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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!!
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The operator is responsible for proper and safe use INTRODUCTION of the equipment. The manufacturer strongly recom- Thank you for purchasing this model of the standby mends that the operator read this Owner's Manual generator set. and thoroughly understand all instructions before Every effort was expended to make sure that the using this equipment. The manufacturer also strong- information and instructions in this manual are both ly recommends instructing other users to properly accurate
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Table of Contents Liquid-cooled 30 kW Generators INTRODUCTION ...............................................IFC Section 3 — OPERATION ................................ 12 3.1 Using a Standard “GTS” Transfer Switch ...........12 SAFETY RULES ....................................................2 3.2 Control Console Components ..............................13 Section 1 — GENERAL INFORMATION ............. 4 3.3 Manual Transfer and Startup ..............................14 1.1 Generator .............
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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. SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. WARNIN
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IMPORTANT SAFETY INSTRUCTIONS 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- only factory-approved parts. MAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic � Before performing any maintenance on the generator, start-up and possible injury to per
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Section 1 - General Information Liquid-cooled 30 kW Generators 1.1 GENERATOR 1.3 AUTOMATIC SYSTEM OPERATION This equipment is a liquid-cooled, engine-driven When this generator, along with a transfer switch, has generator set. The generator is designed to supply been installed and interconnected, a circuit board electrical power that operates critical electrical loads in the generator panel constantly monitors UTILITY during utility power failure. The unit has been facto- power source voltage
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Section 1 - General Information Liquid-cooled 30 kW Generators Figure 1.4 - Low Oil Pressure Switch 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, 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. Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.
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Section 1 — General Information 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, h
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Section 1 — General Information Liquid-cooled 30 kW Generators Fuel pressure for a natural gas set up should be five 1.10 SPECIFICATIONS inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges. 1.10.1 GENERATOR SPECIFICATIONS 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. Model 004988-4 Rated Max. Cont. 27 (NG), 30 (LP) AC Power Output (kW) 1.12 RECONFIGURING THE FUEL Rated volta
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Section 2 — Installation Liquid-cooled 30 kW Generators The generator’s rated wattage/amperage capacity 1.13 TORQUE SPECIFICATIONS must be adequate to handle all electrical loads that Cylinder Head ............................................ 15 (+ 90° + 90°) ft.lb. the unit will power. The critical (essential) loads may Intake Manifold ................................................................13 ft.lb. need to be grouped together and wired into a sepa- rate “emergency” distribution pan
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Section 2 — Installation Liquid-cooled 30 kW Generators � NFPA No. 37, STATIONARY COMBUSTION � Where strong prevailing winds blow from one ENGINES AND GAS TURBINES. direction, face the generator air inlet openings into the prevailing winds. � NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES. � Install the generator as close as possible to the transfer switch. This reduces the length of wiring � NFPA No. 220, STANDARD TYPES OF BUILDING and conduit. CONSTRUCTION � Instal
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Section 2 — Installation Liquid-cooled 30 kW Generators Figure 2.2 – Generator Grounding Lug (typical) 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 can only power criti- cal loads, within it’s wattage/amperage capacity, dur- ing utility power outages, use the emergency circuit isolation method. GROUNDING Critical electrical loads are grouped together and LUG
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Section 2 — Installation Liquid-cooled 30 kW Generators Control system interconnections consist of N1 and Battery electrolyte fluid is an extremely caus- N2, and leads 23 and 194. Control system intercon- tic sulfuric acid solution that can cause severe nection leads must be run in a conduit that is sepa- burns. Do not permit fluid to contact eyes, skin, rate from the AC power lead. Recommended wire clothing, painted surfaces, etc. Wear protective gauge sizes for this wiring depends on
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Section 3 — Operation Liquid-cooled 30 kW Generators 2.11.1 PRIOR TO INITIAL START-UP 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 Prior to initially starting the generator, it must approximately 22 pounds (10 kg), applied midway be properly prepared for use. Any attempt to between pulleys, deflects the belt about 3/8- to 5/8- crank or start the engine b
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F Section 3 - Operation Liquid-cooled 30 kW Generators MANUAL — The control board will start and run DANGER the generator whenever the switch is in the manual position. With switch set to AUTO, engine can crank and AUTO — The control board will monitor the two- start suddenly without warning. Such automatic wire start circuit. When a two-wire start is issued the start up normally occurs when utility source control board will immediately start and run the gen- voltage drops below a pre-
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Section 3 — Operation Liquid-cooled 30 kW Generators The system ready LED will be OFF when the switch Figure 3.2 — Engine Governor Adjustment is in the manual or OFF positions. R44 The system ready LED is also used to indicate the C27 Q2 C9 presence of utility sensing at the PCB when the switch J2 is either in the AUTO or MANUAL modes. The LED C26 will flash at the rate of 1/2 second on, 1/2 second off U7 C4 if the utility sensing level is below the transfer back D10 threshold. C21 This sec
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E E S S U F F Section 4 — Maintenance Liquid-cooled 30 kW Generators 3.7 WEEKLY EXERCISE CYCLE 4.1 MAINTENANCE PERFORMED BY The engine control board will start and run the gen- AUTHORIZED SERVICE FACILITIES erator once every seven days for approximately 12 minutes. If utility should fail during this exercise EVERY THREE MONTHS period, the engine control board will transfer the load to the generator output and continue to run until util- 1. Check battery state of charge and condition. ity
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Section 4 — Maintenance Liquid-cooled 30 kW Generators 4.4.3 ENGINE COOLANT 4.3 OVERLOAD PROTECTION FOR Check coolant level in coolant recovery bottle. See ENGINE DC ELECTRICAL SYSTEM Specifications, Section 1.10. Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. � Add recommended coolant mixture as necessary. Battery voltage is delivered to that circuit board via � Periodically remove radiator pressure cap to make a 15 amp fuse. These
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Section 4 — Maintenance Liquid-cooled 30 kW Generators Figure 4.2 - Oil Filter 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. DANGER Do not attempt to adjust the governor. Only qualified servi
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Section 4 — Maintenance Liquid-cooled 30 kW Generators Finally, have the insulation resistance of stator and 4.5.12 SPARK PLUGS rotor windings checked. If insulation resistances are Reset the spark plug gap or replace the spark plugs excessively low, the generator may require drying. as necessary. See Section 6. 1. Clean the area around the base of the spark plugs 4.6.2 BATTERY to keep dirt and debris out of the engine. Clean All lead-acid storage batteries discharge when not in by scrap
