Generac Power Systems 004988-4 Owner'S Manual Download

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Owner’s Manual

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

This manual should remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model Number: 004988-4

27kW NG, 30kW LP Vapor

Summary of Contents for 004988-4

Page 1: ...s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Number 004988 4 27kW NG 30kW LP Vapor ...

Page 2: ...This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properl...

Page 3: ... Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustments 14 3 5 Retran...

Page 4: ...ure that the genera tor is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient c...

Page 5: ...rating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an acceptable pre...

Page 6: ...rosive vapors If a transfer switch is not included one may be pur chased separately from an Authorized Dealer 1 3 AUTOMATIC SYSTEM OPERATION 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 Should that voltage drop below a preset value and remain at such a low state for a p...

Page 7: ...H COOLANT TEMPERATURE HIGH LOW COOLANT LEVEL SWITCH 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close the engine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 Figure 1 4 Low Oil Pressure Switch NOTE ...

Page 8: ...will not attempt to start the engine if there is a low battery condition however if the engine is already running when the low battery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 1 7 8 ALARM RESET If the engine control board shuts down the genera tor for any of the above reasons the engine remains stopped until the al...

Page 9: ...uel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regul...

Page 10: ...e unit will power The critical essential loads may need to be grouped together and wired into a sepa rate emergency distribution panel This generator can be installed in conjunction with an engineered GTS type transfer switch if neces sary The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which c...

Page 11: ... the unit Install the generator on high ground where water levels will not rise and endanger it This genset must be installed on a level surface The base frame must be level within 1 2 inch all around Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow five feet of space on all sides Where strong prevailing winds blow from one direction face th...

Page 12: ...d to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gen erator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations Figure 2 2 Generator Grounding Lug typical GROUNDING LUG DANGER Do not connect the ground wire to any pipe that carries a flammable or explosiv...

Page 13: ...en handling a battery If fluid is spilled flush the affected area immediately with clear water 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...

Page 14: ... Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications Section 1 10 and Coolant Section 1 15 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applie...

Page 15: ...ANGER With switch set to AUTO engine can crank and start suddenly without warning Such automatic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on control console 3 2 2 FAULT INDICATOR LED This...

Page 16: ...bility 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 It can be set to zero full CCW if a small amount causes oscillations at some load Figure 3 2 Engine Governor Adjustment P C B 0 E 4 9 0 6 R E V R49 D17 J2 C2 C26 U7 C27 R44 Q2 D19 C30 R...

Page 17: ...E E US F F S U S E E US F F US F U S BAT FUSE CHARGER ON OFF EXERCISE TIME SET 4A MANUAL AUTO OFF FUSE 15A MAIN 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES 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 Check engine ignition system 6 Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine...

Page 18: ...odically 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 To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recovery system for leaks 4 5 MAINTENANCE OWNER OPERATOR...

Page 19: ...l warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose o...

Page 20: ...ator and rotor windings checked If insulation resistances are excessively low the generator may require drying 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 c...

Page 21: ...ution 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 Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging Ensure that the 15A and 4A fuses are removed from the control console the AUTO OFF MANUA...

Page 22: ...removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to ensure it is ready to operate and carry the load when required and to identify any pot...

Page 23: ...orrect as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring ...

Page 24: ... abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the engine fuel fil...

Page 25: ...n regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Lo...

Page 26: ...24 Section 6 Notes Liquid cooled 30 kW Generators ...

Page 27: ...25 Section 7 Installation Diagram Liquid cooled 30 kW Generators Installation Diagram Drawing No 0E8695 ...

Page 28: ...OTE START TRANSFER RELAY COIL TRANSFER RELAY COIL TRANSFER SWITCH 15E N2 N1 13A 23 183 178 14 13 13A 0 14 14A 16 15 IC 13 13 11 14 13A 15A 239 1b 16 1a 15 1 16 16 15 2a 2b 1 15 VOLT UL LISTED UNLESS ALL WIRES ARE 18 AWG 300 224 OTHERWISE NOTED AS SHOWN 16 14 16 14 225 NOTE OA SIZE AWG BA 66 6 6 6 33 44 22 11 STATOR TR1 178 183 194 178 6 N1 225A 224A 178 178 44 4 5 6 2 55 11 N2 1 N1 N2 23 66 23 66 ...

Page 29: ...6 0 0 1 7 10 11 12 9 8 4 5 6 2 3 15A 224 225 15E 239 14 14A 0A 13 0 0 11 14 13 12 8 9 10 6 7 85 14A 225 66 C1 239 15E 0 RED 0 14 85 85 0 BLK FS 0A 0 0 16 16 13 GND2 0 0 0 4 16 10 0 0 SM 4 10 16 3 769 PCB J1 2 3 4 1 6 7 8 4 5 15A 86 23 56 768 766 N C 0 14 PCB J2 1 2 767 765 VOLT UL LISTED UNLESS ALL WIRES ARE 18 AWG 300 OTHERWISE NOTED AS SHOWN 13 14 0 56 13 13 10 10 CC NOTE 16 BAT 13 13 16 10 JB 4...

Page 30: ...MANUAL FUSE B C 4A AGC TYPE TERMINAL BLOCK INTERCONNECT TRANSFORMER 1 56 VA 240 16 VAC NEUTRAL BLOCK LEGEND CONT RL1 SW1 SW2 TR1 NB F2 ICT F1 RELAY 1 2 4 3 5 6 TRANSFER SWITCH 5 CUSTOMER CONNECTION 120 240V 1 PHASE CB1 E1 NB 00 DPE AS 2 CONNECTION N2 E3 N1 23 194 183 178 CB2 11 44 162 N1 N2 D1 BCW BA 55 AR 4 6 1 66 14 1 194 178 183 15 ICT N2 225A 183 178 23 194 224A TR1 N1 15 N1 SW1 224 23 225 178...

Page 31: ...SWITCH LOW OIL PRESSURE SENSOR COOLANT LEVEL IGNITION COIL STARTER MOTOR 14A 13 14 15E 224 225 15A 239 11 12 10 7 9 8 4 6 5 2 1 3 0A 0 0 0 23 66 PCB GOV 14A 225 85 66 4 6 5 1 3 2 J1 12 J1 13 J1 11 J1 14 224 239 15E 0 86 15A 23 56 J1 5 J1 7 J1 6 J1 8 J1 9 J1 10 J1 2 J1 3 J1 4 J1 1 J2 5 768 N C 770 766 N C 771 765 767 J2 7 J2 6 J2 8 14 0 767 769 766 765 J2 1 J2 3 J2 2 J2 4 56 16 13 13 85 14 CC FS 86...

Page 32: ...17 12 8 18 16 43 BLOCK ENGINE 30 TO 44 35 34 39 36 33 44 42 22 20 32 38 18 31 20 21 TO STARTER STARTER BOLT TO BLOCK ENGINE 18 TO 11 1 12 10 14 REAR BEARING 13 15 37 14 CARRIER 3 4 16 2 30 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Mounting Base Drawing No 0E6266 F ...

Page 33: ...SHAKEPROOF EXT 5 16 STL 21 022129 1 WASHER LOCK M8 5 16 22 045771 1 NUT HEX M8 1 25 G8 YEL CHR 23 051756 1 SCREW HHC M10 1 5 X 20 G8 8 24 046526 1 WASHER LOCK M10 25 022131 1 WASHER FLAT 3 8 M10 ZINC 26 055934M 1 CLAMP VINYL 75 X 343 Z 30 077483 REF BATT 12VDC 75 AH 26 058665 REF BATT 12VDC 90 AH 27F 31 038804D 1 CABLE BATT RED 4 X 20 00 32 038805AA 1 CABLE BATT BLK 4 X 30 33 021991 1 EARTH STRAP ...

Page 34: ... TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION SECURE AS SHOWN 4 4 49 35 RADIATOR SUPPORT 33 25 47 7 4 49 4 36 4 18 4 26 44 4 4 4 8 4 29 A A A A 12 13 53 17 52 48 B 20 11 10 14 15 19 16 28 4 1 24 17 42 41 9 53 18 23 45 4 4 4 4 5 45 17 40 4 26 2 PLCS TO B 10 18 39 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Enclosure Drawing No 0F1142 B ...

Page 35: ...4 LG 26 0E7869 2 BRACKET STIFFENING BACK 27 0E8001 1 MUFFLER BOX 28 0F5551 1 ROOF W SHOCK MOUNT 29 0E8406 1 BRACE FRONT TOP 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E7794 1 SUPPORT LH SIDE 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E8007 1 POST CORNER LH FRONT 36 0E8008 1 POST CORNER RH FRONT 37 0F1130 1 BRACE FRONT BOT 3 0L FD STEEL 38 0E805...

Page 36: ...34 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Control Panel Drawing No 0E7118 K ...

Page 37: ...L PANEL 34 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V 35 0E7252 1 BRACKET CB 221 5 X 102 36 0C1229 1 DECAL WARNING ELECTRICAL SHOCK ITEM PART NO QTY DESCRIPTION 37 0C1127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 41 074908 6 SCREW HHTT M5 0 8 X 10 BP 42 0C5141 1 CONN DEUTSCH GASKET 8 12 POS DT 43 0C2699 11 SCREW PHTT...

Page 38: ...35 39 86 68 66 67 32 16 18 19 80 48 47 42 41 44 45 31 30 81 88 84 42 78 49 21 49 46 20 47 47 46 4 43 64 38 42 63 1 26 42 15 47 43 81 2 38 42 28 34 REAR UPPER BAFFLE 40 42 36 5 6 7 35 37 89 36 43 3 8 35 83 12 29 74 72 73 38 10 82 33 36 42 84 34 35 27 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Engine Drawing No 0F6836 B 36 ...

Page 39: ...75 X 45 G10 9 45 098780 2 SCREW HHC M12 1 75 X 65 G8 8 46 051769 3 WASHER LOCK M12 ITEM PART NO QTY DESCRIPTION 47 049808 4 WASHER FLAT M12 48 051430 4 WASHER SHAKEPROOF INT 1 2 49 045773 3 NUT HEX M12 1 75 G8 YEL CHR 50 0E6203C 1 COIL IGNITION 3 0L FORD 51 0E6679 2 BRACKET IGN COIL 3 0L FORD 53 049226 7 WASHER LOCK M5 54 091526 3 SCREW PPHM M5 0 8 X 12 ZNC 55 093278 4 SCREW HHTT M5 0 8 X 25 BP 56...

Page 40: ...5 A 20 21 TO WATER 12 4 PUMP 6 15 17 7 13 1 15 3 5 24 22 23 2 24 12 31 28 32 12 TO A 18 14 HOUSING THERMOSTAT TO 29 12 33 35 30 ENGINE 12 TO Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Radiator Drawing No 0F6848 B ...

Page 41: ...5 0C2454 9 SCREW TH FRM M6 1 X 16 N WA Z JS 17 048031C 1 CLAMP HOSE BAND 1 4 18 029032 1 HOSE 9 32 ID 30 LG 20 046627 1 CAP RADIATOR 21 069811 1 CAP HEX 1 4 NPT BRASS 22 065852 1 SPRING CLIP HOLDER 37 62 23 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 24 052250 2 TAPE FOAM 1 X 1 27 LG 25 035461 1 BARBED STR 1 4 NPT X 3 8 26 0C7649 1 CLAMP HOSE 38 87 27 069860C 1 HOSE OIL DRAIN ASSY 21 28 0F6746 1 TUBE U...

Page 42: ... 2 17 5 9 1 7 6 29 32 30 11 29 13 15 8 3 12 6 13 AIR TO CLEANER 34 33 29 14 TO B 19 26 27 18 43 41 40 21 28 20 26 25 42 39 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Fuel System Drawing No 0F6849 A ...

Page 43: ...OR BOSCH 32 GOVERNOR 21 057753B 1 HOSE 1 5 ID X 2 LG 20R4 25 047487 4 SCREW SHC M6 1 0 X 18 G12 9 26 022097 8 WASHER LOCK M6 1 4 27 051751 4 SCREW HHC M6 1 0 X 50 G8 8 28 035685 2 CLAMP HOSE 28 1 32 2 25 29 0C7649 4 CLAMP HOSE 38 87 30 047290 1 HOSE 3 8 ID SINGLE BRAID 305mm 22 LONG 31 047290 1 HOSE 3 8 ID SINGLE BRAID 432mm 13 LONG 32 0A4121 1 VALVE PCV 33 0E6609 1 GROMMET ROCKER COVER 3 0LFORD 3...

Page 44: ...42 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Alternator Drawing No 0F5092 B ...

Page 45: ...COR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD 2 5L FORD 04576100BF 4 STUD M14 2 0 X 540 G5 ZINC 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 1 WASHER SHAKEPROOF INT 8 14 092980 4 SCREW PPHM M4 0 7 X 25 15 057192 4 SCREW SHC M10 ...

Page 46: ...NO QTY DESCRIPTION 12 0E8816 2 EXHAUST FLANGE 2 PIPE 13 085917 8 WASHER LOCK 3 8 SS 14 0D2611 4 SCREW HHC 3 8 16 X 1 3 4 SS 15 039253 2 SCREW HHC M8 1 25 X 20 G8 8 16 022145 4 WASHER FLAT 5 16 M8 ZINC 17 022129 7 WASHER LOCK M8 5 16 18 045771 3 NUT HEX M8 1 25 G8 YEL CHR 19 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS 20 022259 4 NUT HEX 5 16 18 STEEL 21 022241 2 NUT HEX 3 8 16 STEEL 44 MANIFOLD 10 1...

Page 47: ...R LOCK M5 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 0C8127 1 ELEMENT AIR CLEANER 6 022127 1 NUT HEX 1 4 20 STEEL 7 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 8 0A5547 1 COVER AIR CLEANER 9 037561 1 NUT WING 1 4 20 NYLK 4 7 1 6 2 5 3 9 8 Section 9 Exploded Views and Parts Liquid cooled 30 kW Generators Air Cleaner Drawing No 0F6850 A ...

Page 48: ...ures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Gener...

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