Generac QT04524GNSC Bruksanvisning

Generac Generator QT04524GNSC

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1-1

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.

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

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.

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.

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.

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

The Stationary Emergency Generator may be equipped with one of

the following fuel systems:

• Natural gas fuel system

• Propane vapor (LPV) fuel system

Recommended fuels should have a Btu content of at least 1,000

Btu's per cubic foot for natural gas; or at least 2,520 Btu's per

cubic foot for LP gas. Ask the fuel supplier for the Btu content of

the fuel.

NOTE:

The fuel consumption requirements are identified in the

Specifications section of the Owner's Manual. Refer to the

Installation Manual if assistance is required for the sizing of

the pipe diameter for the generator. Any piping used to connect

the generator to the fuel supply should be of adequate size to

achieve the 100% load fuel consumption requirements identi-

fied in the Specifications section regardless of actual load.

NOTE:

The recommended fuel pressure is identified in the Specifications

section this manual.

NOTE:

It is the responsibility of the installer to make sure that only

the correct recommended fuel is supplied to the generator fuel

system. Thereafter, the owner/operator must make certain that

only the proper fuel is supplied.

Natural gas is supplied in its vapor state. In most cases, the gas

distribution company provides piping from the main gas distribu-

tion line to the standby generator site. The following information

applies to natural gas fuel systems.

• Gas pressure in a building is usually regulated by national, state

and local codes.

• To reduce gas pressure to a safe level before the gas enters a

building, a primary regulator is needed. The natural gas supplier

may or may not supply such a regulator.

• It is the responsibility of the gas supplier to make sure sufficient

gas pressure is available to operate the primary regulator.

• Gas pressure at the inlet to the fuel shutoff solenoid must never

exceed approximately 14 inches water column (0.5 psi).

This type of system utilizes the vapors formed above the liquid

fuel in the supply tank. Approximately 10 to 20 percent of the tank

capacity is needed for fuel expansion from the liquid to the vapor

state. The vapor withdrawal system is generally best suited for

smaller engines that require less fuel. The installer should be aware

of the following:

• When ambient temperatures are low and engine fuel consump-

tion is high, the vapor withdrawal system may not function

efficiently.

• Ambient temperatures around the supply tank must be high

enough to sustain adequate vaporization, or the system will not

deliver the needed fuel volume.

• In addition to the cooling effects of ambient air, the vaporization

process itself provides an additional cooling effect.

5-1

FuelSys001 Rev. F 04/11

STATIONARY EMERGENCY GENERATOR

Type......................................................................Synchronous

Rotor Insulation .............................................................Class H

Stator Insulation ............................................................Class H

Telephone Interference Factor (TIF) .................................. < 50

Alternator Output Leads 3-phase ..................................... 6-wire

Bearings ..................................................................Sealed Ball

Coupling ................................................................Flexible Disc

Load Capacity (Standby Rating) ....................................45 kW*

* 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

120/240 V, 1-phase, 1.0 pf 45 188 200

120/208 V, 3-phase, 0.8 pf 45 156 175

277/480 V, 3-phase, 0.8 pf 45 68 80

Generator Locked Rotor kVA Available @ Voltage Dip of 35%

Single-phase or 208 V, 3-phase ...................................72 kVA

480 V, 3-phase ............................................................80 kVA

ENGINE

Make ........................................................................... Generac

Model .............................................................................In Line

Cylinders and Arrangement .....................................................4

Displacement ............................................................... 2.4 Liter

Bore............................................................ 86.5 mm (3.41 in.)

Stroke .......................................................... 100 mm (3.94 in.)

Compression Ratio....................................................... 9.5-to-1

Air Intake System .........................................Naturally Aspirated

Valve Seats ................................................................ Hardened

Lifter Type .................................................................. Hydraulic

Spark Plug Gap .................... 1.07-1.17 mm (0.042-0.046 inch)

Engine Parameters

Rated Synchronous rpm.........................................60 Hz, 3600

Exhaust System

Exhaust Flow at Rated Output 60 Hz .............................420 cfm

Exhaust Temp. at Rated Output ......................................1100 °F

Combustion Air Requirements (Natural Gas)

Flow at rated power, 60 Hz ...........................................144 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 U.S. qts.

(including filter capacity)

COOLING SYSTEM

Type............................................. Pressurized Closed Recovery

Water Pump ............................................................. Belt Driven

Fan Speed ..................................................................1865 rpm

Fan Diameter ..............................................................22 inches

Fan Mode ......................................................................... Puller

Air Flow (inlet air including alternator and

combustion air) ................................................. 2725 ft

3/min.

Coolant Capacity ....................................................3.0 U.S. gal.

Heat Rejection to Coolant ....................................193,000 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 - ft 3/hr (Natural Gas/LPV)

Exercise 25% 50% 75% 100%

Cycle Load Load Load Load

65/25 210/83 380/151 545/216 730/290

ELECTRICAL SYSTEM

Battery Charge Alternator .....................................12 V, 30 Amp

Static Battery Charger ..................................................2.5 Amp

Recommended Battery .................................Group 26, 525CCA

System Voltage ............................................................ 12 Volts

NOTE:

Battery dimensions (L x W x H) for the Group 26 battery should

not exceed 8 3/16" x 6 13/16" x 7 3/4" (208 mm x 173 mm x

197 mm).

Voltage Regulator

Type...........................................................................Electronic

Sensing ................................................................ Single-phase

Regulation ........................................................................± 1%

Features ......................................... Adjustable Voltage and Gain

Power Adjustment for Ambient Conditions

Temperature Deration

3% for every 10 °C above °C ..............................................25

1.65% for every 10 °F above °F ..........................................77

Altitude Deration

1% for every 100 m above m............................................183

3% for every 1000 ft. above ft. .........................................600

Controller ................................................................. Nexus

6-1

GenSpec085 Rev. C 01/14

WEATHER AND MAINTENANCE KITS

To keep the generator running at its peak, the following kits are

offered:

• Cold Weather Kit

~ Recommended for climates with temperatures below 32 °F.

• Extreme Cold Weather Kit

~ Recommended Block Heater Kit for protection in tempera-

tures below 32 °F.

• Scheduled Maintenance Kit

~ Kit includes the recommended parts to maintain the genera-

tor. Refer to the Service Schedule for regular maintenance

intervals.

For additional information, or to order any of these kits, please

contact an Authorized Service Dealer or Customer Service

Representative.

RECONFIGURING THE FUEL

SYSTEM

NOTE:

All models are configured to run on natural gas from the fac-

tory.

Before the generator can be operated using a LP fuel source, the

fuel system and control panel (refer to the installation drawing for

location) must be reconfigured. The steps to reconfigure the gen-

erator from a natural gas (NG) to a liquidified petroleum (LP) fuel

source are as follows:

FUEL SYSTEM

1. Turn the main gas supply off and disconnect the battery.

2. Remove the carburetor fuel hose from the outlet port of the

demand regulator (see Figure 6.1).

3. Disconnect the power wires from the fuel solenoid located

on top of the regulator assembly by removing the screw on

the front of the connector and pulling the connector forward,

away from the solenoid body.

4. Loosen the spring clamp on the small fuel enrichment line and

remove the hose from the hose barb.

5. Remove the black pipe assembly from the outlet port of the

demand regulator. The solenoid assembly may need to be

removed before performing this operation (Figure 6.1).

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 side of 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 side of the regulator housing.

9. Install the previously removed black pipe onto the outlet

port of the demand regulator. Use pipe sealant on the pipe

threads.

10. Reverse steps 1-4 in this procedure to reactivate the demand

regulator.

11. Follow the instructions in the Control Panel section.

 Serious injury, including death, or damage may

occur if not configured properly. Please consult

an Authorized Dealer with any questions.

Figure 6.1 — Reconfigure the Fuel System

BRASS BARBED

ELBOW

FUEL

ENRICHMENT

LINE

BLACK PIPE

FITTINGS

PORT 2

JET KEEPER

PORT

FUEL HOSE

FITTING

CONTROL PANEL

The FUEL TYPE must be reconfigured in the control panel to final-

ize the conversion process. This generator is configured at the

factory to operate on natural gas. If conversion to LP is required,

please complete the mechanical conversion process and then call

888-9ACTIVATE for the control panel password. This fuel selection

conversion is required to be password protected by Environmental

Protection Agency [EPA] regulations.

 Whenever the Generator’s Fuel Regulator is

converted from one Fuel type to the other,

the Control Panel must be reconfigured for

the correct fuel type. Failure to convert both

the Regulator and Control Panel will result in

decreased performance and an increase in

emissions, and is a violation of EPA regula-

tions.

6-2

GenSpec085 Rev. C 01/14

Specifications

ALTERNATOR AC LEAD

CONNECTIONS

The electrical wires in the unit’s AC connection (lower) panel

should be installed according to the number of leads and the

voltage/phase required for the application. The voltage and phase

are described on the generator data label. The number of lead

wires can be identified using the Specifications section and the

power output rating on the generator data label. For example, if

the generator produces 130kW, 277/480 Volt, 3-phase power, the

generator has 12 alternator output leads. Figure 7.3 describes the

stator power winding connection for the generator.

FOUR-LEAD, SINGLE-PHASE STATOR

Four-lead alternators (see Figure 7.1) are designed to supply elec-

trical loads with voltage code “A” (240V, 1-phase, 60 Hz). Electrical

power is produced in the stator power windings. These windings

were connected at the factory to the main circuit breaker as shown

in Figure 7.1.

The rated voltage between each circuit breaker terminal is 240V.

The rated voltage between each circuit breaker terminal and the

neutral point 00 is 120V.

Figure 7.1 — Four-lead, Single-phase Stator

ALTERNATOR POWER WINDING

CONNECTIONS

3-PHASE ALTERNATORS ("Y" CONFIGURATION)

The Stationary Emergency Generator is designed to supply

3-phase electrical loads. Electric power is produced in the alterna-

tor power windings. These windings were connected at the factory

to the main circuit breaker with a “Y” configuration as shown in

Figures 7.2 through 7.6.

The rated voltage between circuit breaker terminals E1-E2, E1-E3

and E2-E3 is 480V, 208V or 600V depending on the model.

The rated voltage between each circuit breaker terminal and the

neutral point 00 is 277V, 120V, or 346V depending on the model.

Figure 7.2 — Stator Power Winding

Connections - 3-phase, 277/480V (6 Lead)

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

Figure 7.3 — Stator Power Winding

Connections - 3-phase, 277/480V (12 Lead)

S12

S11

S10

E3 L - N

L - L

7-1

ACConn007 Rev. C 06/15

General Information

E3 E2

00 (NEUTRAL)

INTERNAL CONNECTIONS E1

L-L

L-N

S1 S1

S4 S4

S5 S2

E3 E2

L-L

L-N

S7 S1

S10 S4

S12

S11 S2

E3 L - N

L - L

INTERNAL

CONNECTIONS

00 (NEUTRAL)

0VAC

2VAC

208C

240C

240 VAC

120 VAC 120 VAC

240 VAC

S2 S12

S11

S10

E1 E3

208 VAC

7-2

General Information

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8-1

8-2

8-3

8-4

8-6

8-7

ACTIVATION

RUN LOGALARM LOG

HISTORY STATUS

COMMANDSTATE VERSIONSDISPLAY

GENERATOR

FREQUENCY

ENGINE

HOURS

ENGINE

RPM

BATTERY

VOLTAGE

DEBUG

INPUTS OUTPUTS DISPLAYS

EDIT

LANGUAGE

TIME/DATE

EXERCISE

TIME/SPEED

ESC Press the “ESCAPE” key

to jump back up through

the menu levels.

+ / - Use the “+/-” key

to navigate through

the menu.

ENTER Use the “ENTER” key

to select items or

enter data.

ESC

ESC ESC

RESET

MAINTENANCE

QT TEST

MAIN MENU

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.

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

 Before working on the Stationary Emergency

Generator, ensure the following:

Oil Fill Cap

Oil

Dipstick

Oil Filter

nHot oil may cause burns. Allow engine to cool

before draining oil. Avoid prolonged or repeat-

ed skin exposure with used oil. Thoroughly

wash exposed areas with soap.

nAfter refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.

 The exhaust system parts from this product get

extremely hot and remains hot after shutdown.

High grass, weeds, brush, leaves, etc. must

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

10-1

nIf a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

nDo not attempt to adjust the governor. Only

qualified service facilities should adjust the

governor. Excessively high operating speeds

are dangerous and increase the risk of personal

injury. Low speeds impose a heavy load on the

engine when adequate engine power is not

available and may shorten engine life. Correct

rated frequency and voltage are supplied only

at the proper governed speed. Some connected

electrical load devices may be damaged by

incorrect frequency and/or voltage. Only quali-

fied service technicians should adjust the gov-

erned speed.

10-2

11-1

12-1

United States Environmental Protection Agency Warranty Statement

(Stationary Emergency Spark-Ignited Generators)

Warranty Rights, Obligations and Coverage

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission

Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo-

nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace-

ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may include parts

such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac will warrant

the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect, unapproved modifica-

tion, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the date of sale to the ulti-

mate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of operation, whichever

comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission Control System war-

ranty is valid for 5 years or 3500 hours of operation, whichever comes ﬁrst.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and conﬁgured in accordance to Gen-

erac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting

adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or com-

ponent must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize

emissions at all times.

Generac may deny any/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system or

component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of

counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either

your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall

be responsible for any expenses or other charges incurred for service calls and/or tr spection or ansportation of the product to/from the in

repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being trans-

ported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty

related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www.generac.com.

Important Note

This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by Gen-

erac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by defects

in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties,

expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Any

implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states

do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

*High-Cost Warranted Component

EmsnWrnty001 Revision F (04/15)

1) Fuel Metering System

1.1) Gasoline Carburetor Assembly and Internal Components

A) Fuel Filter, B) Carburetor, C) Fuel Pump

1.2) Carburetion Assembly and Its Components

A) Fuel Controller, B) Carburetor and Its Gaskets,

C) Mixer and Its Gaskets, D) Primary Gas Regulator,

E) Liquid Vaporizer

1.3) Fuel Regulator

2) Air Induction System Including A) Intake Pipe/Manifold,

B) Air Cleaner

3) Ignition System Including A) Spark Plug, B) Ignition Module,

C) Ignition Coil, D) Spark Plug Wires

4) Exhaust System

A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,

D) Exhaust Pipe, E) Muffler Gasket

5) Crankcase Breather Assembly Including

A) Breather Connection Tube, B) PCV Valve

6) Oxygen Sensor

7) Diagnostic Emission-Control System

United States Environmental Protection Agency Compliance Requirements

(Stationary Emergency Spark-Ignited Generators)

Purchaser's/Owner's Record Keeping Responsibilities

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record

keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion

Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains

their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in

this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)

Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record

keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel

solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted

to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the

operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130

HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of oper-

ation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.

Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.

Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air

Quality Management or Air Pollution Control District for specific requirements.

Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,

provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the

engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emer-

gency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to be

used for maintenance checks and readiness testing, but a petition t Federal, is not required if the owner maintains records indicating tha

State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may

operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for

maintenance and testing.

The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to

an electric grid or otherwise supply power as part of a ﬁnancial arrangement with another entity. For purchaser/owner of emergency engines,

any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,

as permitted in this section is prohibited.

If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance

to the speciﬁcations and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be con-

sidered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark Igni-

tion Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and

replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States

Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized

Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow t ified engine in a hese instructions when installing a cert

piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

EmsnWrnty001 Revision F (04/15)