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Instruction Manual Generac Power Systems - 004917-2

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Installation and

Owner’s Manual

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

DANGER

This manual should

remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model Number

004917-2

27 kW NG, 30 kW LP Vapor

Not intended for use in life-support applications.

!

!

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Summary of Contents

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    Installation and Owner’s Manual DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!! DANGER This manual should remain with the unit. Liquid-cooled, Prepackaged Standby Generators Model Number 004917-2 27 kW NG, 30 kW LP Vapor Not intended for use in life-support
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    Generac ® Power Systems, Inc. INTRODUCTION Thank you for purchasing this model of the standbygenerator set product line by Generac Power Systems. Every effort was expended to make sure that theinformation and instructions in this manual are bothaccurate
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    Table of Contents QUIETSOURCE™ Liquid-cooled 30 kW Generators Generac ® Power Systems, Inc. 1 INTRODUCTION ................................................IFC SAFETY RULES ....................................................2 Section 1 — GENERAL INFORMATION
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    2 Generac ® Power Systems, Inc. Study these SAFETY RULES carefully before installing,operating or servicing this equipment. Become familiarwith this Owner’s Manual and with the unit. The gen-erator can operate safely, efficiently and reliably only ifit is
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    Generac ® Power Systems, Inc. 3 • 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
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    4 Generac ® Power Systems, Inc. 1.1 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 loadsduring utility power failure. The unit has been facto-ry-installed
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    Generac ® Power Systems, Inc. 5 1.6 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using anatural 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
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    6 Generac ® Power Systems, Inc. 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 threeseconds
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    1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS 1.10.2 ENGINE SPECIFICATIONS Make ......................................................................................FordDisplacement ..................................................................3.0
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    8 Generac ® Power Systems, Inc. NOTE: Port 1 is for NG only and Port 2 is for LP vaporonly. No provision for dual fuel has been made. Serious injury or damage may occur if notconfigured properly. Please consult an author-ized Generac Service Dealer with
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    Generac ® Power Systems, Inc. 9 Only qualified, competent installation contractors orelectricians thoroughly familiar with applicablecodes, standards and regulations should install thisstandby electric power system. The installation mustcomply strictly with
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    10 Generac ® Power Systems, Inc. Figure 2.1 – Basic Standby Electric System 2.5 EMERGENCY CIRCUIT ISOLATIONMETHOD This prevents overloading the generator by keepingelectrical loads below the wattage/amperage capacityof the generator. If the generator is
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    Generac ® Power Systems, Inc. 11 Setting switch two to OFF allows the control PCB toperform the ATS control functions. Control system interconnections consist of N1 andN2, and leads 23 and 194. Control system intercon-nection leads must be run in a conduit
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    12 Generac ® Power Systems, Inc. When using maintenance-free batteries, it is not nec-essary to check the specific gravity or electrolyte level.Have these procedures performed at the intervalsspecified in Section 4, “Maintenance.” A negativeground system
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    Generac ® Power Systems, Inc. 13 • 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 thisdocument. Pos2 OFF — ATS Application • The control board will
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    14 Generac ® Power Systems, Inc. 3.2.6 SYSTEM READY LED The System Ready LED (green) has two main pro-poses. First, the LED will be ON when theAUTO/OFF/MANUAL switch is in the AUTO position,utility is present, and there are no system alarms.This ON state
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    Generac ® Power Systems, Inc. 15 3.6 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. •
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    16 Generac ® Power Systems, Inc. 4.2 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.
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    Generac ® Power Systems, Inc. 17 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
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    18 Generac ® Power Systems, Inc. Figure 4.3 – Engine Air Cleaner See the “Service Schedule,” Section 6, for air cleanermaintenance. 4.5.12 SPARK PLUGS Reset the spark plug gap or replace the spark plugsas necessary. See Section 6. 1. Clean the area around
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    Generac ® Power Systems, Inc. 19 4.6.3 BATTERY MAINTENANCE The battery should be inspected per the “ServiceSchedule,” Section 6. The following procedureshould be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion.
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    20 Generac ® Power Systems, Inc. Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators 4.7 SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for Generac small standby and residential generator sets. Theestablished intervals
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    Generac ® Power Systems, Inc. 21 Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp.
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    22 Generac ® Power Systems, Inc. Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp.
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    Generac ® Power Systems, Inc. 23 Section 5 — Troubleshooting QUIETSOURCE™ Liquid-cooled 30 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten,
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    FUSE, BAT. POWER (15A AGC TYPE) CIRCUIT BREAKER (EXCITATION) BULKHEAD CONNECTOR 1 (ENGINE) AUTOMATIC VOLTAGE REGULATORBRUSH ASSEMLY (GENERATOR)BATTERY CHARGER DIODE [FIELD BOOST] CIRCUIT BREAKER (OUTPUT) BC1 - CB2 -D1 -F1 - CB1 - LEGEND: B/C - BA - AVR -
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    Generac ® Power Systems, Inc. 25 IC -IM -J-1 - HCT - WLS - JB - SM - LOS - J-2 - LEGEND [CONT.]: 12VDC BATTERY FUEL SOLENOID DRIVER ELEC. GOVERNOR CONNECTOR 1 (ENGINE)STARTER CONTACTOR D.C. CHARGE ALTERNATOR GROUND (POWER/HIGH AMP) GROUND (SENSING/LOW AMP)
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    26 Generac ® Power Systems, Inc. Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-A DISPLACED PHASE EXCITATION CIRCUIT BREAKER (EXCITATION) BATTERY CAHRGE WINDING BRUSH ASSEMLY (GENERATOR)
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    Generac ® Power Systems, Inc. 27 Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-A LEGEND [CONT.]: WLS - SM - LOS - IM - HCT - IC - CONNECTOR (C1) ELEC. GOVERNOR ACTUATOR SOLENOID
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    CONTACTOR WIRE H ARNE SS 7 5 6 16 E N G INE FOO T 2 4 3 41 40 16 7 6 5 35 9 13 17 12 8 18 16 43 BLOCK E N G INE 30 TO 44 35 34 3 36 33 44 42 22 20 32 38 18 31 20 TO S TARTER S TARTER BO LT TO B LOC K E N G INE 18 TO 11 1 12 10 14 R EAR BEARIN G 13 15 37
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    ITEM PART NO. QTY. DESCRIPTION 1 0E5822 1 BASEFRAME, WELDMENT 3.0L FORD 2 052860 4 NUT FLANGED HEX M12-1.75 3 052251 4 DAMPENER VIBRATION 40 BLUE 4 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZNC 5 052252 4 DAMPENER VIBRATION 6 052259 4 WASHER FLAT M12 7 052891
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    30 Generac ® Power Systems, Inc. S TATE S F O AM I S O N NEAR S IDE S TATE S F O AM I S O N FAR S ID E 37 17 LAT C H DETAIL 30 1 31 34 38 32 3 45 18 27 41 4 2 S EE LAT C H 7 DETAIL 25 "B" 52 11 9 4 6 53 54 5 TO "A" S E CU RE A S S H O WN.
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    Generac ® Power Systems, Inc. 31 ITEM PART NO. QTY. DESCRIPTION 1 0E8418 1 DUCT INTAKE MID AL 2 0E8414 1 DUCT DISCHARGE RH AL 3 0E8413 1 DUCT DISCHARGE LH AL 4 0C2454 62 SCREW TH-FRM M6-1 X 16 N WA Z/JS 5 0E8402 1 BAFFLE REAR BOTTOM 6 0E5902 1 POST CORNER
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    32 Generac ® Power Systems, Inc. Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7118-G
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    Generac ® Power Systems, Inc. 33 ITEM PART NO. QTY. DESCRIPTION 1 0E7195 1 CONTROL BOX HSB 2 0E7196 1 COVER FRONT PANEL HSB 3 0E7197 1 COVER TOP PANEL HSB 4 0E7193 1 DECAL WARNINGS HSB 5 0E7194 1 DECAL CONTROLS HSB 6 0E4494 1 SWITCH ROC DPDT ON-OFF-ON 7
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    11 36 17 57 24 61 60 30 68 25 58 35 39 66 36 WIRE GROUND 39 32 64 65 31 35 79 54 43 2 38 51 55 61 25 60 58 57 35 16 18 19 48 48 42 41 44 45 31 30 43 21 7 78 47 42 38 1 2 47 43 26 42 42 69 28 REAR UPPER BAFFLE 40 36 6 7 5 35 37 15 36 8 3 14 3 12 29 73 35
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    ITEM PART NO. QTY. DESCRIPTION 1 0E6202 1 ENGINE 3.0L FORD (RD) (MAKE) 2 0E8824 2 STAMPING ENG FOOT 3.0L FORD 3 0E8963 1 PULLEY CRANKSHAFT 3.0L FORDRD 4 0E9020 1 BRACKET DC ALT 3.0L FORD 5 0A1232 1 D.C. ALTERNATOR ASSY 6 0A7801B 1 PULLEY POLY-V 82 OD. 7
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    E N G INE 5 "A " 12 FRAME 10 9 11 8 9 3 21 27 PU MP TO WATER 4 12 17 6 15 7 1 15 20 3 22 24 24 TO 2 12 TO "A" 18 13 14 12 Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Radiator — Drawing No. 0E8528-B 36
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    ITEM PART NO. QTY. DESCRIPTION 1 0E9947 1 RADIATOR R-IN,L-OUT 658X489X49 2 0E6340 1 VENTURI 3.0L FORD HSB 3 0E8531 2 SIDE SUPPORT RADIATOR HSB 4 0E6398 1 TUBE LOWER RAD 3.0L FORD HSB 5 0E6397 1 HOSE UPPER RAD 3.0LFORD HSB 6 080713 1 BRACKET COOLANT TANK
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    38 Generac ® Power Systems, Inc. "B " 31 10 16 4 2 17 5 9 1 7 6 30 32 29 11 29 15 8 3 6 13 ANER 29 19 26 27 18 21 2 39 Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Fuel System — Drawing No. 0E8190-B
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    Generac ® Power Systems, Inc. 39 ITEM PART NO. QTY. DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E7691 1 ASSY REGULATOR 3.0L NG OR LPV 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 WASHER FLAT 5/16 ZINC 6 022129
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    40 Generac ® Power Systems, Inc. 4 15 7 17 8 7 1 18 31 30 LEAD S 5 2 6 21 9 3 20 11 12 * 10 19 14 Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Alternator — Drawing No. 0E8660-B
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    Generac ® Power Systems, Inc. 41 ITEM PART NO. QTY. DESCRIPTION 1 0F1659A 1 ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD) 0E5093A 1 ROTOR 390 30KW 1P DIRECT
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    ITEM PART NO. QTY. DESCRIPTION 1 0E8616 1 MUFFLER 7" X 9" X 21" 2.5" IN &OUT 2 0E8727 1 PIPE MUFFLER OUT 3 0E8822 1 WYE PIPE 2-1/2" 4 0E8821 2 EXHAUST ELBOW HSB (2"-2-1/2") 5 0E6465 1 EXHAUST PIPE LH 3.0L FORD HSB 6 0E6465A
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    Generac ® Power Systems, Inc. 43 ITEM PART NO. QTY. DESCRIPTION 1 0E5193 1 PLATE AIR CLEANER ADAPTER 2 0E8200 1 TUBE AIR INTAKE 3.0L FORD 3 0E8201 1 BRACKET AIR INTAKE 3.0L FORD 4 036434 1 BOLT U 5/16-18 X 2.09 5 0E0519A 1 ADAPTER, CARBURETOR W/PVCCONN 6
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    44 Generac ® Power Systems, Inc. Section 8 — Installation Diagram QUIETSOURCE™ Liquid-cooled 30 kW Generators Installation Diagram — Drawing No. 0E8696
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    Generac ® Power Systems, Inc. 45 Section 9 — Notes QUIETSOURCE™ Liquid-cooled 30 kW Generators
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    Part No. 0E8565 Revision E (10/06/04) Printed in U.S.A. Section 10 – Warranty QUIETSOURCE™ Liquid-cooled 30 kW Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR QUIETSOURCE™ "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"