Generac Power Systems GUARDIAN 04079-2 Installationshandbuch

POWER SYSTEMS, INC.

Post Installation Start-up

and Adjustment Manual

Air-cooled, Prepackaged

Standby Generators

Models:

04109-2 (8 kW)

04079-2 (10 kW)

Section1—PostInstallation Start-up and Adjustments

Guardian Air-cooled Generators

Section1–PostInstallation Start-up

and Adjustments ..........................................2

1.1 Before Initial Start-up ..............................2

1.2 Battery Installation ..................................2

1.3 Check Transfer Switch Operation..............3

1.4 Electrical Checks ......................................3

1.5 Generator Tests Under Load......................3

1.6 Checking Automatic Operation..................4

1.7 Setting the Exercise Timer ........................4

1.8 Adjusting the Load Block ..........................5

1.9 Engine Governor Adjustment ....................5

1.9.1 8 kW and 10 kW Units ..................5

1.9.2 Additional Corrosion Protection......5

1.10 Voltage Regulator Adjustment ..................6

1.11 Additional Generator Features ..................6

Section 2 – Notes ............................................7

1.1 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 nec-

essary, fill to the dipstick FULL mark with the

recommended oil. Do not fill above the FULL

mark.

4. Check the fuel supply. Gaseous fuel lines must

have been properly purged and leak tested in

accordance with applicable fuel-gas codes. All

fuel shutoff valves in the fuel supply lines must be

open.

Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

1.2 BATTERY INSTALLATION

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 Auto/Off/Manual switch

to OFF.

2. Turn off utility power supply to the transfer

switch.

If the Auto/Off/Manual switch is not set to its

OFF position, the generator can crank and start

as soon as the battery cables are connected. If

the utility power supply is not turned off,

sparking can occur at the battery posts and

cause an explosion.

Battery cables were factory connected at the genera-

tor (Figure 1.1). Connect cables to battery posts as

follows:

1. Connect the red battery cable (from starter con-

tactor) to the battery post indicated by a positive,

POS or (+).

2. Connect the black battery cable (from frame

ground) to the battery post indicated by a nega-

tive, NEG or (—). NOTE:

Damage will result if battery connections are made

in reverse.

2 Generac®Power Systems, Inc.

Generac®Power Systems, Inc. 3

Section1—PostInstallation Start-up and Adjustments

Guardian Air-cooled Generators

Figure 1.1 – Battery Cable Connections

NOTE:

With the battery installed and utility power source

voltage available to the transfer switch, the battery

receives a trickle charge while the engine is not

running, to prevent self-discharge. The trickle

charge feature cannot be used to recharge a dis-

charged battery.

1.3 CHECK TRANSFER

SWITCH OPERATION

Refer to Section 2.5 (Page 9), of the owner’s manual

for manual operation procedures.

Do not attempt manual transfer switch opera-

tion 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.

1.4 ELECTRICAL CHECKS

Complete electrical checks as follows:

1. Turn on the utility power supply to the transfer

switch using the means provided (such as a utili-

ty main line circuit breaker).

The transfer switch is now electrically “hot.”

Contact with “hot” parts will result in extreme-

ly hazardous and possibly fatal electrical shock.

Proceed with caution.

2. Use an accurate AC voltmeter to check utility

power source voltage across terminals N1 and

N2. Nominal line-to-line voltage should be 240

volts AC.

3. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then

across terminal N2 and neutral. Nominal line-to-

neutral voltage should be 120 volts AC.

4. When certain that utility supply voltage is com-

patible with transfer switch and load circuit rat-

ings, turn OFF the utility power supply to the

transfer switch.

5. Set the generator's main circuit breaker to its

OFF (or open) position. Initial tests will be con-

ducted at no-load condition.

6. On the generator panel, set the Auto/Off/Manual

switch to MANUAL. The engine should crank and

start.

7. Let the engine warm up for about five minutes to

allow internal temperatures to stabilize. Then, set

the generator’s main circuit breaker to its ON (or

closed) position.

Proceed with caution! Generator power voltage

is now supplied to the transfer switch. Contact

with live transfer switch parts will result in

dangerous and possibly fatal electrical shock.

8. Connect an accurate AC voltmeter and an AC fre-

quency meter across transfer switch terminal

lugs E1 and E2. Voltage should be 242-252 volts;

frequency should read about 61-63 Hertz.

9. Connect the AC voltmeter test leads across termi-

nal lug E1 and neutral; then across E2 and neu-

tral. In both cases, voltage reading should be 121-

126 volts AC.

10. Set the generator’s main circuit breaker to its

OFF (or open) position. Let the engine run at no-

load for a few minutes to stabilize internal engine

generator temperatures.

11. Set the generator's Auto/Off/Manual switch to

OFF. The engine should shut down.

NOTE:

It is important that you do not proceed until you

are certain that generator AC voltage and frequen-

cy are correct and within the stated limits.

Generally, if both AC frequency and voltage are

high or low, the engine governor requires adjust-

ment. If frequency is correct, but voltage is high or

low, the generator’s voltage regulator requires

adjustment.

1.5 GENERATOR TESTS UNDER LOAD

To test the generator set with electrical loads applied,

proceed as follows:

1. Set generator’s main circuit breaker to its OFF

(or open) position.

2. Set the generator's Auto/Off/Manual switch

to OFF.

3. Turn OFF the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).

4 Generac®Power Systems, Inc.

Section1—PostInstallation Start-up and Adjustments

Guardian Air-cooled Generators

Do not attempt manual transfer switch opera-

tion 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. The transfer switch

operating lever should be down.

5. Set the generator's Auto/Off/Manual switch to

MANUAL. The engine should crank and start

immediately.

6. Let the engine stabilize and warm up for a few

minutes.

7. Set the generator’s main circuit breaker to its ON

(or closed) position. Loads are now powered by

the standby generator.

8. Turn ON electrical loads. Apply an electrical load

equal to the full rated wattage/amperage capacity

of the installed generator.

9. Connect an accurate AC frequency meter across

terminal lugs E1 and E2. Voltage should be

greater than 230 volts; frequency should be

greater than 58 Hertz.

10. Let the generator run at full rated load for 20-30

minutes. Listen for unusual noises, vibration or

other indications of abnormal operation. Check

for oil leaks, evidence of overheating, etc.

11. When testing under load is complete, turn OFF

electrical loads.

12. Set the generator's main circuit breakers to their

OFF (or open) positions.

13. Let the engine run at no-load for a few minutes.

14. Set the Auto/Off/Manual switch to OFF. The

engine should shut down.

1.6 CHECKING AUTOMATIC

OPERATION

To check the system for proper automatic operation,

proceed as follows:

1. Check that the Auto/Off/Manual switch is set to

OFF.

2. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the util-

ity power source side.

3. Turn ON the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).

4. Set the Auto/Off/Manual switch to AUTO. The sys-

tem is now ready for automatic operation.

5. Turn OFF the utility power supply to the transfer

switch.

With the Auto/Off/Manual switch at AUTO, the engine

should crank and start when the utility source power

is turned OFF. After starting, the transfer switch

should connect load circuits to the standby side. Let

the system go through its entire automatic sequence

of operation.

With the generator running and loads powered by

generator AC output, turn ON the utility power sup-

ply to the transfer switch. The following should

occur:

• After about six seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine

should shut down.

1.7 SETTING THE EXERCISE TIMER

Your generator is equipped with an exercise timer

(Figure 1.2). 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 the day that you complete the

following sequence. For example, if you want the gen-

erator to exercise on sundays at 6:00 PM, you will

need to complete the sequence at that exact time.

1. Verify or place the “Auto/Off/Manual” switch in the

AUTO position.

2. Hold down the “Set Exercise Timer” switch until

the generator starts (approximately 10 seconds)

and then release.

Figure 1.2 — Setting the Exercise Timer

3. The generator will start and run for approximate-

ly 12 minutes and then shut down automatically.

The exerciser is now set to run at the same time

and day every week.

NOTE:

The exerciser will only work in the AUTO mode

and will not work unless this procedure is per-

formed. The exerciser will need to be reset every

time the 12 volt battery is disconnected and then

reconnected. The exerciser WILL NOT work if dip

switch 2 (Remote Not Auto) is ON.

Set Exercise Timer Auto/Off/Manual Switch

Generac®Power Systems, Inc. 5

1.8 ADJUSTING THE LOAD BLOCK

When the natural gas system is being used, the load

block is fitted with an adjustment screw that has

been calibrated to provide maximum power.

However, because of variations in the Btu content of

natural gas across the country, it may be necessary to

readjust the load block.

• Connect a frequency meter to the output of the gen-

erator.

• Start the unit and apply full load according to the

following chart:

• Allow the unit to stabilize; then, turn the adjust-

ment screw slowly clockwise or counterclockwise

and watch the frequency.

• When the highest frequency is reached, turn the

adjustment screw counterclockwise 1/4 turn.

• The fuel system is now set.

• For LP gas operations, the hose and blanking plug

must be reconfigured as shown in Figure 1.4, (Page

7) of the owner’s manual. The unit is set to provide

maximum power using LP gas.

Do not make any unnecessary adjustments.

Factory settings are correct for most applica-

tions. However, when making adjustments, be

careful to avoid overspeeding the engine.

1.9 ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly

high or low, adjust the engine governor as follows:

1.9.1 8 KW AND 10 KW UNITS

1. Loosen the governor clamp bolt (Figure 1.3).

2. Push the spring end of the governor lever clock-

wise to the wide open throttle position of

the lever.

• Hold the governor lever at wide open throttle and,

with a screwdriver, rotate the governor shaft fully

clockwise.

• Before tightening, verify that the governor lever is

pushed all the way onto the governor shaft.

• While holding the governor shaft fully clockwise

and the governor lever at wide open throttle,

tighten the governor clamp bolt to 130 inch-

pounds (8 N-m).

3. Start the engine; let it stabilize and warm up at

no-load.

4. Turn the speed adjust nut to obtain a frequency

reading of 62 Hertz.

5. When frequency is correct at no-load, check the

AC voltage reading. If voltage is incorrect, the volt-

age regulator may require adjustment.

Figure 1.3–8kWand10kW

Engine Governor Adjustment

NOTE:

If the engine continues to run fast, use a pair of

pliers to bend the bend tab clockwise to release

tension on the lower governor spring.

1.9.2 ADDITIONAL CORROSION PROTECTION

Periodically spray all engine linkage parts and brack-

ets with corrosion inhibiting spray such as WD-40 or

a comparable product.

◆

Side View

Back View

Front View

Carburetor

Spring

Carburetor

Spring

Governor Lever

Spring Speed Adjust Nut

Bend Tab

Governor Spring

Governor

Shaft

Governor

C amp Bo t

◆

Section1—PostInstallation Start-up and Adjustments

Guardian Air-cooled Generators

Unit 120 Volts 240 Volts

8 kW 66.7 amps 33.3 amps

10 kW 83.3 amps 41.6 amps

6 Generac®Power Systems, Inc.

1.10 VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 61-62 Hertz, slowly turn

the slotted potentiometer (Figure 1.4) until line volt-

age reads 244-252 volts.

NOTE:

You must remove the roof to adjust the voltage

regulator.

Figure 1.4 – Voltage Adjustment Potentiometer

NOTE:

The voltage regulator is housed in the generator's

control panel. The regulator maintains

a voltage in direct proportion to frequency at a 2-

to-1 ratio. For example, at 62 Hertz, line-to-neu-

tral voltage will be 124 volts.

1.11 ADDITIONAL GENERATOR

FEATURES

1.11.1 8 KW AND 10 KW UNITS

The 8 kW and 10 kW air-cooled Guardians offer addi-

tional features that are not factory preset:

1. Remote Start – This allows for remote starting of

the generator by means of the #183 (common)

and #178 (normally open) lines with the

Auto/Off/Manual switch set to AUTO. Closure of

the circuit starts the unit; opening of the circuit

stops the unit. See Figure 1.5.

NOTE:

This function will work only with the unit in the

AUTO mode.

Figure 1.5 – Remote Start/Alarm Options

–Type 14 AWG wire is recommended.

–These options should be wired to the unit by a qualified electrician or

Generac/Guardian Authorized Dealer.

2. Remote/Common Alarm – This allows for an

alarm, light, horn, etc., to activate when any fault

has occurred. Lines #210 (common) and #211

(normally open) provide a “closure” on common

fault, which can be used for 120 volts, 10 amps

maximum. See Figure 1.5.

3. Remote Not Auto – The generator will not auto-

matically start during a utility failure.

◆

Section1—PostInstallation Start-up and Adjustments

Guardian Air-cooled Generators

Generac®Power Systems, Inc. 7

Section2—Notes

Guardian Air-cooled Generators

Part No. D1962

GENERAC®POWER SYSTEMS, INC.

757 NORTH NEWCOMB ROAD

WHITEWATER, WI 53190

PH: (262) 473-5514 •FAX: (262) 472-6511

Revision 0 (11/08/00) Printed in U.S.A.

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