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Generac Power Systems 004917-2 Owner's Manual

Quietsource liquid-cooled, prepackaged standby generator owner's manual.
Installation and
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number
004917-2
27 kW NG, 30 kW LP Vapor
This manual should
remain with the unit.
!
!
Not intended for use in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

   Related Manuals for Generac Power Systems 004917-2

   Summary of Contents for Generac Power Systems 004917-2

  • Page 1

    Installation and Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 004917-2 27 kW NG, 30 kW LP Vapor This manual should remain with the unit. Not intended for use in life-support applications. DANGER DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

  • Page 2

    INTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac Power Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten.

  • Page 3: Table Of Contents

    INTRODUCTION ...IFC SAFETY RULES ...2 Section 1 — GENERAL INFORMATION ...4 Generator ...4 Transfer Switch ...4 Automatic System Operation ...4 Generator AC Connection Systems...4 Main Circuit Breaker ...4 Generator Fuel System ...5 Engine Protective Devices ...5 Unpacking ...6 Lifting the Generator ...6 1.10 Specifications ...7 1.11 Fuel Consumption ...7 1.12 Reconfiguring the Fuel System ...7...

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS QUIETSOURCE™ Liquid-cooled 30 kW Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. SAVE THESE INSTRUCTIONS –...

  • Page 5

    • Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first.

  • Page 6: Section 1 — General Information, Generator, Transfer Switch, Automatic System Operation, Generator Ac Connection Systems

    Section 1 - General Information QUIETSOURCE™ Liquid-cooled 30 kW Generators GENERATOR This equipment is a liquid-cooled, engine-driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all aluminum enclosure and is intended for outdoor installation only.

  • Page 7: Generator Fuel System, Engine Protective Devices

    GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is neces- sary. Refer to Section 1.11, Fuel Consumption. Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

  • Page 8: Unpacking, Lifting The Generator

    Section 1 — General Information QUIETSOURCE™ Liquid-cooled 30 kW Generators Figure 1.6 - Low Coolant Level Sensor 1.7.4 OVERSPEED SHUTDOWN The engine control board receives AC frequency sig- nals from an engine run winding in the alternator. Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaniously, the engine shuts down and the overspeed LED turns on.

  • Page 9: Specifications, Fuel Consumption, Reconfiguring The Fuel System

    1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No. of Rotor Poles Driven Speed of Rotor Rotor Excitation System Direct excited brush type Type of Stator Rotor/Stator Insulation 1.10.2 ENGINE SPECIFICATIONS Make ...Ford Displacement ...3.0 liters Cylinder Arrangement ...V-6 Valve Arrangement ...Overhead Valve...

  • Page 10: Torque Specifications, Engine Oil Recommendations, Coolant Recommendations, Before Installation, Section 2 — Installation

    Section 2 — Installation QUIETSOURCE™ Liquid-cooled 30 kW Generators NOTE: Port 1 is for NG only and Port 2 is for LP vapor only. No provision for dual fuel has been made. DANGER Serious injury or damage may occur if not configured properly.

  • Page 11: Generator Location, Generator Mounting And Support, Basic Standby Electric System

    Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regula- tions pertaining to the installation. After the system has been installed, do nothing that might render the installation in noncompli- ance with such codes, standards and regulations.

  • Page 12: Emergency Circuit Isolation Method, Total Circuit Isolation Method, Grounding The Generator, Generator Ac Neutral Connections

    Section 2 — Installation QUIETSOURCE™ Liquid-cooled 30 kW Generators Figure 2.1 – Basic Standby Electric System EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only crit- ical loads, within the wattage/amperage capacity, dur- ing utility power outages, consider using the emer- gency circuit isolation method.

  • Page 13: Battery Installation

    Setting switch two to OFF allows the control PCB to perform the ATS control functions. Control system interconnections consist of N1 and N2, and leads 23 and 194. Control system intercon- nection leads must be run in a conduit that is sepa- rate from the AC power leads.

  • Page 14: Preparation Before Start-up, Section 3 — Operation, Using A Standard "gts" Transfer Switch

    Section 3 — Operation QUIETSOURCE™ Liquid-cooled 30 kW Generators When using maintenance-free batteries, it is not nec- essary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used.

  • Page 15: Control Console Components

    • The control board will NOT activate the transfer output. • The control board WILL monitor all engine condi- tions and shut down on all the faults listed in this document. Pos2 OFF — ATS Application • The control board will perform all of the automat- ic features listed in this document.

  • Page 16: Manual Transfer And Startup, Engine Governor Adjustments, Retransfer And Shutdown

    Section 3 — Operation QUIETSOURCE™ Liquid-cooled 30 kW Generators 3.2.6 SYSTEM READY LED The System Ready LED (green) has two main pro- poses. First, the LED will be ON when the AUTO/OFF/MANUAL switch is in the AUTO position, utility is present, and there are no system alarms. This ON state indicates the system is fully ready for automatic operation.

  • Page 17: Automatic Operation, Weekly Exercise Cycle, Section 4 — Maintenance, Maintenance Performed By Authorized Service Facilities

    AUTOMATIC OPERATION To set the system for fully automatic operation, pro- ceed as follows: • Check that load circuits are connected to the utility power supply. • Set the AUTO/OFF/MANUAL switch to its AUTO position. • Set the generator main circuit breaker to its ON or CLOSED position.

  • Page 18: Cooling System, Overload Protection For Engine Dc Electrical System, Checking Fluid Levels

    Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators COOLING SYSTEM Air intake and outlet openings in the generator com- partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions as high grass, weeds, brush, leaves and snow. Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.

  • Page 19

    4.5.4 INSPECT COOLING SYSTEM • Inspect engine cooling system at least once each month. • Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found. • Check hose clamps for tightness. 4.5.5 CHECK ENGINE COOLANT LEVEL See “Checking Fluid Levels” in Section 4.4. 4.5.6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine-generator monthly.

  • Page 20: Miscellaneous Maintenance

    Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators Figure 4.3 – Engine Air Cleaner See the “Service Schedule,” Section 6, for air cleaner maintenance. 4.5.12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary. See Section 6. 1.

  • Page 21

    4.6.3 BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule,” Section 6. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY.

  • Page 22: Scheduled Maintenance

    Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.

  • Page 23

    Maintenance Level 1 Tasks Recom- mended to be done monthly 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level.

  • Page 24

    Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators Maintenance Level 1 Tasks Recom- mended to be done monthly 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating...

  • Page 25: Section 5 — Troubleshooting

    TROUBLESHOOTING POINTS PROBLEM Engine won’t crank. Engine cranks, but won't start Engine starts hard, runs rough. Engine starts, then shuts down. AUTO/OFF/MANUAL Switch at, OFF engine continues to run No AC output from generator. Section 5 — Troubleshooting QUIETSOURCE™ Liquid-cooled 30 kW Generators CAUSE 1.

  • Page 26: Section 6 — Electrical Data

    Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Wiring Diagram — Engine — Drawing No. 0E6199-E NOTE: SIZE (AWG) ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN: TRANSFER SWITCH CUSTOMER CONNECTION LEGEND: AVR - AUTOMATIC VOLTAGE REGULATOR BA -...

  • Page 27

    PCB J2 PCB J1 Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Wiring Diagram — Engine — Drawing No. 0E6199-E NOTE: SIZE (AWG) ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS OTHERWISE NOTED AS SHOWN: GND1 LEGEND: ALT - D.C.

  • Page 28

    Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-A LEGEND: AR - AS - AVR - BA - B/C - BCW - CB1 - CB2 - D1 - DPE - TRANSFER SWITCH CUSTOMER CONNECTION CONNECTION 120/240V 1-PHASE...

  • Page 29

    Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-A J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J2-1 J1-8 J2-2 J1-9 J2-3 J2-4 J1-10 J2-5 J1-11 J2-6 J1-12 J2-7 J1-13 J1-14 J2-8 LEGEND: ALT - D.C.

  • Page 30

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Mounting Base — Drawing No. 0E6266-E 28 Generac ® Power Systems, Inc.

  • Page 31

    ITEM PART NO. QTY. 0E5822 052860 052251 052257 052252 052259 052891 0536210213 074906 047411 055414 026850 022097 022473 049813 0A1694 052213 025507 027482 022129 045771 23 * 051756 24 * 046526 25 * 022131 26 * 055934M 077483 REF. 058665 REF.

  • Page 32

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Compartment — Drawing No. 0E8519-B 30 Generac ® Power Systems, Inc.

  • Page 33

    ITEM PART NO. QTY. 0E8418 0E8414 0E8413 0C2454 0E8402 0E5902 0E5903 0E8387 0E5912 0E5911 089961 0A2115 0E8404 0D2538A 0D2538 043116 022097 022473 0E7570 0E7571 070015 0E7662 0D2537A 0D2537 0D2023 0E7869 0E8001 0E5913 0E5915 0D3037A 0C7781 0E5910 0E8052 0D3037 0E5900 0E5901 0E5916 0E8415 026850...

  • Page 34

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7118-G 32 Generac ® Power Systems, Inc.

  • Page 35

    ITEM PART NO. QTY. DESCRIPTION 0E7195 CONTROL BOX HSB 0E7196 COVER FRONT PANEL HSB 0E7197 COVER TOP PANEL HSB 0E7193 DECAL WARNINGS HSB 0E7194 DECAL CONTROLS HSB 0E4494 SWITCH ROC DPDT ON-OFF-ON 082573 SWITCH ROCKER DPST 125V SPD 032300 HOLDER FUSE 022676 FUSE 15A X AGC15 067682B...

  • Page 36

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Engine — Drawing No. 0E8170-J GROUND WIRE 34 Generac ® Power Systems, Inc. BAFFLE REAR UPPER...

  • Page 37

    ITEM PART NO. QTY. DESCRIPTION 0E6202 ENGINE 3.0L FORD (RD) (MAKE) 0E8824 STAMPING ENG FOOT 3.0L FORD 0E8963 PULLEY CRANKSHAFT 3.0L FORD 0E9020 BRACKET DC ALT 3.0L FORD 0A1232 D.C. ALTERNATOR ASSY 0A7801B PULLEY POLY-V 82 OD. 0A5610 BRACKET ALTERNATOR 0E6308 PULLEY WATERPUMP 3.0L FORD (RD)

  • Page 38

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Radiator — Drawing No. 0E8528-B 36 Generac ® Power Systems, Inc.

  • Page 39

    ITEM PART NO. QTY. 0E9947 0E6340 0E8531 0E6398 0E6397 080713 076749 049814 022131 046526 045772 035685 0E8562 058443 0C2454 048031C 029032 046627 069811 065852 0A2111 052250 035461 0C7649 069860C Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Radiator —...

  • Page 40

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Fuel System — Drawing No. 0E8190-B 38 Generac ® Power Systems, Inc.

  • Page 41

    ITEM PART NO. QTY. --------- 075580 0E7691 039253 022145 022129 045771 042907 0C2454 026307 0E1056 0E6584 057823 059194 044117 0D1509 050279 0E6123 0E6586 0E4395 057753B 047487 022097 051751 035685 057823 047290 047290 0A4121 0E6609 049099 35 ** 055934M 36 ** 047411 37 ** 022097...

  • Page 42

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Alternator — Drawing No. 0E8660-B 40 Generac ® Power Systems, Inc.

  • Page 43

    ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A 0F1660A 0F1658A 0F1656A 0E5094A 0E7412A 0E5706 0E5048 0E5048A 0E5048B 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 7 - Exploded Views and Parts...

  • Page 44

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Muffler — Drawing No. 0E8766-B ITEM PART NO. QTY. DESCRIPTION 0E8616 MUFFLER 7" X 9" X 21" 2.5" IN & 0E8727 PIPE MUFFLER OUT 0E8822 WYE PIPE 2-1/2" 0E8821 EXHAUST ELBOW HSB (2"-2-1/2") 0E6465...

  • Page 45

    ITEM PART NO. QTY. DESCRIPTION 0E5193 PLATE AIR CLEANER ADAPTER 0E8200 TUBE AIR INTAKE 3.0L FORD 0E8201 BRACKET AIR INTAKE 3.0L FORD 036434 BOLT U 5/16-18 X 2.09 0E0519A ADAPTER, CARBURETOR W/PVC CONN 0C8127 ELEMENT, AIR CLEANER 0A5547 COVER - AIR CLEANER 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 022127...

  • Page 46: Section 8 — Installation Diagram

    Section 8 — Installation Diagram QUIETSOURCE™ Liquid-cooled 30 kW Generators Installation Diagram — Drawing No. 0E8696 44 Generac ® Power Systems, Inc.

  • Page 47: Section 9 — Notes

    Section 9 — Notes QUIETSOURCE™ Liquid-cooled 30 kW Generators Generac ® Power Systems, Inc. 45...

  • Page 48

    "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource gener- ator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty Service Dealer, is found to be defective.

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