Használati útmutató Generac QT04542GNAN
Generac
A generátor
QT04542GNAN
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Oldal 1/120
STANDBY GENERATOR
OWNER'S MANUAL
This manual should remain with the unit.
A new standard of reliability
Serial Number
4.2L
35/45kW
Models
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
— — CAUTION
Cover119 Rev. B 09/07 Part No. 0G5966
Catalog Number OMASPEA035-045-1
n
1-1
n
n
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only respon-
sible and capable persons to install, operate or
maintain 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.
n
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
1-2
1-3
IDENTIFICATION RECORD
2-1
General Information
n
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.
n
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chro-
mium hydroxide (“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. The manufacturer also
recommends that any soluble oil inhibitor is
NOT used for this equipment.
n
Do not remove the radiator pressure cap while
the engine is hot or serious burns from boiling
liquid or steam could result.
n
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze even though it is poisonous to them.
3-1
Equip001 Rev. G 05/10
4-1
5-1
SPECIFICATIONS
STATIONARY EMERGENCY GENERATOR
Type ............................................................................. Synchronous
Rotor Insulation ................................................................... Class H
Stator Insulation .................................................................. Class H
Total Harmonic Distortion ..........................................................<5%
Telephone Interference Factor (TIF) ..........................................< 50
Alternator Output Leads 3-phase ........................................... 4-wire
Bearings .........................................................................Sealed Ball
Coupling .......................................................................Flexible Disc
Load Capacity (Standby Rating) .......................................35/45kW*
* NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349,
ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural
gas.
Excitation System ....................................................................Direct
Generator Output Voltage/kW - 60 Hz kW Amp CB Size
120/240V, 1-phase, 1.0 pf 35/45 146/188 175/200
120/240V, 3-phase, 0.8 pf 35/45 105/135 125/150
120/208V, 3-phase, 0.8 pf 35/45 121/156 150/175
277/480V, 3-phase, 0.8 pf 35/45 53/68 63/80
Generator Locked Rotor KVA Available @ Voltage Dip of 35%
Single-phase or 208, 3-phase (35/45kW) ..................... 63/90 KVA
480V, 3-phase (35/45kW) ............................................ 84/120 KVA
ENGINE
Make ................................................................................... Generac
Cylinders and Arrangement ................................................ 6, V-type
Displacement .......................................................................4.2 Liter
Bore .....................................................................96.8 mm (3.81 in.)
Stroke .....................................................................88 mm (3.46 in.)
Compression Ratio .............................................................9.35-to-1
Air Intake System ...............................................Naturally Aspirated
Valve Seats ......................................... Precision Ground, Hardened
Lifter Type ...............................................................Roller, Hydraulic
Engine Parameters
Rated Synchronous RPM ..............................................60 Hz, 1800
HP at rated kW (35/45kW) ...................................................... 54/71
Exhaust System
Exhaust Flow at Rated Output 60 Hz (35/45kW) ......... 261/336 cfm
Exhaust Temp. at Rated Output (35/45kW) ..............900° F/1000° F
Combustion Air Requirements (Natural Gas)
Flow at rated power, 60 Hz (35/45kW) ........................... 81/105 cfm
Governor
Type .................................................................................. Electronic
Frequency Regulation ...................................................Isochronous
Steady State Regulation ......................................................± 0.25%
Engine Lubrication System
Type of Oil Pump ...................................................................... Gear
Oil Filter ............................................... Full Flow Spin-on, Cartridge
Crankcase Oil Capacity ...............................................4.73 U.S. qts.
COOLING SYSTEM
Type ...................................................Pressurized Closed Recovery
Water Pump .................................................................... Belt Driven
Fan Speed .........................................................................1300 rpm
Fan Diameter .....................................................................22 inches
Fan Mode ................................................................................Puller
Air Flow (inlet air including alternator and
combustion air) ...........................................................2460 ft 3/min.
Coolant Capacity ............................................. 21.6 L (5.7 U.S. gal.)
Heat Rejection to Coolant (35/45kW) ...........139,000/190,000 Btu/h
Maximum Operating Air Temp. on Radiator ..............60° C (150° F)
Maximum Ambient Temperature ................................50° C (140° F)
FUEL SYSTEM
Type of Fuel .........................................Natural Gas, Propane Vapor
Carburetor ...................................................................... Down Draft
Secondary Fuel Regulator .................................................Standard
Fuel Shut-off Solenoid ........................................................Standard
Operating Fuel Pressure ...................... 5 in. - 14 in. Water Column
Fuel Consumption - ft3/hr (Natural Gas/LPV)
Exercise 25% 50% 75% 100%
Cycle Load Load Load Load
35kW 104/50 188/60 300/111 385/147 485/189
45kW 104/50 244/78 500/144 445/192 630/240
ELECTRICAL SYSTEM
Battery Charge Alternator ............................................12V, 30 Amp
Static Battery Charger ............................................................2 Amp
Recommended Battery .....................................Group 24F, 525CCA
System Voltage .....................................................................12 Volts
Voltage Regulator
Type .................................................................................. Electronic
Sensing ........................................................................ Single-phase
Regulation ................................................................................± 1%
Features ................................................. V/F Adjustable, Adjustable
Voltage and Gain LED Indicators
Power Adjustment for Ambient Conditions
Temperature Deration
3% for every 10° C above °C (35/45kW) .............................. 40/25
1.65% for every 10° above °F (35/45kW) ........................... 104/77
Altitude Deration
1% for every 100 m above m (35/45kW) .......................... 915/183
3% for every 1000 ft. above ft. (35/45kW) ....................... 3000/600
Controller ...................................... R-200 Series
6-1
Stationary Emergency Generator
Specifications
GenSpec042 Rev. D 10/08
COLD WEATHER KIT
For cold climates, optional cold weather kit (part
number 0F6148) is recommended. The kit includes:
Battery Warmer•
4” Junction Box with hardware•
6 qt. pack 5W-30 synthetic oil (engine)•
COOLANT HEATER KIT
The optional Coolant Heater Kit (part number
0G6446) is available to be used in cunjuntion with
the Optional Cold Weather Kit. This kit includes:
1000 watt, 120 volt Engine Block Heater•
Heater Mounting Bracket•
All fittings, hoses and hardware to mount and •
plumb heater
RECONFIGURING THE FUEL SYSTEM
NOTE:
All models are configured to run on natural gas
from the factory.
To reconfigure the fuel system from NG to LP, follow
these steps:
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port of the demand regulator (see Figure 6.2).
Figure 6.2 — Reconfigure the Fuel System
TO
ALTERNATOR
NEUTRAL
GROUND
CIRCUIT
BREAKER
NEUTRAL
Ground Level
Concrete Slab STUB-UP AREA
See Install Dwg for
Dimensions
CONTROL PANEL
FRAME RAIL
N1
N2
23
194
To Generator Control Panel
Utility In
Load
Out
Gen
N1
N2
23
194
183
178
120 Volt +
Neutral
Grd
Battery
Charger
Input
Transfer Switch
ALTERNATOR
CONNECTION
BOX
4- # 14 GA
WIRES TO
ALTERNATOR
CONNECTION
BOX
TO ALTERNATOR
CONNECTION BOX
Figure 1 — Interconnections
6-2
Stationary Emergency Generator
Specifications
GenSpec042 Rev. D 10/08
6-3
Stationary Emergency Generator
Specifications
GenSpec042 Rev. D 10/08
3. Disconnect the power wires from the fuel sole-
noid located on top of the regulator assembly.
4. Loosen the spring clamp on the small fuel enrich-
ment line and remove the hose from the hose
barb.
5. Remove the black pipe assembly from the outlet
port of the demand regulator.
6. Remove the NG fuel jet (loosen counter clockwise)
from the outlet port.
7. Remove the LP fuel jet (loosen counter clockwise)
from the jet keeper port on the regulator housing.
Install this jet into the outlet port in the regulator
casting.
NOTE:
The jet sizes are stamped on the individual jets.
The larger jet size is used for running on NG.
8. Install the previously removed NG jet into the jet
keeper port on the regulator housing.
9. Install the previously removed black pipe onto
the outlet port of the demand regulator. Use pipe
sealant on pipe threads.
10. Reverse steps 1-4 in this procedure to reactivate
the demand regulator.
11. For LP vapor application, substitute LP fuel inlet
decal for NG fuel inlet decal.
12. The dip switch inside the control panel must be
in the LP or NG position when switching to dif-
ferent fuels (see Control Panel Manual for more
information).
DANGER
Serious injury or damage may occur if not con-
figured properly. Please consult an Authorized
Dealer with any questions.
4.2L IGNITION DESCRIPTION
This single-fire ignition is intended to operate a 6-cyl-
inder, 4.2L, 1800rpm ignition. The 4.2L engine uses
a 36-1 crank sensor, a CAM sensor and coil-on-plug
coils for each spark plug. Engine Timing for the 4.2L,
1800rpm engine is 15 degrees BTDC for both LP and
NG.
The Cam Sensor is factory set to the FULL coun-
ter-clockwise position. Tampering with the posi-
tion of the Cam Sensor could result in engine
failure.
IGNITION POWER-UP INPUT (“56 LINE INPUT)
When battery voltage is applied to this input the igni-
tion will power-up. For the ignition to power itself
down, the battery voltage must be removed from this
input.
DIAGNOSTIC BLINK PATTERNS (RED LED)
During normal ignition operation the RED LED,
located on the ignition control board, flashes at a 0.5
second ON and a 0.5 second OFF rate. This is con-
sidered one (1) blink.
RED LED Fault Codes with priority as shown:
1. Ignition cannot initialize: LED is ON continu-
ously during cranking.
2. Engine Overspeed: LED blinks four (4) times, is
OFF for three (3) seconds and then repeats.
3. No Crank Signal: LED blinks two (2) times, is
OFF for three (3) seconds and then repeats.
4. No Cam Signal: LED blinks three (3) times, is
OFF for three (3) seconds and then repeats.
Only one LED fault code is displayed at a time.
If multiple fault codes exist then the highest priority
fault must be resolved prior to a lower priority fault
code being displayed.
The LED fault code blink pattern is displayed for 60
seconds after a fault and then the ignition will power
itself down.
The Generator must have been in the OFF mode for
60 seconds prior to cranking for the Crank and CAM
LED fault diagnostics to be valid.
The Crank and CAM LED fault codes are not valid
during a re-crank.
NOTE:
The ignition cover does not need to be removed to
see the RED LED
Figure 7.1 — Four-lead, Single-phase Stator
S6
E
3
S3
INTERNAL
CO
NNE
C
TI
O
N
S
L-
N
L
-
L
S4
E2
S2
S5
S1
E1
NE
U
TRA
L
E
3
E2
00
(
NEUTRAL
)
E1
L
-
L
L
-
N
S1
S1
S4
S4
S
6
S6
S3
S3
S5
S5
S2
S2
7-1
START-UP CHECKLIST
n
Before working on the Stationary Emergency
Generator, ensure the following:
• The AUTO/OFF/MANUAL switch is in the OFF position.
• The 120VAC supply to the battery charger is switched OFF.
PREPARATION FOR START-UP
• Ensure that the 120VAC circuit breaker to the battery charger is
open.
• Remove the fuse from the the control panel. Open the front door
of the control box and remove the 15 Amp ATO fuse in the lower
left-hand corner of the control box.
• Connect the battery cables to the battery. Attach negative bat-
tery cable last.
• Close the 120VAC circuit breaker to the battery charger.
• Measure the voltage at the battery before and after the charger
is turned on.
• Verify all AC electrical connections are tight at the circuit breaker
and transfer switch.
• Visually inspect entire area looking for loose paper, plastic
wrappings, leaves, etc.
• Check all hoses clamps fittings for leaks or damage.
• Check all electrical plugs throughout the generator. Ensure each
plug is seated correctly and fully inserted into its receptacle.
• Verify the AUTO/OFF/MANUAL switch is in OFF position.
• Open the valve to the engine fuel line.
• Bleed the fuel system of air. (necessary for long fuel lines).
• Open the generator main line circuit breaker.
• Connect a manometer to the gas line and record the static pres-
sure. It must be as listed in the Specifications.
• Insert the fuse into the control panel.
• Move the AUTO/OFF/MANUAL switch to the manual position.
The engine should now crank and start.
• Check voltage at the generator terminals.
• For 3-phase units, check phase rotation at the transfer switch
terminals. The generator phase rotation must match the utility
phase rotation.
• Check for coolant, fuel, oil, and exhaust leaks.
• Close the generators main line circuit breaker.
• Turn the generator set off.
• Connect the UTILITY supply to the transfer switch.
• Set the AUTO/OFF/MANUAL switch to AUTO.
• Disconnect utility power before the transfer switch.
Engine should start, transfer to load.
Run at least 15 minutes on generator power. Make certain all
3-phase loads are functioning correctly (correct phase rota-
tion).
• Reconnect Utility power
Transfer switch will transfer back to Utility and engine will
shut down within the given time parameters set up for the
specific transfer switch and controller.
• Install all covers, access plates and door panels.
• Put the Owners Manual in a safe and accessible place.
• Make certain the AUTO/OFF/MANUAL switch is in the AUTO
position.
8-2
Install002 Rev. G 06/10
Installation
n
The Maintenance Disconnect Switch and the
AUTO/OFF/MANUAL switches (if so equipped)
must be set properly, or the generator will
crank and start as soon as the utility power to
the transfer switch is turned off. Refer to appli-
cable control panel and transfer switch manuals
for more information.
n
Do not proceed until certain that utility source
voltage is available to the transfer switch and
the transfer switch main contacts are set to
UTILITY.
Do not attempt manual operation until all
power supplies to the transfer switch have been
positively turned off, or extremely dangerous -
possibly lethal - electrical shock will result.
Transfer switch enclosure doors should be kept
closed and locked. Only authorized personnel
should be allowed access to the transfer switch
interior. Extremely high and dangerous voltages
are present in the transfer switch.
nDo not crank the engine continuously for lon-
ger than 30 seconds, or the heat may
damage the starter motor.
9-1
Cam Sensor (turn
counter-clockwise)
Cam
Sensor
Stop
Retaining
Washer
10-1
n
n
OIL FILTER
OIL DIPSTICK
n
AIR
CLEANER
COVER
10-3
n
10-5
SERVICE SCHEDULE
30 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR SETS
The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator Sets from 30kW to 150 kW in size. 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. Use calendar time, from the previous maintenance
interval to determine the next required maintenance interval.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.
This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting
automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel Auto/Off/Manual switch to the
“OFF” position.
• Remove the 15 amp control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.
The battery charger must be turned off BEFORE 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 wear-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any
potential problem areas.
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed semi-annually or following each 50 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential
problem areas.
Performed annually or following each 100 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed annually or following each 250 hours of operation of the unit.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be
performed only by a Service Dealer.
11-1
SrvSchd003 Rev. D 06/10
Service Schedule
Termékspecifikációk
| Márka: | Generac |
| Kategória: | A generátor |
| Modell: | QT04542GNAN |
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