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!!
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
INTRODUCTION................................................IFC
Section 3 — OPERATION ................................13
3.1 Using a Standard “GTS” Transfer Switch............13
3.2 Control Console Components..............................13
3.3 Manual Transfer and Startup..............................14
3.4 Engine Governor Adjustments ............................14
3.5 Retransfer and Shutdown....................................15
3.6 Automatic Operation ..........................................15
3.7 Weekly Exercise Cycle..........................................15
Section 4 — MAINTENANCE ..........................16
SAFETY RULES....................................................2
Section 1 — GENERAL INFORMATION ............4
1.1 Generator..............................................................4
1.2 Transfer Switch ....................................................4
1.3 Automatic System Operation ................................4
1.4 Generator AC Connection Systems........................4
1.5 Main Circuit Breaker ............................................4
1.6 Generator Fuel System..........................................5
1.7 Engine Protective Devices......................................5
1.8 Unpacking ............................................................6
1.9 Lifting the Generator ............................................6
1.10 Specifications ........................................................7
1.11 Fuel Consumption ................................................7
1.12 Reconfiguring the Fuel System ..............................7
1.13 Torque Specifications............................................8
1.14 Engine Oil Recommendations ..............................8
1.15 Coolant Recommendations....................................8
1.16 Before Installation ................................................8
Section 2 — INSTALLATION ............................8
2.1 Standby Generator Installation ............................8
2.2 Generator Location................................................9
2.3 Generator Mounting and Support ........................9
2.4 Basic Standby Electric System..............................9
2.5 Emergency Circuit Isolation Method....................10
2.6 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 ..........11
2.10 Battery Installation..............................................11
2.11 Preparation Before Start-Up................................12
4.1 Maintenance Performed by Authorized
Service Facilities..................................................16
4.2 Cooling System....................................................16
4.3 Overload Protection for Engine DC
Electrical System ................................................16
4.4 Checking Fluid Levels ........................................16
4.5 Maintenance Owner/Operator
Can Perform........................................................17
4.6 Miscellaneous Maintenance ................................18
4.7 Scheduled Maintenance ......................................20
Section 5 — TROUBLESHOOTING ..................23
Section 6 — ELECTRICAL DATA ....................24
Section 7 — EXPLODED VIEWS AND
PARTS LISTS ..............................28
Section 8 — INSTALLATION DIAGRAM ..........44
Section 9 — NOTES ........................................45
Section 10 — WARRANTY .................Back Cover
®
Generac Power Systems, Inc.
1
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
!
!
!
!
!
GENERAL HAZARDS
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• For safety reasons, Generac recommends that this
equipment be installed, serviced and repaired by a
Generac Authorized Service Dealer or other compe-
tent, qualified electrician or installation technician
who is familiar with applicable codes, standards and
regulations. The operator also must comply with all
such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always comply with
applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical
and building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the gener-
ator 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 concentrations, can cause
unconsciousness or even death. For that reason, ade-
quate ventilation must be provided. Exhaust gases
must be piped safely away from any building or
enclosure that houses the generator to an area where
people, animals, etc., will not be harmed. This
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilat-
ing air is critical to prevent buildup of explosive gases
and to ensure correct generator operation. Do not
alter the installation or permit even partial blockage
of ventilation provisions, as this can seriously affect
safe operation of the generator.
!
!
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The gen-
erator can operate safely, efficiently and reliably only if
it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and
fundamental rules or precautions.
Generac cannot possibly anticipate every possible cir-
cumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit
are, therefore, not all-inclusive. If using a procedure,
work method or operating technique that Generac does
not specifically recommend, ensure that it is safe for
others. Also make sure the procedure, work method or
operating technique chosen does not render the genera-
tor unsafe.
DANGER
Despite the safe design of this generator,
!
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
• Keep the area around the generator clean and unclut-
tered. Remove any materials that could become haz-
ardous.
• When working on this equipment, remain alert at all
times. Never work on the equipment when physically
or mentally fatigued.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running gen-
!
erators.
®
2
Generac Power Systems, Inc.
Download from Www.Somanuals.com. All Manuals Search And Download.
IMPORTANT SAFETY INSTRUCTIONS
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
• Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer
or replace all worn, damaged or defective parts using
switch will crank and start automatically when NOR-
MAL (UTILITY) source voltage is removed or is below
an acceptable preset level. To prevent such automat-
ic start-up and possible injury to personnel, disable
the generator’s automatic start circuit (battery cables,
etc.) before working on or around the unit. Then,
place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
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.
Stepping on the unit can stress and break parts, and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
• In case of accident caused by electric shock, immedi-
ately shut down the source of electrical power. If this
is not possible, attempt to free the victim from the
live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement, such
as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
ELECTRICAL HAZARDS
• All generators covered by this manual produce dan-
gerous electrical voltages and can cause fatal electrical
shock. Utility power delivers extremely high and dan-
gerous voltages to the transfer switch as well as the
standby generator. Avoid contact with bare wires, ter-
minals, connections, etc., on the generator as well as
the transfer switch, if applicable. Ensure all appropri-
ate covers, guards and barriers are in place before
operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing
this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
FIRE HAZARDS
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher
properly charged and be familiar with its use. If there
are any questions pertaining to fire extinguishers,
consult the local fire department.
EXPLOSION HAZARDS
• The National Electrical Code (NEC), Article 250
requires the frame and external electrically conduc-
tive parts of the generator to be connected to an
approved earth ground and/or grounding rods. This
grounding will help prevent dangerous electrical
shock that might be caused by a ground fault condi-
tion in the generator set or by static electricity. Never
disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum elec-
trical current (ampacity) to which they will be sub-
jected.
• Before installing or servicing this (and related) equip-
ment, make sure that all power voltage supplies are
positively turned off at their source. Failure to do so
will result in hazardous and possibly fatal electrical
shock.
• Connecting this unit to an electrical system normally
supplied by an electric utility shall be by means of a
transfer switch so as to isolate the generator electric
system from the electric utility distribution system
when the generator is operating. 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.
• Properly ventilate any room or building housing the
generator to prevent build-up of explosive gas.
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or
on or near the generator, as FIRE or EXPLOSION
may result. Keep the area surrounding the generator
clean and free from debris.
• Generac generator sets may operate using one of sev-
eral types of fuels. All fuel types are potentially FLAM-
MABLE and/or EXPLOSIVE and should be handled
with care. Comply with all laws regulating the storage
and handling of fuels. Inspect the unit’s fuel system
frequently and correct any leaks immediately. Fuel
supply lines must be properly installed, purged and
leak tested according to applicable fuel-gas codes
before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids
such as natural gas and liquid propane (LP) gas are
extremely EXPLOSIVE. Natural gas is lighter than air,
and LP gas is heavier than air; install leak detectors
accordingly.
®
Generac Power Systems, Inc.
3
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 1 - General Information
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
1.1 GENERATOR
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
preset amount of time, the generator cranks and
starts. After the generator starts, the transfer switch
transfers load circuits so the generator can power
them.
This equipment is a liquid-cooled, engine-driven gen-
erator set. The generator is designed to supply elec-
trical power that operates critical electrical loads
during utility power failure. The unit has been facto-
ry-installed in a weather resistant, all aluminum
enclosure and is intended for outdoor installation
only. Use this generator as a source of electrical
power for the operation of 120 and/or 240VAC, sin-
gle-phase loads.
When utility source voltage has been restored, the
switch re-transfers back to the UTILITY source volt-
age and the generator then shuts down.
If this generator is used to power electrical load
circuits normally powered by a UTILITY power
!
Please reference the transfer switch manual for spe-
cific information.
source, it is required by code to install a trans-
fer switch. The transfer switch must effectively
isolate the electric system from the utility distri-
bution system when the generator is operating
(NEC 701). Failure to isolate an electrical system
by such means results in damage to the genera-
tor and may also result in injury or even death
to utility power workers due to backfeed of
electrical energy.
1.4 GENERATOR AC CONNECTION
SYSTEMS
The generator was shipped from the factory with its
stator AC output leads connected in a single-phase,
three-wire generator AC connection system (Figure
1.1). The stator assembly in this system consists of a
pair of stationary windings, with two leads brought
out of each winding. Each single winding can supply
120VAC, 60 Hertz. When the two windings are con-
nected in series, a 240VAC, 60 Hertz AC output
results. Typically the two HOT leads in the circuit are
wires 11 and 44. The NEUTRAL leads are the junc-
tion of Wires 22 and 33. The NEUTRAL is not
grounded.
1.2 TRANSFER SWITCH
This generator system may include a matched auto-
matic transfer switch which is intended to be used in
conjunction with the Generac generator. It is supplied
in either a NEMA 1 enclosure or a NEMA 3R enclo-
sure. The NEMA 1 enclosure is intended for indoor
use only. The NEMA 3R enclosure is weather proof
and can be used indoors or outdoors. Follow these
rules:
Figure 1.1 - Generator AC Connection System
• Install the transfer switch on a firm, sturdy sup-
porting structure.
• To prevent switch distortion, level the switch if nec-
essary. This can be done by placing washers
between the switch enclosure and the mounting
surface.
• Never install the switch where water or any corro-
sive substance might drip onto the enclosure.
• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and cor-
rosive vapors.
If a transfer switch is not included, one may be pur-
chased separately from a Generac Authorized Dealer.
1.5 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with
the unit as shipped from the factory. The breaker for
each unit is described in Figure 1.2.
Figure 1.2 - Main Circuit Breaker
Model
004917-3
Rating
27,000 NG
30,000 LP
Phase
Actual Current
112.5
C/B Rating*
Circuit Breaker
150A QN2
1
1
150
150
125.0
150A QN2
* Amp Rating of C/B structured under model.
®
4
Generac Power Systems, Inc.
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 1 - General Information
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
NOTE:
1.6 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.
The Low Oil Pressure, High Coolant Temperature
and Low Coolant Level are not monitored for the
first 10 seconds of engine run time.
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.
Figure 1.4 - Low Oil Pressure Switch
Fuel 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.
NOTE:
A seperate gas line and regulator may be needed
to assure proper gas pressure to the generator.
Improper gas pressure can cause hard starting and
affect engine durability.
Gaseous fuels such as natural and LP (propane)
gas are highly explosive. Even the slightest
spark can ignite such fuels and cause an explo-
sion. No leakage of fuel is permitted. Natural
gas, which is lighter than air, tends to collect in
high areas. LP gas is heavier than air and tends
to settle in low areas.
1.7.2 HIGH COOLANT TEMPERATURE
SWITCH
‹
This normally open (N.O.) thermostatic switch has
sensing tip which is immersed in captive coolant.
Should coolant temperature exceed about 230°F
(110°C), the switch contacts close. This causes the
engine to shut down automatically and turns on the
high coolant temperature/low coolant level LED
(Figure 1.5).
1.7 ENGINE PROTECTIVE DEVICES
The engine has several safety switches which cause
the engine to automatically shut down under the fol-
lowing conditions: low oil pressure, high coolant tem-
perature, engine overspeed, low coolant level or over-
crank (Figure 1.3).
Figure 1.5- High Coolant Temperature Switch
Figure 1.3 - Engine Protective Devices
LOW COOLANT
LEVEL SWITCH
LOW OIL
PRESURE
SWITCH
HIGH
COOLANT
TEMPERATURE
SWITCH
1.7.3 LOW COOLANT LEVEL SWITCH
‹
Should engine coolant level drop below the level of
the high coolant temperature switch, it is possible for
the engine to overheat without automatic shutdown.
To prevent such overheating without automatic shut
down, the engine has a low coolant level sensor. If the
engine coolant drops too low, the engine automatical-
ly shuts down and turns on the high coolant temper-
ature/low coolant level LED (Figure 1.6 on page 6).
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).
®
Generac Power Systems, Inc.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 1 — General Information
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
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.
The control system 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.
1.7.4 OVERSPEED SHUTDOWN
‹
Battery voltage is NOT monitored during the crank
cycle.
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. Should AC
frequency exceed about 72 Hertz, circuit board action
will automatically shutdown the engine (Figure 1.7).
1.7.8 ALARM RESET
‹
If the engine control board shuts down the generator
for any of the above reasons, the engine remains
stopped until the alarm is cleared by placing the
AUTO/OFF/MANUAL switch into the OFF position.
Figure 1.7 - Printed Circuit Board Assembly
1.7.9 DC FUSE
‹
These fuses are located on the front panel of the con-
trol system. They protect the panel wiring and com-
ponents from damaging overload. Always remove the
15 amp main fuse before working on the generator.
The unit will not start or crank if this fuse is blown.
Replace the fuse with one of the same size, type, and
rating (main AGC-15, battery charger AG4).
R44
LED1
C27
Q2
C9
J2
C26
U7
C4
D10
C21
C30
C2
1.8 UNPACKING
RL1
RL2
R1
R48
D17
1.8.1 UNPACKING PRECAUTIONS
‹
R49
Handle shipping cartons and crates with care. Use
care to avoid damage from dropping, bumping, colli-
sion, etc. Store and unpack cartons with the proper
side up, as noted on the shipping carton.
U1
J1
L3
D19
.
R E V 9 0 6 E 0 4 B #
‹
1.8.2 INSPECTION
1.7.5 RPM SENSOR LOSS
‹
After unpacking, carefully inspect the generator for
any damage that may have occurred during ship-
ment. If loss or damage is noted at the time of deliv-
ery, have the person(s) making delivery note all dam-
age on the freight bill or affix their signature under
the consignor’s memo of loss or damage.
If the engine control board does not receive a proper
rpm signal from the starter during cranking or run-
ning, it shuts down the engine on rpm sensor loss
and flash the overspeed LED.
1.7.6 OVERCRANK SHUTDOWN
‹
The engine control board uses a cyclic cranking
process when attempting to start the engine. The first
crank cycle is a 15-second crank followed by a seven-
second rest. This is followed by five more crank
cycles each with a seven second crank followed by a
seven second rest.
1.9 LIFTING THE GENERATOR
When lifting or hoisting equipment is used, be
!
careful not to touch overhead power lines. The
generators weight of more than 900 pounds
requires proper tools, equipment, and qualified
personnel to be used in all phases of handling
and unpacking.
If the engine fails to start after all six attempts, the
start attempt is stopped and the overcrank LED
turned on.
®
6
Generac Power Systems, Inc.
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 1 — General Information
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
NOTE:
1.10 SPECIFICATIONS
Fuel consumption is given at rated maximum con-
tinuous power output when using natural gas rated
at 1000 Btu per cubic foot. LP gas is rated at 2520
Btu per cubic foot. Actual fuel consumption
obtained may vary depending on such variables as
applied load, ambient temperature, engine condi-
tions and other environmental factors.
1.10.1 GENERATOR SPECIFICATIONS
‹
Single-phase
4917-3
27 (NG), 30 (LP)
Model
Rated Max. Cont.
AC Power Output (kW)
Rated voltage (volts)
No. of Rotor Poles
Driven Speed of Rotor
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.
120/240
4
1800
Fuel 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.
Rotor Excitation System Direct excited brush type
Type of Stator
4 Wire
Class F/H
Rotor/Stator Insulation
1.12 RECONFIGURING THE FUEL
1.10.2 ENGINE SPECIFICATIONS
‹
SYSTEM
Make ......................................................................................Ford
Displacement ..................................................................3.0 liters
Cylinder Arrangement ..............................................................V-6
Valve Arrangement ..............................................Overhead Valve
Firing Order ................................................................1-4-2-5-3-6
Number of Main Bearings............................................................4
Compression Ratio............................................................9.3 to 1
No. of Teeth on Flywheel ........................................................164
Ignition Timing at 1800 rpm..............................30 degrees BTDC
Spark Plug Gap ..................................................0.042-0.046 inch
Recommended Spark Plugs
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 regulator (Figure 1.8).
3. Remove the brass hose fitting from the outlet port
(Port 1) of the demand regulator.
4. Remove pipe plug from Port 2.
Motor Craft..........................................................AG, SF 32PGM
Oil Pressure....................................................................40-50 psi
Crankcase Oil Capacity........................5.0 U.S. quarts (4.7 liters)
Recommended Engine Oil..........................................SAE 5W-20
Type of Cooling System ..................Pressurized, closed recovery
Cooling Fan ..............................................................Pusher Type
Cooling System Capacity..................3.0 U.S. gallons (11.4 liters)
5. Install brass hose fitting into Port 2.
6. Install pipe plug into Port 1.
7. Connect carburetor gas hose to brass fitting.
8. Tighten all clamps and plugs.
9. Make sure fuel supply is of the proper pressure
and type for configuration.
10. Reverse the procedure to convert back to natural
gas.
Recommended Coolant............................Use a 50-50 mixture of
ethylene glycol base
Figure 1.8 — Reconfigure the Fuel System
and de-ionized water.
Port 1
Port 2
FUEL HOSE
FUEL HOSE
1.11 FUEL CONSUMPTION
BRASS HOSE
FITTING
BRASS HOSE
FITTING
Natural Gas:
PLUG
PLUG
OUT
PORT 1
OUT
PORT 2
% of Load
m3/hr
25%
3.1
50%
5.9
75%
8.5
100%
11.0
HOUSING
PORTS
HOUSING
PORTS
ft3/hr
110.3
209.0
299.5
387.0
LP Vapor:
% of Load
m3/hr
25%
1.3
50%
2.4
75%
3.5
100%
4.5
ft3/hr
45.6
86.4
123.8
160.0
NG FUEL SYSTEM
LP FUEL SYSTEM
®
Generac Power Systems, Inc.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chromi-
umhydroxide (“green slime”) forms and will
cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base anti-freeze. Using any high
silicate anti-freeze boosters or additives will
also cause overheating. It is also recommend
that any soluble oil inhibitor is NOT USED for
this equipment.
!
DANGER
Serious injury or damage may occur if not con-
figured properly. Please consult an authorized
Generac Service Dealer with any questions.
!
1.13 TORQUE SPECIFICATIONS
Cylinder Head ............................................15 (+ 90° + 90°) ft.lb.
Intake Manifold ................................................................13 ft.lb.
Exhaust Manifold..............................................................13 ft.lb.
1.16 BEFORE INSTALLATION
Before installing this equipment, check the ratings of
both the generator and the transfer switch. Read
“Emergency Isolation Method” and “Total Circuit
Isolation Method” in the installation manual (Part No.
079699).
1.14 ENGINE OIL RECOMMENDATIONS
The unit has been filled with 5W-20 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service CC, SD, SE, SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
The generator’s rated wattage/amperage capacity
must be adequate to handle all electrical loads that
the unit will power. The critical (essential) loads may
need to be grouped together and wired into a sepa-
rate “emergency” distribution panel.
Temperature
Above 80° F (27° C)
32° to 80° F (-1° to 27° C)
Below 32° F (0° C)
Oil Grade (Recommended)
SAE 5W-20
This generator can be installed in conjunction with a
standard Generac “GTS” type transfer switch, if nec-
essary.
SAE 5W-20
SAE 5W-20
The standard transfer switch has no sensing or con-
trolling circuit boards. Instead, the generator control
console houses a “Printed Circuit Board Assembly”,
which controls all phases of operation, including
engine start up and load transfer.
NOTE:
5W-30 full synthetic oil is highly recommended in
any element with temperatures above 90°F or
below 30°F.
2.1 STANDBY GENERATOR
INSTALLATION
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
!
DANGER
Connecting this generator to an electrical sys-
tem normally supplied by an electric utility
shall be by means of a transfer switch, so as to
isolate the electric system from the utility distri-
bution system when the generator is operating.
Failure to isolate the electric system by these
means will result in damage to the generator
and may also result in injury or death to utility
workers due to backfeed of electrical energy.
1.15 COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base
anti-freeze and half de-ionized water. Cooling system
capacity is about 12 U.S. quarts (11.4 liters). Use
only de-ionized water and only low silicate anti-
freeze. If desired, add a high quality rust inhibitor to
the recommended coolant mixture. When adding
coolant, always add the recommended 50-50 mix-
ture.
If an open bottom is used, the engine-genera-
tor is to be installed over non-combustible
materials and should be located such that com-
bustible materials are not capable of accumu-
lating under the generator set.
®
8
Generac Power Systems, Inc.
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 2 — Installation
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
Only qualified, competent installation contractors or
• ASAE EP-364.2, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYS-
TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
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-
!
2.2 GENERATOR LOCATION
ance with such codes, standards and regula-
tions.
Install the generator set, in its protective enclosure
outdoors, where adequate cooling and ventilating air
always is available. Consider these factors:
NOTE:
For more information about the installation of a
standby system, order Engine-Generator Standby
Electric Power Systems Installer’s Guide and
Reference Manual (part #046622) from the
Generac Authorized Service Dealer.
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drift-
ing, consider using a windbreak to protect 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 the generator air inlet openings into
the prevailing winds.
• Install the generator as close as possible to the
transfer switch. This reduces the length of wiring
and conduit.
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping. HOWEVER,
REMEMBER THAT LAWS OR CODES MAY REG-
ULATE THE DISTANCE.
2.1.1 NFPA STANDARDS
‹
The following published standards booklets pertain-
ing to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
NOTE:
It is essential to use the latest version of any stan-
dard to ensure correct and current information.
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS 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.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
2.3 GENERATOR MOUNTING AND
SUPPORT
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
Retain the generator compartment to a concrete slab
with 1/4-inch masonry type anchor bolts. Be sure the
bolts are long enough to retain the compartment. The
slab should be at least six inches thick and should
extend beyond the enclosure to a distance of at least
three inches on all sides. See Section 6 for generator
major dimensions.
USE OF PORTABLE FIRE EXTINGUISHERS.
2.1.2 OTHER PUBLISHED STANDARDS
‹
In addition to NFPA standards, the following infor-
mation pertaining to the installation and use of
standby electric systems is available:
NOTE:
2.4 BASIC STANDBY ELECTRIC
It is essential to use the latest version of any stan-
dard to ensure correct and current information.
SYSTEM
Figure 2.1 shows a schematic diagram of a basic
standby electric system. Both the UTILITY power
supply and the STANDBY (GENERATOR) output are
connected to an approved transfer switch. The trans-
fer switch is required by electrical code and serves
the following functions:
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
®
Generac Power Systems, Inc.
9
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 2 — Installation
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
• Allows the LOAD circuits to be connected to only
one power supply at a time.
• Ampere rating of the transfer switch must equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility
service entrance and the building distribution
panel.
• 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.
2.7 GROUNDING THE GENERATOR
The National Electrical Code requires the frame and
external electrically conductive parts of this equip-
ment to be properly connected to an approved earth
ground and/or grounding rods. For that purpose, a
GROUND LUG (Figure 2.2) is provided on the gener-
ator mounting base. Consult a qualified electrician
for grounding requirements in the area. Grounding
procedures must meet local regulations.
Figure 2.1 – Basic Standby Electric System
DANGER
Do not connect the ground wire to any pipe
that carries a flammable or explosive substance
– FIRE or an EXPLOSION may result.
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condi-
tion in the generator or in connected electrical
devices. In addition, grounding helps dissipate static
electricity that often builds up in ungrounded
devices.
2.5 EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping
electrical loads below the wattage/amperage capacity
of the generator. If the generator is powering only crit-
ical loads, within the wattage/amperage capacity, dur-
ing utility power outages, consider using the emer-
gency circuit isolation method.
Figure 2.2 – Generator Grounding Lug (typical)
Critical electrical loads are grouped together and
wired into a separate “Emergency Distribution
Panel.” Load circuits powered by that panel are with-
in the wattage/amperage capacity of the generator set.
When this method is used, it is difficult to overload
the generator. The transfer switch must meet the fol-
lowing requirements:
GROUNDING
LUG
• It must have an ampere rating equal to the total
amperage rating of the emergency distribution
panel circuit.
• Have it installed between the building’s main dis-
tribution panel and the emergency distribution
panel.
2.8 GENERATOR AC NEUTRAL
CONNECTIONS
Generac uses an UNGROUNDED AC neutral.
Grounding is recommended only at the main service
entrance. If the neutral wire is grounded and one of
the phase loads becomes grounded, the excessive
current opens the load circuit breaker or collapses
the generator field. The actual result depends on the
electrical characteristics of the particular installed
generator.
2.6 TOTAL CIRCUIT ISOLATION
METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, use the “Total
Circuit Isolation Method.” It is possible for the gener-
ator to be overloaded when this isolation method is
employed. The following apply to the transfer switch
in this type of system.
®
10 Generac Power Systems, Inc.
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 2 — Installation
QUIETSOURCE
™
Liquid-cooled 30 kW Generators
2.10 BATTERY INSTALLATION
DANGER
Failure to connect the generator neutral prop-
!
erly will result in unbalanced line-to-neutral
voltages. Resulting high voltages will cause
equipment damage.
Standby generators installed with automatic
transfer switches will crank and start automati-
!
cally when NORMAL (UTILITY) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and possible
injury to personnel, do not connect battery
cables until certain that normal source voltage
at the transfer switch is correct and the system
is ready to be placed into operation.
2.9 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.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Setting switch two to OFF allows the control PCB to
perform the ATS control functions.
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 leads. Recommended wire
gauge sizes for this wiring depends on the length of
the wire, as recommended below:
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 fluid is spilled, flush the
affected area immediately with clear water.
MAXIMUM WIRE LENGTH
RECOMMENDED WIRE
SIZE
460 feet (140m)
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
No. 12 AWG.
461 to 730 feet (223m)
731 to 1,160 feet (354m)
1,161 to 1,850 feet (565m)
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding.
‹
2.9.2 GTS-TYPE ATS
If the generator is to be installed with an automatic
transfer switch, such as a Generac GTS-type switch,
it is necessary to connect the two-wire start control
system.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
!
The battery represents a risk of high short circuit
current. When working on the battery, always
remove watches, rings or other metal objects,
and only use tools that have insulated handles.
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection,
which is located in the middle, on the bottom, inside
the control panel. Match wires 178 and 183 in the
transfer switch to 178 and 183 on the terminal strip
in the control panel. The conductors for the two-wire
start circuit must be in their own conduit. (See
Section 3.1 for further explanation.)
2.10.1 VENTED BATTERIES
‹
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following proce-
dures are to be observed:
!
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
• Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek med-
ical attention, and
®
Generac Power Systems, Inc. 11
Download from Www.Somanuals.com. All Manuals Search And Download.
|