® POWER SYSTEMS, INC.
INTRODUCTION Thank you for purchasing a model of the Guardian product line by Generac Power Systems Inc. These models are compact, high performance, air-cooled, engine-driven generators designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation.
Table of Contents Guardian Air-cooled Generators Introduction ......................Inside Front Cover Section 2 – Operation ..................................18 Safety Rules ......................................................2 2.2 2.3 2.4 Read This Manual Thoroughly ......................IFC Operation and Maintenance............................IFC How to Obtain Service ....................................IFC Authorized Dealer Location Number..................IFC 2.1 Section 1 – Installation .....
Important Safety Instructions Guardian Air-cooled 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: The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Important Safety Instructions Guardian Air-cooled Generators ELECTRICAL HAZARDS FIRE HAZARDS • 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 operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.
Section 1 — Installation Guardian Air-cooled Generators 1.1 INTRODUCTION TO INSTALLATION DANGER: Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. NOTE: Read the entire manual before starting the installation. Ensure that the model number of the unit being installed matches a model on the front cover.
Section 1 — Installation Guardian Air-cooled Generators 1.3 BEFORE INSTALLATION Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Circuit Isolation Method” and “Total Circuit Isolation Method” in Sections 1.8 and 1.9 (Page 11) carefully. When lifting or hoisting equipment is used, be careful not to touch overhead power lines.
Section 1 — Installation Guardian Air-cooled Generators With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed above the liquid fuel in the storage tank. The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas.
Section 1 — Installation Guardian Air-cooled Generators 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 1.7.1.1 6 kW, 8 kW and 10 kW Units (Non-SA) These Guardian units are supplied with their own mounting pads and DO NOT require a concrete pad.
Section 1 — Installation Guardian Air-cooled Generators Figure 1.4 – Generator and Transfer Switch Mounting Dimensions (6 kW, 8 kW and 10 kW Non-SA) 8 Generac® Power Systems, Inc.
Section 1 — Installation Guardian Air-cooled Generators Figure 1.4 (Continued) Generac® Power Systems, Inc.
Section 1 — Installation Guardian Air-cooled Generators Figure 1.5 – Generator Mounting Dimensions (Sound Attenuated) 10 Generac® Power Systems, Inc.
Section 1 — Installation Guardian Air-cooled Generators 1.8 EMERGENCY CIRCUIT ISOLATION 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 emergency distribution panel must be within the unit's rated wattage capacity.
Section 1 — Installation Guardian Air-cooled Generators 1.10 GENERATOR AC CONNECTION SYSTEM Figure 1.8 represents a single-phase, three-wire generator 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 single winding can supply a 120-volt, 60-Hertz AC output. When the two windings are connected in series, a 240-volt, 60-Hertz AC output results.
Section 1 — Installation Guardian Air-cooled Generators Figure 1.9 – Interconnection Diagram for Single-Phase Power System (6 kW, 8 kW and 10 kW Non-SA) Figure 1.10 – Interconnection Diagram for Single-Phase Power System (Sound Attenuated) Generac® Power Systems, Inc.
Section 1 — Installation Guardian Air-cooled Generators Figure 1.11 – Interconnection With GTS Transfer Switch (100A, y-type) 1.12 GENERATORS AND GTS TRANSFER SWITCHES Guardian generators (this DOES NOT APPLY to singlephase sound attenuated units) may be installed with either a prepackaged transfer switch or with a standard GTS-type automatic transfer switch (Figure 1.11). You can do this by connecting generator control console terminals 178 and 183 to identically numbered terminals in the GTS switch.
Section 1 — Installation Guardian Air-cooled Generators 1.14 ADAPTING THREE-PHASE TRANSFER SWITCH Figure 1.12 – Control Board Configuration The generator you are installing may include a prepackaged transfer switch configured for threephase 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 the enclosure. You will not use it with a single-phase system. 2.
Section 1 — Installation Guardian Air-cooled Generators 1.17 THE BATTERY Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. When replacing the battery, use the following type of battery: Group 26/26R 12-volt battery with a rating of 350 cold-cranking amps at -17.8º C (0º F) minimum.
Section 1 — Installation Guardian Air-cooled Generators ◆ 1.17.1 BATTERY INSTALLATION Figure 1.14 – Battery Cable Connections Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it. Before installing and connecting the battery, complete the following steps: 1. Set the generator's Auto/Off/Manual switch to OFF. 2. Turn off utility power supply to the transfer switch.
Section 2 — Operation Guardian Air-cooled Generators NOTE: Figure 2.2 – Generator Control Panel (Sound Attenuated) Throughout the “Operation” section, differences in procedures specific to sound attenuated units will be denoted as follows: (SA = information). 2.1 USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 2.1/2.2) ◆ 2.1.1 “AUTO” POSITION Selecting this switch position activates fully automatic system operation.
Section 2 — Operation Guardian Air-cooled Generators 2.3 SEQUENCE OF AUTOMATIC OPERATION The generator’s control panel houses a control logic circuit board. This board constantly monitors utility power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start.
Section 2 — Operation Guardian Air-cooled Generators 6. To crank and start the engine, set the Auto/Off/Manual switch to MANUAL. 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 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored, you will want to transfer back to that source and shut down the generator. This can be accomplished as follows: 1.
Section 2 — Operation Guardian Air-cooled Generators 2.5.3.1 Approximate Crank Cycle Times • • • • • 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 preset limit. This protection also prevents the generator from supplying an output that could potentially damage appliances connected to the generator circuit.
Section 3 — Post-installation Start-up Adjustments Guardian Air-cooled Generators 3.1 BEFORE INITIAL START-UP Before starting, complete the following: 1. Set the generator's Auto/Off/Manual switch to the OFF position. 2. Turn 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 oil level and, if necessary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark. 4.
Section 3 — Post-installation Start-up Adjustments Guardian Air-cooled Generators Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock. 4. Manually set the transfer switch to the STANDBY position, i.e., load terminals connected to the generator's E1/E2 terminals.
Section 3 — Post-installation Start-up Adjustments Guardian Air-cooled Generators 3.7 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low, adjust the engine governor as follows: ◆ 3.7.1 6 KW UNITS (NON-SA) 1. Loosen the governor clamp bolt (Figure 3.1). 2. Push the spring end of the governor lever clockwise to the wide open throttle position of the lever.
Section 3 — Post-installation Start-up Adjustments Guardian Air-cooled Generators ◆ 3.7.3 SOUND ATTENUATED UNITS Figure 3.4 – Voltage Adjustment Potentiometer 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.
Section 3 — Post-installation Start-up Adjustments Guardian Air-cooled Generators 3.10 SETTING THE EXERCISE TIMER ◆ 3.10.1 6 KW, 8 KW AND 10 KW UNITS (NON-SA) Your 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 exercise period, the unit runs for approximately 12 minutes and then shuts down.
Section 4 — Troubleshooting Guardian Air-cooled Generators 4.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 1. Fuse blown 2. Loose, corroded or defective battery cables 3. Defective starter contactor 4. Defective starter motor 5. Dead battery 1. Replace fuse. 2. Tighten, clean or replace as necessary. 3. Replace starter contactor. 4. Replace starter motor. 5. Charge or replace battery. The engine cranks but will not start. 1. Out of fuel 2.
Section 4 — Troubleshooting Guardian Air-cooled Generators 4.2 INSTALLATION CHECKLIST ◆ BATTERY INSTALLATION ❏ Battery is connected properly. ❏ Recommended battery is installed. ❏ Cables are clean and tight. ◆ ELECTRICAL CONNECTIONS ❏ Complies with local code requirements and all National Electrical Codes. ❏ Utility is connected and present. ❏ Transfer switch is connected. ❏ Terminals are coated with anti-corrosion grease, and terminal covers are positioned.
Section 5 — Notes Guardian Air-cooled Generators Generac® Power Systems, Inc.
GENERAC® POWER SYSTEMS, INC. P.O. BOX 8 WAUKESHA, WI 53187 Part No. C4219 Revision * (12/13/99) Printed in U.S.A.
