Summary of Contents for Generac Power Systems 004988-4
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Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number: 004988-4 27kW NG, 30kW LP Vapor This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
INTRODUCTION Thank you for purchasing this model of the standby generator set. 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. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
IMPORTANT SAFETY INSTRUCTIONS 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. ...
• 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.
If a transfer switch is not included, one may be pur- chased separately from an Authorized Dealer. Model Rating 004988-4 27,000 NG 30,000 LP When this generator, along with a transfer switch, has been installed and interconnected, a circuit board in the generator panel constantly monitors UTILITY power source voltage.
GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is neces- sary, contact an authorized service dealer. 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.
Section 1 — General Information 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.
Fuel pressure for an LP vapor set up should be 11 Single-phase inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges. 004988-4 27 (NG), 30 (LP) 1.12 RECONFIGURING THE FUEL 120/240 1800...
• NFPA STATIONARY ENGINES AND GAS TURBINES. • NFPA 76A, ESSENTIAL SYSTEMS FOR HEALTH CARE FACILITIES. • NFPA No. 220, STANDARD TYPES OF BUILDING CONSTRUCTION • NFPA No. 68, GUIDE FOR EXPLOSION VENTING • NFPA No. 70, NATIONAL ELECTRICAL CODE. •...
Section 2 — Installation Liquid-cooled 30 kW Generators EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator can only power criti- cal loads, within it’s wattage/amperage capacity, dur- ing utility power outages, use the emergency circuit isolation method.
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 lead. Recommended wire gauge sizes for this wiring depends on the length of the wire, as recommended below: MAXIMUM WIRE LENGTH RECOMMENDED WIRE...
Section 3 — Operation Liquid-cooled 30 kW Generators 2.11.1 PRIOR TO INITIAL START-UP Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.
MANUAL — The control board will start and run the generator whenever the switch is in the manual position. AUTO — The control board will monitor the two- wire start circuit. When a two-wire start is issued the control board will immediately start and run the gen- erator.
Section 3 — Operation Liquid-cooled 30 kW Generators The system ready LED will be OFF when the switch is in the manual or OFF positions. The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes.
WEEKLY EXERCISE CYCLE The engine control board will start and run the gen- erator once every seven days for approximately 12 minutes. If utility should fail during this exercise period, the engine control board will transfer the load to the generator output and continue to run until util- ity returns.
Section 4 — Maintenance Liquid-cooled 30 kW Generators OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse.
4.5.8 CHECK FAN BELT • Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defec- tive belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 inch. Adjust belt tension as required. 4.5.9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor.
Section 4 — Maintenance Liquid-cooled 30 kW Generators 4.5.12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary. See Section 6. 1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent.
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DANGER Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charg- ing. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shat- ter the battery and cause blindness or other injury.
Section 4 — Maintenance Liquid-cooled 30 kW Generators SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for 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.
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Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 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.
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Section 4 — Maintenance Liquid-cooled 30 kW Generators Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 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...
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 Liquid-cooled 30 kW Generators CAUSE 1.
"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 Guardian 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 a Guardian Authorized Warranty Service Dealer, is found to be defective.