Installation and Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 004917-4 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.
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 written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
Table of Contents QUIETSOURCE™ Liquid-cooled 30 kW Generators INTRODUCTION ................................................IFC SAFETY RULES ....................................................2 Section 3 — OPERATION ................................13 3.1 Using a Standard “GTS” Transfer Switch............13 3.2 Control Console Components..............................13 Section 1 — GENERAL INFORMATION ............4 3.3 Manual Transfer and Startup ..............................14 1.1 Generator ......
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 – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
• 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. Reconnect that cable last. • Never use the generator or any of its parts as a step.
Section 1 - General Information QUIETSOURCE™ Liquid-cooled 30 kW Generators 1.1 GENERATOR 1.3 This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all aluminum enclosure and is intended for outdoor installation only.
1.6 NOTE: GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is necessary. Refer to Section 1.12, Reconfiguring the Fuel System. 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. The Low Oil Pressure, High Coolant Temperature and Low Coolant Level are not monitored for the first 10 seconds of engine run time. Figure 1.
Figure 1.6 - Low Coolant Level Sensor 1.7.7 LOW BATTERY The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 11.0 VDC for one minute. Low battery voltage is a non-latching alarm, which will automatically clear if the battery voltage rises above 11.0 VDC. 1.7.
Section 1 — General Information QUIETSOURCE™ Liquid-cooled 30 kW Generators NOTE: 1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Single-phase 4917-4 27 (NG), 30 (LP) Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) 120/240 No. of Rotor Poles 4 Driven Speed of Rotor 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor/Stator Insulation Class F/H 1.10.2 ENGINE SPECIFICATIONS Make .......................................................................
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. Please consult an authorized Generac Service Dealer with any questions. 1.13 TORQUE SPECIFICATIONS Cylinder Head ............................................15 (+ 90° + 90°) ft.lb. Intake Manifold ...............................................................
Section 2 — Installation QUIETSOURCE™ Liquid-cooled 30 kW Generators 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 regulations pertaining to the installation.
• 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. • Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service.
Section 2 — Installation QUIETSOURCE™ Liquid-cooled 30 kW Generators 2.10 BATTERY INSTALLATION ! 2.9 Failure to connect the generator neutral properly will result in unbalanced line-to-neutral voltages. Resulting high voltages will cause equipment damage. DANGER ! TRANSFER SWITCH SIGNAL CONNECTIONS 2.9.
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) bicarbonate 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. The resulting liquid is to be flushed with water and the area dried.
Section 3 - Operation QUIETSOURCE™ Liquid-cooled 30 kW Generators NOTE: 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 connections. Restrain any loose wires to keep them clear of any moving generator set components. 3.
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 • Overspeed/RPM Sensor Loss • High Coolant Temperature/Low Coolant Level See Section 1.7 for further explanation of engine protection functions. 3.2.3 15 AMP FUSE This fuse protects the control console’s DC control circuit against electrical overload.
Section 3 - Operation QUIETSOURCE™ Liquid-cooled 30 kW Generators Figure 3.2 - “Set Exercise” Switch US FUSE 15A MAIN US F USE FUSE 4A BAT. CHARGER F SE • 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. If a failure occurs while running in this mode, the five red LEDs will stop flashing, the individual fault LED will turn on and the engine will shut down.
4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHS 1. 2. 3. 4. 5. 6. Check battery state of charge and condition. Inspect and test fuel system. Check transfer switch. Inspect exhaust system. Check engine ignition system. Check fan belts. 4.3 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.
Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators 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. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary.
Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter 2. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule,” Section 6, for recommended inspection. 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 1.06-1.16 mm (0.0420.046 inch) by carefully bending the ground electrode (Figure 4.4). Figure 4.
4.6.2 BATTERY Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If the fluid is spilled, flush the affected area immediately with clear water. All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery.
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. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators Maintenance Tasks Level 1 Recommended to be done monthly Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in Level 3 Task Comp. (DateInitials) Required to be done Semiannually Level 4 Task Comp. (DateInitials) Required to be done Annually Task Comp. (DateInitials) 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3.
Section 4 — Maintenance QUIETSOURCE™ Liquid-cooled 30 kW Generators Maintenance Tasks Level 1 Recommended 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 conditions. Correct as necessary. 14.
Section 5 — Troubleshooting QUIETSOURCE™ Liquid-cooled 30 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 4 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5. Remove, change or replace battery. 6. Replace fuse.
2 CB2 16 1 AVR 2 3 4 5 6 14 0 0 TB1 0 0 14 16 16 225 224 1 3 3 6 2a N2 BC1 N1 15 13 13 194 15 2 7 4 5 14 11 44 1 4 2 5 6 55 66 183 178 N1 N2 23 13A 8 1 2 194 178 178 1a TR1 N2 N1 14A 15E 15 2b 1 55 0 0 0 225A 224A 178 178 183 16 14 1b 16 1 2 1 2 3 239 15A 15 14 13 13A 0 B/C 14 14 225 224 OA 16 16 85 4 4 TR2 13A 1 0 55 14 4 5 11 6 6 UTILITY FROM T/SW UTILITY FROM T/SW TRANSFER RELAY COIL TRANSFER RELAY COIL C - REMOTE START NO - REMOTE START IC 44 N
Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Wiring Diagram — Engine — Drawing No.
Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B LEGEND: AR AS AVR BA B/C BCW CB1 CB2 D1 DPE - ALTERNATOR ROTOR ALTERNATOR STATOR AUTOMATIC VOLTAGE REGULATOR BRUSH ASSEMLY (GENERATOR) BATTERY CHARGER BATTERY CHARGE WINDING CIRCUIT BREAKER (OUTPUT) CIRCUIT BREAKER (EXCITATION) DIODE [FIELD BOOST] DISPLACED PHASE EXCITATION LEGEND {CONT.]: F1 FUSE, BAT.
Section 6 - Electrical Data QUIETSOURCE™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No.
30 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Compartment — Drawing No. 0F1141-A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 * 51 52 53 54 PART NO.
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7118-J 32 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7118-J ITEM PART NO. QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0E7195 0E7196 0E7197 0E7193 0E7194 0E4494 082573 032300 022676 067682B 060015 054199 0C2657 099076 040213 0E9668 0E4905 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 17 18 19 20 21 067680 0E6875A 0E6881 * 0C5139 * 0C5142 * 1 1 REF. REF. REF.
38 85 11
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Engine — Drawing No. 0E8170-N ITEM PART NO. QTY.
12 "A" ENGINE 5
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Radiator — Drawing No. 0E8528-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 20 21 22 23 24 25 26 27 PART NO. 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 QTY. 1 1 2 1 1 1 1 4 8 4 4 4 1 4 9 1 1 1 1 1 1 2 1 1 1 DESCRIPTION RADIATOR R-IN,L-OUT 658X489X49 VENTURI 3.
38 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Fuel System — Drawing No. 0E8190-C ITEM PART NO.
3 40 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Alternator — Drawing No. 0F5092-A ITEM PART NO. QTY.
21 13 2 11 18 1 19 17 16 7 8 16 16 17 6 18 TO MANIFOLD 19 8 TO COMPARTMENT 10 15 20 16 17 3 10 20 17 5 TO MANIFOLD 13 14 3 4 12 ITEM PART NO. QTY. 1 2 3 4 5 6 7 0F0738 0F6258 044149 0F1008 0F1009 039288 0E5914 1 1 2 1 1 1 1 8 9 10 11 0E8726 0E0170 036797 080762 2 2 2 1 DESCRIPTION MUFFLER 7"X9"-(2)2"IN/2.5"OUT PIPE MUFFLER OUT GASKET EXHAUST RING EXHAUST PIPE LH 3.0L HSB EXHAUST PIPE RH 3.0L HSB SCREW HHC M8-1.25 X 55 G8.8 BRACKET MUFFLER 3.
ITEM PART NO. QTY. 1 2 3 4 5 0E5193 0E8200 0E8201 036434 0E0519A 1 1 1 1 1 6 7 8 9 10 0C8127 0A5547 062974 022127 037561 1 1 1 1 1 DESCRIPTION PLATE AIR CLEANER ADAPTER TUBE AIR INTAKE 3.0L FORD BRACKET AIR INTAKE 3.0L FORD BOLT U 5/16-18 X 2.09 ADAPTER CARBURETOR W/PVC CONN ELEMENT AIR CLEANER COVER - AIR CLEANER STUD TH 1/4-20 X 4-1/2 G2 ZNC NUT HEX 1/4-20 STEEL NUT WING 1/4-20 NYLK ITEM 11 12 13 14 15 16 17 18 19 20 21 PART NO.
Section 8 — Installation Diagram QUIETSOURCE™ Liquid-cooled 30 kW Generators Installation Diagram — Drawing No. 0E8696 44 Generac® Power Systems, Inc.
Section 9 — Notes QUIETSOURCE™ Liquid-cooled 30 kW Generators Generac® Power Systems, Inc.
Part No.
