]

22 Generac ® Pow er Systems, Inc. 3.1 B EFOR E I N ITIAL S T ART -U P Before starting, complete the following: 1. Set the generator's A uto/Off/Manual switch to the OFF position. 2. T urn 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 [...]

Generac ® Pow er Systems, Inc. 23 Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned off. Failur e to turn off all power voltage supplies will result in extr emely hazardous and possibly fatal electrical shock. 4. Manually set the transfer switch to the ST ANDB Y posi[...]

24 Generac ® Pow er Systems, Inc. 3.7 ENGI N E G O VER NOR ADJ US TM ENT If both AC frequency and voltage are correspondingly high or low , adjust the engine governor as follows: 3.7 .1 6 KW U N IT S (NON-SA) 1. Loosen the governor clamp bolt (F igure 3.1). 2. Push the spring end of the governor lever clock- wise to the wide open throttle position[...]

Generac ® Pow er Systems, Inc. 25 3.7 .3 SOUN D A T TEN UA TED UN ITS 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 in[...]

26 Generac ® Pow er Systems, Inc. 3.1 0 SE T TI NG TH E EXERCISE TI M ER 3.1 0.1 6 KW , 8 KW AN D 1 0 KW UN ITS (NON-S A) Y our 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 ex[...]

Generac ® Pow er Systems, Inc. 27 4.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2. T ighten, clean or replace battery cables as necessary . 3. Defective starter contactor 3. Replace starter contactor . 4. Defective starter motor 4. Replace [...]

28 Generac ® Pow er Systems, Inc. Section 4 — T roubleshooting Guardian Air-cooled Generators 4.2 I NS T ALLA TION CH ECKLIS T BA TTER Y INST ALL A TION ❏ Battery is connected properly . ❏ Recommended battery is installed. ❏ Cables are clean and tight. ❏ T erminals are coated with anti- corrosion grease, and terminal covers are positione[...]

Generac ® Pow er Systems, Inc. 29 Section 5 — Notes Guardian Air-cooled Generators[...]

Part No. C4219 GENERAC ® POWER SY STEMS, INC. P .O. BOX 8 W AUKESHA, WI 53187 Revision * (12/13/99) Printed in U.S.A.[...]