Generac Power Systems 6055 Owner's Manual
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Generac Power Systems 6055 Owner's Manual

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  • Page 2 Use this page to record important information about your generator set. Record the information found on your unit data label on this page for quick and easy reference. The label is affixed to the inside partition left of the control pad. For direc- tions on how to open the lid and remove the front panel, see Section 3 Operation.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Section 1 Safety 1.1 Introduction .......................... 1 1.2 General Safety ........................2 1.3 General Safety Hazards ....................... 2 1.4 Exhaust Hazards ........................3 1.5 Electrical Hazards ........................ 3 1.6 Fire Hazards .......................... 3 1.7 Explosion Hazards ....................... 4 Section 2 General Information 2.1 Synergy Operating Principle ....................
  • Page 4 Table of Contents 3.4 Change Time and Date .......................15 3.5 Programmable Timers ......................15 3.5.1 Dealer Programmable ........................ 15 3.5.1.1 High Run Speed Timer ....................... 15 3.5.1.2 Start-Up Delay Timer ......................15 3.5.2 User Programmable ........................16 3.5.2.1 Exercise Time ........................16 3.6 USB Port for Firmware Updates ..................16 3.7 Transfer Switch Automatic Operation ................18 3.7.1 Automatic Sequence of Operation ....................
  • Page 5 Table of Contents 4.6 Schedule A Maintenance ....................26 4.6.1 Check Battery Condition/Fluid Level ................... 26 4.6.1.1 Check Condition and Clean ....................26 4.6.1.2 Check Fluid Level ....................... 26 4.6.1.3 Check State of Charge......................26 4.6.1.4 Battery Replacement ......................26 4.6.2 Replace AVR Filter ........................
  • Page 6 Table of Contents This page intentionally left blank. Synergy Automatic Standby Generator Owner’s Manual...

  • Page 7: Section 1 Safety

    Safety Sect ion 1 1.1 — Introduction Thank you for purchasing this compact, high performance, variable speed, air-cooled, engine-driven stationary auto- matic standby generator set. Every effort was made to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written.

  • Page 8: General Safety

    Safety Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of informa- tion each indicates is as follows: This symbol points out important Safety Information that, if not followed, could endanger personal safety and/or property of others. This symbol points out a potential Explosion Hazard.

  • Page 9: Exhaust Hazards

    Safety The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. DO NOT alter or add to the exhaust system or do anything that might render the system unsafe or in noncompliance with applicable codes and standards. Install a carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.

  • Page 10: Explosion Hazards

    Safety Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regu- lations.

  • Page 11: Section 2 General Information

    General Information Sect ion 2 2.1 — Synergy Operating Principle 2.1.1— Benefits The Synergy 20 kW generator brings exciting new technology to the Home Standby generator product. The generator is significantly more fuel efficient than constant speed generators at normal loads, provides premium power quality, and is significantly quieter while operating at exercise and normal loads.

  • Page 12: Overload

    General Information 2.1.6— Overload If a load is sensed that is too large for the engine, that load will be locked out for a period of 30 minutes. If the load is not connected through a fast Loadshed enabled controller and module, then the generator shuts down with an “Over- load”...

  • Page 13: The Generator

    General Information 2.2 — The Generator Figure 2-1. Component Locations Automatic Voltage Regulator (AVR) Circuit Breakers Oil Dipstick Fuel Inlet (Back) Oil Fill Cap Fuel Regulator Engine Air Filter Battery Compartment AVR Air Filter Oil Filter Data Label Composite Base Control Pad Exhaust Enclosure Synergy Automatic Standby Generator Owner’s Manual...

  • Page 14: Protection Systems

    General Information 2.3 — Protection Systems The owner/operator is alerted to Alarm and/or Warning conditions via the control pad LCD screen. All Alarm conditions cause the generator to shut down. The Warning messages alert the operator to conditions that do not disable the unit, require immediate correction, or result in shut down.

  • Page 15: Specifications

    General Information 2.5 — Specifications 2.5.1— Generator Model 20 kW Synergy Rated Voltage Rated Maximum Load 83.3 Current (Amps) at 240 Volts (LP)* Main Circuit Breaker 90 Amp Phase Rated AC Frequency 60 Hz Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum (Generac Part No. 0H3421S) Unit Weight in Lbs.

  • Page 16: Fuel Requirements

    General Information 2.5.3— Fuel Requirements The engine has been fitted with a dual fuel carburetion system. The unit will run on natural gas or LP gas (vapor), but it has been factory set to run on natural gas. The fuel system is configured for the selected fuel source during installation. Recommended fuels should have a btu content of at least 1,000 Btus per cubic foot (37.26 megajoules per cubic meter) for natural gas, or at least 2,500 Btus per cubic foot (93.15 megajoules per cubic meter) for LP gas (vapor).
  • Page 17 General Information Table 2-1. Accessories (Continued) Accessory Description Power Management Mod- Includes one module with transformer. The transformer, which is mounted inside the ATS enclo- ule (PMM) Starter Kit sure, interfaces with the OPCB to generate the 24 Vac signal needed for control of the contac- tor (Load 1 on the OPCB).
  • Page 18 General Information This page intentionally left blank. Synergy Automatic Standby Generator Owner’s Manual...

  • Page 19: Section 3 Operation

    Operation Sect ion 3 3.1 — Control Pad The control pad is intended for use by qualified service personnel only. See Figure 3-1. The control pad is located under the lid of the enclosure. The lid is secured by two locks, one on each side of the enclosure.

  • Page 20: Auto/Manual/Off

    Operation With the control pad set to AUTO, the engine may crank and start at any time without warning. Such automatic starting occurs during the programmed exercise cycle or when utility power source voltage drops below the configured level. To prevent possible injury that might occur during sudden starts, always set the control pad to OFF and remove the 7.5 amp fuse before working on or around the gener- ator or transfer switch.

  • Page 21: Menu Navigation

    Operation 3.3 — Menu Navigation Feature Description System Menus The system returns to the Home screen if the control pad is not used for five minutes. The screen normally displays a Status message, such as Ready to Run (Auto mode) or Switched to OFF (Off mode), and the total Hours of Protection.

  • Page 22: User Programmable

    Operation 3.5.2— User Programmable 3.5.2.1—Exercise Time A programmable exercise time is provided. In the AUTO mode, the engine starts and runs at the programmed interval, either weekly, bi-weekly (the default), or monthly, at the time and day specified. During the exercise cycle, the unit runs approximately five minutes and then shuts down.
  • Page 23 Operation Figure 3-3. Navigation Menu Synergy Automatic Standby Generator Owner’s Manual...

  • Page 24: Transfer Switch Automatic Operation

    Operation 3.7 — Transfer Switch Automatic Operation In AUTO, the generator starts automatically when utility source voltage drops below the preset level. Once the unit starts, loads are transferred to the standby power source. To select automatic operation: Verify that the transfer switch main contacts are set to the UTILITY position (loads connected to the utility power source).

  • Page 25: Load Shed Functionality

    Operation 3.7.2— Load Shed Functionality The Synergy product Transfer Switch includes an Overload Prevention Control Board (OPCB) to shed critical loads. The OPCB, commonly referred to as the Load Shed Board, has “Fast Load Shed” capability, which effectively prevents large loads from stalling the engine. ALL LOADS GREATER THAN 10 kW OR 2 HP (MOTORS) MUST BE CON- NECTED TO THE OPCB.

  • Page 26: Removal From Service During Utility Outages

    Operation Manual Transfer Handle Load Connected to Utility Load Connected to Standby Transfer Switch Operating Lever Figure 3-4. Manual Transfer Switch Operation (Typical) Turn on the utility power supply to the transfer switch using the means provided. Press AUTO on the control pad. A green LED illuminates to confirm that the system is in the AUTO mode. 3.9 —...

  • Page 27: Side Door Compartment

    Operation 3.10 — Side Door Compartment Check local codes for side door locking requirements. A hasp is provided, so that the side door can be secured with a customer supplied padlock if necessary. LED Indicators 15 Amp Outlet Breaker GFCI BREAKER ON ON GENERATOR DISCONNECT 120 GFCI Outlet...

  • Page 28: Battery Charger

    Operation 3.11 — Battery Charger NOTE: The battery charger is integrated into the control module. The battery charger operates as a “Smart Charger” that ensures: Output is continually optimized to promote maximum battery life. Charging levels are safe. NOTE: A warning is displayed on the LCD screen when the battery needs service. 3.12 —...

  • Page 29: Section 4 Maintenance

    Maintenance Sect ion 4 4.1 — Maintenance NOTE: Proper maintenance is necessary for safe operation and is crucial to the life of the generator. Genuine Generac parts MUST be used to ensure warranty coverage NOTE: Since most maintenance alerts occur at the same time (two or four year intervals), only one will appear at any one time.

  • Page 30: Remove From Service

    Maintenance Table 4-1. Service Maintenance Schedule Daily If Running Schedule A Schedule B Continuously Every Every Every Service Year Two Years Four Years or 200 Hours or 400 Hours Before Each Use Check Enclosure Louvers for Dirt and Debris Check Lines and Connections for Fuel or Oil Leaks Check Engine Oil Level Check Battery Condition, Electrolyte...

  • Page 31: Check Lines And Connections

    Maintenance 4.5.2— Check Lines and Connections Perform a general inspection as follows: Check Fuel Lines and Connections for Leaks Check Oil Lines and Connections for Leaks 4.5.3— Check Engine Oil Level Remove dipstick and wipe with a clean cloth. See A of Figure 4-1. Completely insert the dipstick and then remove it.

  • Page 32: Schedule A Maintenance

    Maintenance 4.6 — Schedule A Maintenance NOTE: Perform Schedule A maintenance every two years or after 200 hours of service, whichever comes first. 4.6.1— Check Battery Condition/Fluid Level 4.6.1.1— Check Condition and Clean Remove front access panel. Verify that top of battery is clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-dis- charge.

  • Page 33: Replace Avr Filter

    Maintenance 4.6.2— Replace AVR Filter If utility is present, the secondary 12V DC fan continues to operate for up to one hour after the genera- tor is shut down (even if the 7.5 amp ATO fuse is removed). To avoid hand injury, always exercise cau- tion when working near the AVR fan housing.
  • Page 34 Maintenance Press MANUAL on the control pad to start the engine. A blue LED illuminates to confirm that the system is in the MANUAL mode. Allow the engine to run for a few minutes. Check for leaks while the engine is running. Press OFF on the control pad to shut the engine down.

  • Page 35: Schedule B Maintenance

    Maintenance 4.7 — Schedule B Maintenance NOTE: Perform Schedule B maintenance every four years or after 400 hours of service, whichever comes first. Before proceeding below, first perform all tasks listed under Schedule A Maintenance. 4.7.1— Replace Engine Air Filter Remove unit from service.

  • Page 36: Check/Adjust Valve Clearance

    Maintenance NOTE: When disconnecting spark plug cable from spark plug terminal, always grasp and pull on the boot at the terminal end of the cable. Pulling on cable portion can result in parts damage. Thoroughly clean area around spark plugs. Remove spark plugs from cylinder head using a 5/8 inch spark plug socket.

  • Page 37: Adjust Valve Clearance

    Maintenance Move piston to Top Dead Center (TDC) of compression stroke (both valves closed). Proceed as follows: a. Remove intake screen at front of engine to gain access to flywheel nut. b. Place large socket and socket wrench on flywheel nut and rotate engine in a clockwise direction while watch- ing piston through spark plug hole.

  • Page 38: Return To Service

    Maintenance Install the AVR fan. Pivot Ball Rocker Stud Jam Nut Valve Stem Figure 4-7. Check/Adjust Valve Clearance Connect 4-pin connector to AVR. Press pin and socket halves together until external latch engages. Install AVR filter housing so the bottom drops into the slots and ensuring that the rubber boot is completely around the fan opening.

  • Page 39: Return To Service After Storage

    Maintenance Allow the unit to warm up for a few minutes. Press OFF on the control pad to stop the engine. A red LED illuminates to confirm that the system is in the OFF mode. While the engine is still warm, completely drain engine oil and refill the crankcase with oil. See Subsection 4.6.3—Replace Engine Oil and Oil Filter.
  • Page 40 Maintenance Pull up rubber flap covering fuse holder and install 7.5 amp fuse. Follow Install Wizard instructions using LCD screen and control pad. Press MANUAL on the control pad to start the engine. A blue LED illuminates to confirm that the system is in the MANUAL mode.

  • Page 41: Section 5 Troubleshooting

    Troubleshooting Sect ion 5 5.1 — Engine Troubleshooting Table 5-1. Engine Diagnostics Problem Cause Correction Engine will not crank. 1) Fuse blown. 1) Correct short circuit condition by replacing 7.5 Amp fuse. 2) Loose, corroded or defective battery 2) Tighten, clean or replace as necessary.* cables.

  • Page 42: Generator Troubleshooting

    Troubleshooting 5.2 — Generator Troubleshooting Table 5-2. Generator Diagnostics Things to Active Alarm Problem Solution Check NONE GREEN Unit running in AUTO but no Check Gener- Contact servicing dealer if Generator power in house. ator Discon- Disconnect circuit breaker is in the ON nect circuit position.
  • Page 43 Troubleshooting Table 5-2. Generator Diagnostics (Continued) Things to Active Alarm Problem Solution Check STEPPER Unit will not start in AUTO with Check the Contact servicing dealer. OVERCUR- utility loss. LEDs/Screen RENT for alarms. MISWIRE Unit will not start in AUTO with Check the Contact servicing dealer.

  • Page 44: Synergy Troubleshooting

    Troubleshooting 5.3 — Synergy Troubleshooting Table 5-3. Synergy Diagnostics Ecode/Active Things to Problem Possible Causes/Solution Alarm Check 1048 VSCF Overload Unit shuts down Check the Alternator, AVR or wiring is damaged. during operation. LEDs/Screen Contact servicing dealer. for alarms. 1049 VSCF Overload Unit shuts down Check the Generator output is shorted or severely overloaded.
  • Page 45 Troubleshooting Table 5-3. Synergy Diagnostics (Continued) Ecode/Active Things to Problem Possible Causes/Solution Alarm Check 1057 VSCF Unit shuts down Check the Probable causes are: Overvoltage during operation LEDs/Screen 1) The generator has been overloaded. Remove load and or starting. for alarms. attempt to restart unit.

  • Page 46: Load Shed Troubleshooting

    Troubleshooting 5.4 — Load Shed Troubleshooting Table 5-4. Load Shed Diagnostics Symptom Possible Causes Generator stalls when large load is 1) Total load is too big for the generator and fuel type. Contact installing dealer supplied. to correct installation. 2) A large load is not wired through the Loadshed module. Contact installing dealer to correct installation.
  • Page 48 Part No. 0K2502 Rev. C 01/20/2015 Printed in USA Generac Power Systems, Inc. © Generac Power Systems, Inc. All rights reserved S45 W29290 Hwy. 59 Specifications are subject to change without notice. Waukesha, WI 53189 No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722) consent from Generac Power Systems, Inc.

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