Generac Power Systems Quietsource 004917-3 Owner's Manual

Liquid-cooled, prepackaged standby generators.
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Installation and
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number
004917-3
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!!

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   Summary of Contents for Generac Power Systems Quietsource 004917-3

  • Page 1

    Installation and Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 004917-3 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: Electrical Hazards, Fire Hazards, Explosion Hazards

    • 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

    If a transfer switch is not included, one may be pur- chased separately from a Generac Authorized Dealer. Model Rating 004917-3 27,000 NG 30,000 LP Generac ® Power Systems, Inc.

  • 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 con- figured 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 regula- tions.

  • 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 • Allows the LOAD circuits to be connected to only one power supply at a time. • Prevents electrical backfeed between the generator and the UTILITY power circuits. Both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker.

  • Page 13: Battery Installation

    Failure to connect the generator neutral prop- erly will result in unbalanced line-to-neutral voltages. Resulting high voltages will cause equipment damage. TRANSFER SWITCH SIGNAL CONNECTIONS 2.9.1 PRE-PACKAGED ATS If the generator is to be installed with a pre-packaged transfer switch, it is necessary to connect the control wires to the generator and set position two of the four-position dip switch to OFF .

  • Page 14: Preparation Before Start-up

    Section 2 — Installation QUIETSOURCE™ Liquid-cooled 30 kW Generators • Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbon- ate of soda to one gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased.

  • Page 15: Section 3 — Operation, Using A Standard "gts" Transfer Switch, Control Console Components

    2.11.7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and/or ground rod. Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical con- nections.

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

    Section 3 — Operation QUIETSOURCE™ Liquid-cooled 30 kW Generators 3.2.2 FAULT INDICATOR LED This LED goes ON when one or more of the following engine faults occurs and when engine shuts down. • Low Oil Pressure • Overcrank • Low Battery •...

  • Page 17: Retransfer And Shutdown, Automatic Operation, Weekly Exercise Cycle

    5. Reduce load to 3/4, 1/2, 1/4 and no load. Decrease the stability pot if there is instability at any load point. 6. Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot. If it is set too high it may introduce oscillations at some load.

  • Page 18: Section 4 — Maintenance, Maintenance Performed By Authorized Service Facilities, Cooling System

    Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5.

  • Page 19: Maintenance Owner/operator Can Perform

    4.4.3 ENGINE COOLANT Check coolant level in coolant recovery bottle. See Specifications, Section 1.10. • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck.

  • Page 20: Miscellaneous Maintenance

    Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter OIL FILTER 4.5.11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 059402), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.3).

  • Page 21

    4.6.2 BATTERY All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery. If such information is not available, observe the following precautions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start the generator engine.

  • 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-F 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 LEGEND: ALT - D.C. CHARGE ALTERNATOR BAT - 12VDC BATTERY C1 - CONNECTOR 1 (ENGINE) CC - STARTER CONTACTOR DEG - DRIVER ELEC. GOVERNOR FS - FUEL SOLENOID GND1- GROUND (SENSING/LOW AMP) GND2- GROUND (POWER/HIGH AMP) GOV - ELEC.

  • Page 28

    Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B LEGEND: AR - ALTERNATOR ROTOR AS - ALTERNATOR STATOR AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMLY (GENERATOR) B/C - BATTERY CHARGER BCW - BATTERY CHARGE WINDING CB1 -...

  • Page 29

    Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J2-1 J1-7 J2-2 J1-8 J2-3 J1-9 J2-4 J1-10 J1-11 J2-5 J1-12 J2-6 J1-13 J2-7 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-K 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-N 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-C 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. 0F5092-A 40 Generac ® Power Systems, Inc.

  • Page 43

    ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048B 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 0C3993 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-C 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 generator 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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