Service
ServiceManual
Manual
HomeStandbyGeneratorSet
GSBB(SpecA-B)
GSBC(SpecB)
English
OriginalInstructions
9-2013
A030A239(Issue10)
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TableofContents
1. IMPORTANTSAFETYINSTRUCTIONS
1
1.1SaveTheseInstructions
1
1.2GeneralPrecautions
1
1.3GeneratorVoltageisDeadly
2
1.4EngineExhaustisDeadly
2
1.5FuelisFlammableandExplosive
2
1.6BatteriesCanExplode
2
1.7MovingPartsCanCauseSeverePersonalInjuryorDeath ..................................................
3
1.8TheHazardsofCarbonMonoxide
3
1.8.1WhatIsCarbonMonoxidePoisoning?........................................................................
3
1.8.2WhatAretheSpecialRisksofCONeartheHome?...................................................
3
1.8.3OnlyYouCanProtectYourselfFromCOPoisoning!..................................................
4
2. INTRODUCTION
5
2.1AboutthisManual
5
2.2AbouttheGeneratorSet
5
2.2.1ModelSpecifications
6
2.3GeneratorSetNameplate
8
3. MAINTENANCE
11
3.1PeriodicMaintenanceSchedule
11
3.2CleaningtheHousingTop
12
3.3ExercisingtheGeneratorSet
12
3.4CompleteSystemTest
12
3.5EngineOilMaintenance
13
3.5.1RecommendedEngineOil
13
3.5.2CheckingEngineOilLevel
13
3.5.3AddorDrainOil
13
3.5.4ChangingEngineOilandOilFilter
14
3.6ReplacingtheAirFilterElement
15
3.7BatteryMaintenance
16
3.8SparkPlugs
16
3.9AccessoryHeaterKits
17
3.10MaintenanceRecord
17
4. SERVICE
19
4.1PlacingtheGeneratorSetBackinService
19
4.2TransferSwitch
19
4.3Engine
20
4.4Engine-GeneratorAssembly
20
4.4.1Engine-AlternatorRemoval
20
4.4.2Engine-AlternatorInstallation
21
4.5FuelSystemComponentsTesting
23
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TableofContents
9-2013
4.5.1FuelPressure
24
4.5.2Gas-AirMixer
24
4.5.3GovernorActuator
25
4.5.4GovernorLinkageAdjustment(50HzLPOnly).........................................................
27
4.5.5GasDemandRegulator
28
4.5.6FuelSolenoid
29
4.5.7LowGasPressureSwitch(IfEquipped)....................................................................
29
4.5.8TestingtheFuelSystemforLeaks
29
4.6Control
31
4.6.1GeneratorControl
32
4.6.2START/STOPSwitchS2
32
4.6.3LineCircuitBreakerCB1/CB2
32
4.6.4CurrentTransformersCT1/CT2
32
4.6.5AlternatorTemperatureSwitch
33
4.7Generator
33
4.7.1Operation
33
4.8AlternatorTemperatureSwitch
35
4.9BrushBlock/SlipRingService
35
4.10StatorService
35
4.11RotorService
35
4.12TestingtheGenerator
36
5. OPERATION
39
5.1In-HomeOperatorPanel
39
5.1.1BACKButton
39
5.1.2StandbyON/OFFButton
39
5.1.3STARTSTOPButton
40
5.2TypicalOperation
40
5.2.1NormalOperation:UtilityPowerAvailableandConnected.......................................
43
5.2.2EmergencyOperation:UtilityPowerInterrupted.......................................................
44
5.3ToEnable/DisableStandby
45
5.4ToManuallyStart/StopGeneratorSet
45
5.5Fault,MaintenanceandNewEventScreens.......................................................................
46
5.5.1FaultScreen
46
5.5.2MaintenanceDueScreen
47
5.5.3NewEventScreen
47
5.6GensetStatus
48
5.7DisplaySetupandSoftwareInfo
49
5.7.1BrightnessandContrast
49
5.7.2SoftwareInfo
50
5.8EventLog
51
5.8.1ToCheckLogofLast20Events
51
5.8.2ListofRecordableEvents
51
5.9FaultLog
52
5.10EthernetSettings
53
5.11ExerciseSettings
55
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9-2013
TableofContents
5.12TimeSetup
56
5.13LoadManagement
57
5.13.1AutomaticLoadManagement
57
5.13.2ManualLoadManagement
58
6. STARTUPANDCONFIGURATION
59
6.1Pre-startupInspection
59
6.2Startup
59
6.3GeneratorSetConfiguration
60
6.4GeneratorAdjustments
62
6.4.1ToAdjusttheOutputVoltage
62
6.4.2ToCalibratetheDisplayMeter
62
6.5TransferSwitchConfiguration
62
6.6TransferSwitchParameterAdjustments
63
7. OPTIONALINTERNET/EMAILINTERFACEDESCRIPTIONS...................................................
65
7.1Introduction
65
7.2ScreenDescriptions
66
7.2.1SettingTimeandDate
66
7.2.2SetExerciseSchedule
67
7.2.3LoadControl(Management)
67
7.2.4EventLog
68
7.2.5FaultLog
68
7.2.6NetworkSetupScreenDescriptions
69
7.2.7EmailSetupScreenDescriptions
69
7.2.8SavingChanges
70
8. OPTIONALINTERNET/EMAILINTERFACESETUP..................................................................
71
8.1NetworkConnectivityOptions
71
8.2Material/CableRouting
71
8.3NetworkInformationNeededForSetup
71
8.3.1NetworkRouter
71
8.3.2Email/InternetServiceProvider(ISP)........................................................................
71
8.4In-HomeNetworkAccesstotheGeneratorSet ..................................................................
72
8.5SettingUpInternetAccessandE-mailAlerts.......................................................................
75
8.6PortForwarding
77
8.7RemoteViewingIPOptionsStaticIP
77
8.8DynamicIPMonitoring
78
8.9EmailSetupParameters
78
8.9.1OutgoingServer(SMTP)Settings
78
8.9.2EmailAddresses
79
8.10RemoteInternetAccesstotheGeneratorSet....................................................................
80
8.11HelpHotline
81
8.12FrequentlyAskedQuestions
81
9. TROUBLESHOOTING
85
9.1TroubleshootingWiththeIn-HomeOperatorPanel ............................................................
85
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TableofContents
9-2013
9.2TroubleshootingwiththeFlashingIndicatorLight ...............................................................
85
9.3FaultCodeBlinking
85
9.4RestoringFaultCodeBlinking
86
9.5GeneratorSetStartsorStopsWithoutCommand-NoFaultCode....................................
86
9.6NoResponse-StatusIndicatorLightDead ........................................................................
87
9.7StartingBatteryRunsDown
88
9.8StarterEngages-Disengages
88
9.9NoACPower-GeneratorSetRunning,StatusLEDOnSteadyorFlashingRapidly.........
89
9.10GeneratorSetCranksButDoesNotStart-NoFaultCode..............................................
89
9.11GensetWarning-TransferSwitchFailedtoTransferBacktoUtilityWhenUtilityis
Restored-NoFaultCode
90
9.12LowOilPressureFault-FaultCode2
90
9.13ServiceCheckFault-FaultCode3
91
9.14Overcrank-FaultCode4
91
9.15Overvoltage-FaultCode12
92
9.16Undervoltage-FaultCode13
93
9.17Overfrequency-FaultCode14
94
9.18Underfrequency-FaultCode15
95
9.19GovernorActuatorShutdown-FaultCode19 ...................................................................
97
9.20GovernorActuatorOverload-FaultCode22....................................................................
97
9.21VoltageSenseLost-FaultCode27
99
9.22HighBatteryVoltage-FaultCode29
99
9.23LowCrankingSpeedSense-FaultCode32 ..................................................................
100
9.24ControlCardFailure-FaultCode35
101
9.25GeneratorSetStoppedWithoutFaultCondition-FaultCode36 ...................................
102
9.26InvalidSetConfiguration-FaultCode37........................................................................
103
9.27ProcessorFault-FaultCode43
103
9.28SpeedSenseFault-FaultCode45
103
9.29GeneratorSetOverload-FaultCode46
104
9.30AlternatorOverTemp-FaultCode76
105
9.31LowFuelPressure-FaultCode78
106
9.32FailureToTransferToGeneratorSet-FaultCode79 ...................................................
106
10.COMMUNICATIONTROUBLESHOOTING
109
10.1In-HomeNetworkAccesstoGeneratorSetTroubleshooting..........................................
109
10.2RemoteInternetAccesstoGeneratorSetTroubleshooting............................................
110
10.3EmailAlertTroubleshooting
111
APPENDIXA.OUTLINEANDSYSTEMDRAWINGS....................................................................
115
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IMPORTANTSAFETYINSTRUCTIONS
1.1
SaveTheseInstructions
Thismanualcontainsimportantinstructionsforthegeneratorsetthatshouldbefollowedduring
installation,operationandmaintenanceofthegeneratorandbatteries.
Thoroughly readthe Operator Manualbeforeoperatingthe generator set. Safe operation and
topperformancecanonlybeobtainedwhenequipmentisproperlyoperatedandmaintained.
The following symbols in this manual alert you u to o potential hazards to the operator, service
personandequipment.
DANGER
Alertsyoutoanimmediatehazardthatwillresultinseverepersonalinjuryor
death.
WARNING
Alertsyoutoahazardorunsafepracticethatcanresultinseverepersonalinjuryor
death.
CAUTION
Alertsyoutoahazardorunsafepracticethatcanresultinpersonalinjuryorequipment
damage.
1.2
GeneralPrecautions
• KeepABCfireextinguishershandy.
• Makesureallfastenersaresecureandtorquedproperly.
• Keep p thegeneratorset and itscompartmentclean.Donot store any items inthegenset
compartment.
• Excessoil,oilyrags(etc.)cancatchfire.
• Dirtandgearstowedinthecompartmentwillrestrictcoolingairflow.
• Before e working on n the e generator set, move e the e Stop p Switch (S2) ) to o the e Stop position,
disconnecttheremoteharness(P7)todisabletheATSmountedchargerandthenremove
thenegative(-)batterycabletopreventstarting.
• Usecaution n whenmakingadjustmentswhilethegenerator set isrunning,hot,moving or
whenpartsareelectricallylive,asallsituationsmaycausepersonalinjuryordeath.
• Usedengineoilhasbeenidentifiedbysomestateandfederalagenciesascausingcancer
or reproductive e toxicity. . Do o not t ingest, inhale or r come into contact with used oil or it's
vapors.
• Donotworkonthegeneratorsetwhenmentallyorphysicallyfatiguedorafterconsuming
alcoholordrugs.
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1.IMPORTANTSAFETYINSTRUCTIONS
9-2013
1.3
GeneratorVoltageisDeadly
• Generatoroutput t connections must bemadeby a trainedandexperienced electricianin
accordancewithallapplicablecodes.
• This s standby generator set and the public utility may only be connected to the house
circuitsbymeansoftheautomatictransferswitch.
• Improper r connections can lead to o electrocution n of utility workers and damage e to
equipment.
• Use e caution n when working g on n live e electrical l equipment. Remove e jewelry, make sure
clothingandshoesaredryandstandonadrywoodenplatform.
1.4
EngineExhaustisDeadly
• SeeWhatIsCarbonMonoxidePoisoning?tolearnthesymptomsofCarbonMonoxide
poisoning.
• Thisgeneratorsetisforoutdoorinstallationonly.
• Itmustbelocatedwellawayfromdoors,windows,otheropeningsintothehouseand
wheretheexhaustgaseswilldisperseawayfromthehouse.
1.5
FuelisFlammableandExplosive
• Keep p flames, cigarettes, sparks, pilot lights, electricalarc-producing equipment, switches
and allothersources of ignition wellaway fromareas where fuelfumesarepresent and
areassharingventilation.
• Fuellinesmustbesecured,freeofleaksandseparatedorshieldedfromelectricalwiring.
• Leakscanleadtoexplosiveaccumulationsofgas.Preventleaksandtheaccumulationof
gas.
• A"rottenegg"smellindicatesapossibleNaturalGasorPropaneleak:
• NaturalGas s rises when released and canaccumulate underhoodsand inside
housingsandbuildings.
• Propane sinks when released and can n accumulate e inside e housings s and
basementsandotherbelow-gradespaces.
1.6
BatteriesCanExplode
Batteriescanexplode,causingsevereskinandeyeburnsandcanreleasetoxicelectrolytes.
• Wearsafetyglasses.
• Donotsmoke.
• Donotdisposeofthebatteryinafire.
• Thebatteryiscapableofexploding.
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A030A239(Issue10)
9-2013
1.IMPORTANTSAFETYINSTRUCTIONS
• Donotopenormutilatethebattery.
• Releasedelectrolyteshavebeenknowntobeharmfultotheskinandeyesandtobe
toxic.
• Batteriespresenttherisktohighshortcircuitcurrent:
• Removewatches,ringsorothermetalobjectsandusetoolswithinsulatedhandles.
• Topreventarcingwhendisconnectingthebattery:
• MovetheStopSwitch(S2)totheStopposition,disconnecttheremoteharness(P7)
todisabletheATSmountedchargerandthenremovethenegative(-)batterycableto
preventstarting.
• Topreventarcingwhenreconnectingthebattery:
• First, , reconnect the positive (+) cable, then the negative (-) cable, and finally
reconnectthebatterycharger.
• When n replacingthegeneratorsetbattery,always replaceit withabatteryas specifiedin
theModelSpecificationssectionofthismanual.
1.7
MovingPartsCanCauseSeverePersonalInjuryor
Death
• Donotwearlooseclothingorjewelrynearmovingpartssuchasfans.
• Keephandsawayfrommovingparts.
• Keepguardsinplace,overfans.
1.8
TheHazardsofCarbonMonoxide
Engine-drivengeneratorscanproduceharmfullevelsofcarbonmonoxidethatcaninjureorkill
you.
1.8.1 WhatIsCarbonMonoxidePoisoning?
Carbon Monoxide (CO)is an odorless,colorless,tasteless and non-irritatinggas. Youcannot
see it or smell l it. . Red blood cells, however, have a greater affinity for CO than n for r Oxygen.
Therefore, exposureeven to lowlevelsof COforaprolongedperiodcanleadtoasphyxiation
(lackofOxygen)resultingindeath.MildeffectsofCOpoisoningincludeeyeirritation,dizziness,
headaches,fatigueandtheinabilitytothinkclearly.Moreextremesymptomsincludevomiting,
seizuresandcollapse.
1.8.2 WhatAretheSpecialRisksofCONeartheHome?
ResidentscanbeexposedtolethallevelsofCOwhenthegensetisrunning.Dependingonair
temperatureandwind,COcanaccumulateinornearthehome.
To protect yourself f and others from the dangers s of f CO poisoning, , it t is s recommended that
reliableandapprovedCOdetectoralarmsbeinstalledinthehome.
WARNING
CarbonMonoxide(CO)gascancausenausea,faintingordeath.
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1.IMPORTANTSAFETYINSTRUCTIONS
9-2013
1.8.3 OnlyYouCanProtectYourselfFromCOPoisoning!
• Locatethegeneratorinanareawheretherearenowindows,doorsorotheraccesspoints
intothehome.
• MakesureallCOdetectorsareworkingproperly.
• PayattentiontothesignsofCOpoisoning.
• Check k the e exhaust t system for corrosion, obstruction and leaks s each time you u start the
generatorsetandeveryeighthoursifyourunitcontinuously.
4
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