Generac Power Systems Quietsource 004917-2, Owner'S Manual

Page 1: ...DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY DANGER This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Number 004917 2 27 kW NG 30 kW LP Vapor Not intended for use in life support applications ...

Page 2: ...explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing other users to properly ...

Page 3: ...tion 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 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 12 Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustm...

Page 4: ... 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 concentra...

Page 5: ...ator 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 Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an acc...

Page 6: ... 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 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 b...

Page 7: ...URE 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 NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 sec...

Page 8: ...unning when the low battery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 1 7 8 ALARM RESET If the engine control board shuts down the 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 1 7 9 DC FUSE These fuses are loc...

Page 9: ... 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 4 to 0 5 psi at all load ranges 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the ma...

Page 10: ...ing any high silicate anti freeze boosters or addi tives will also cause overheating It is also rec ommend that any soluble oil inhibitor is NOT USED for this equipment 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 ...

Page 11: ... Institute 1430 Broadway New York N Y 10018 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors 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 ...

Page 12: ...e entrance and the building distribution panel 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 requireme...

Page 13: ... 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 Do not dispose of the battery in a fire The bat tery is capable of exploding 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 ci...

Page 14: ...s standards and regulations 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications Section 1 10 for more information 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the prop...

Page 15: ...ic start up normally occurs when utili ty source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on control console 3 2 2 FAULT INDICATOR LED This LED goes ON when one or more of the following engine faults occurs and when engine shuts dow...

Page 16: ... the unit Decrease the GAIN pot if there is instability at any load point 4 Under full load condition increase the stability pot until the unit returns to 60 Hertz or 50 Hertz in 50 Hertz applications 5 Reduce load to 3 4 1 2 1 4 and no load Decrease the stability pot if there is instability at any load point 6 Adjust differential pot to make the recovery to load changes even faster and minimize l...

Page 17: ...t and run if UTILITY is lost while in Auto mode but it will not perform a weekly exercise cycle If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switch to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise...

Page 18: ... FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recom mended oils Figure 4 1 Oil Dipstick and Oil Fill Cap 4 4 2 BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is...

Page 19: ...ge are sup plied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only qualified service technicians should adjust the governed speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized serv ice facilities for engine oil and filter change frequen cies Drain the oil while the engine is still warm from r...

Page 20: ...r sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That deal er will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator m...

Page 21: ...ric 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 the fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharg...

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

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

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

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

Page 26: ...RELAY COIL TRANSFER RELAY COIL TRANSFER SWITCH 15E N2 N1 13A 23 183 178 14 13 13A 0 14 14A 16 15 IC 13 13 11 14 13A 239 15A 1b 1a 16 15 1 16 16 15 2a 2b 1 15 ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS 224 OTHERWISE NOTED AS SHOWN 16 14 16 14 225 NOTE OA SIZE AWG BA 66 6 6 6 33 44 22 11 STATOR TR1 178 194 183 178 6 N1 225A 224A 178 178 2 6 5 4 44 55 11 N2 1 N1 N2 23 66 23 66 11 BC1 0 16 16 14 1...

Page 27: ... 23 66 0 86 0 0 1 7 10 11 12 9 8 4 6 5 2 3 15A 225 224 15E 239 14 14A 0A 13 0 0 11 14 13 12 8 9 10 6 7 85 225 14A 66 C1 239 15E 0 RED 0 0 85 85 14 BLK FS 0A 0 0 16 16 13 GND2 0 0 0 4 16 10 0 0 SM 4 10 16 769 3 PCB J1 2 3 4 1 6 7 8 4 5 15A 86 23 56 766 768 N C 0 14 PCB J2 1 2 765 767 OTHERWISE NOTED AS SHOWN ALL WIRES ARE 18 AWG 300 VOLT UL LISTED UNLESS 14 13 0 56 13 13 1 10 CC NOTE 16 BAT 13 13 1...

Page 28: ...WITCH AUTO OFF MANUAL SWITCH SET EXERCISER LEGEND CONT SW2 SW1 TR1 RL1 NB ICT F2 RELAY 1 LEGEND ALTERNATOR ROTOR ALTERNATOR STATOR AR AS FUSE BAT POWER 15A AGC TYPE F1 TRANSFER SWITCH 6 5 3 4 2 5 120 240V 1 PHASE CUSTOMER CONNECTION E1 00 DPE NB 2 CONNECTION N2 E3 N1 23 194 183 178 CB2 44 11 162 N1 N2 D1 BCW 55 AR 4 6 1 66 14 1 183 178 194 15 ICT 225A N2 183 178 194 23 224A TR1 N1 15 N1 SW1 225 23...

Page 29: ...EMP IGNITION MODULE ON DISTRIBUTOR STARTER MOTOR IGNITION COIL CONTACTOR STARTER MOTOR SC 239 15A 225 224 15E 14 13 14A 11 12 10 7 8 9 4 6 5 2 1 3 0A 0 0 0 23 66 PCB GOV 225 14A 85 66 4 6 5 1 2 3 J1 13 J1 12 J1 11 J1 14 224 15E 239 0 15A 86 23 56 J1 5 J1 6 J1 7 J1 10 J1 9 J1 8 J1 3 J1 2 J1 4 J1 1 J2 5 768 N C 770 766 N C 771 767 765 J2 6 J2 7 J2 8 14 0 767 765 766 769 J2 1 J2 4 J2 2 J2 3 13 16 56 ...

Page 30: ...NGINE 30 TO 44 35 34 3 36 33 44 42 22 20 32 38 18 31 20 TO STARTER STARTER BOLT TO BLOCK ENGINE 18 TO 11 1 12 10 14 REAR BEARING 13 15 37 14 CARRIER 3 4 16 2 28 Generac Power Systems Inc Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Mounting Base Drawing No 0E6266 E ...

Page 31: ... STL 21 022129 1 WASHER LOCK M8 5 16 22 045771 1 NUT HEX M8 1 25 G8 YEL CHR 23 051756 1 SCREW HHC M10 1 5 X 20 G8 8 24 046526 1 WASHER LOCK M10 25 022131 1 WASHER FLAT 3 8 M10 ZINC 26 055934M 1 CLAMP VINYL 75 X 343 Z 30 077483 REF BATT 12VDC 75 AH 26 058665 REF BATT 12VDC 90 AH 27F 31 038804D 1 CABLE BATT RED 4 X 20 00 32 038805AA 1 CABLE BATT BLK 4 X 30 33 021991 1 EARTH STRAP 34 049814 1 SCREW H...

Page 32: ... 54 5 TO A SECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT 4 53 35 RADIATOR 33 4 46 53 4 36 4 57 5 5 5 5 18 4 26 4 8 4 A 22 9 12 13 16 17 56 5 5 6 6 5 52 B 20 53 10 15 14 19 51 21 59 28 43 4 1 2 PLCS TO B 17 16 40 4 17 18 23 57 57 5 5 5 41 26 44 10 39 18 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Compartment Drawing No 0E8519 B ...

Page 33: ... 0E8001 1 MUFFLER BOX 28 0E5913 1 ROOF HSB AL 29 0E5915 1 BRACE FRONT TOP HSB AL 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E5910 1 SUPPORT LH SIDE HSB AL 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E5900 1 POST CORNER LH FRONT HSB AL 36 0E5901 1 POST CORNER RH FRONT HSB AL 37 0E5916 1 BRACE FRONT BOTTOM HSB AL 38 0E8415 1 DUCT DISCHARGE MID AL ...

Page 34: ...32 Generac Power Systems Inc Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Control Panel Drawing No 0E7118 G ...

Page 35: ...N CIRCUIT BREAKER 33 0E7539A 1 DECAL TB1 HSB CONTROL PANEL ITEM PART NO QTY DESCRIPTION 34 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V 35 0E7252 1 BRACKET CB 221 5 X 102 36 0C1229 1 DECAL WARNING ELECTRICAL SHOCK 37 0C1127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL 3 0L FORD NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 41 074908 6 SCREW HHTT M5 0 8 X 10 BP 42 0C5...

Page 36: ... 60 58 57 35 16 18 19 48 48 42 41 44 45 31 30 43 21 7 78 47 42 38 1 2 47 43 26 42 42 69 28 REAR UPPER BAFFLE 40 36 6 7 5 35 37 15 36 8 3 14 3 12 29 73 35 36 10 34 35 27 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Engine Drawing No 0E8170 J 34 Generac Power Systems Inc ...

Page 37: ...5 G10 9 42 046526 17 WASHER LOCK M10 ITEM PART NO QTY DESCRIPTION 43 022131 11 WASHER FLAT 3 8 M10 ZINC 44 059982 4 SCREW SHC M12 1 75 X 45 G10 9 45 098780 2 SCREW HHC M12 1 75 X 65 G8 8 46 051769 3 WASHER LOCK M12 47 049808 2 WASHER FLAT M12 48 051430 6 WASHER SHAKEPROOF INT 1 2 49 045773 3 NUT HEX M12 1 75 G8 YEL CHR 50 0E6203C 1 COIL IGNITION 3 0L FORD 51 0E6679 2 BRACKET IGN COIL 3 0L FORD 53 ...

Page 38: ...9 11 8 9 3 21 27 PUMP TO WATER 4 12 17 6 15 7 1 15 20 3 22 24 24 TO 2 12 TO A 18 13 14 12 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Radiator Drawing No 0E8528 B 36 Generac Power Systems Inc ...

Page 39: ...CHR 12 035685 4 CLAMP HOSE 28 1 32 2 25 13 0E8562 1 FAN GUARD HSB 14 058443 4 SCREW CRIMPTITE 1 4 20 X 5 8 15 0C2454 9 SCREW TH FRM M6 1 X 16 N WA Z JS 17 048031C 1 CLAMP HOSE BAND 1 4 18 029032 1 HOSE 9 32 ID 30 LG 20 046627 1 CAP RADIATOR 21 069811 1 CAP HEX 1 4 NPT BRASS 22 065852 1 SPRING CLIP HOLDER 37 62 23 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 24 052250 2 TAPE FOAM 1 X 1 27 LG 25 035461 1 ...

Page 40: ... Power Systems Inc B 31 10 16 4 2 17 5 9 1 7 6 30 32 29 11 29 15 8 3 6 13 ANER 29 19 26 27 18 21 2 39 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Fuel System Drawing No 0E8190 B ...

Page 41: ...18 0E6123 1 INTAKE ADAPTER 3 0L FORD BOSCH 19 0E6586 1 GASKET BOSCH 32 20 0E4395 1 ACTUATOR BOSCH 32 GOVERNOR 21 057753B 1 HOSE 1 5 ID X 2 LG 20R4 25 047487 4 SCREW SHC M6 1 0 X 18 G12 9 26 022097 8 WASHER LOCK M6 1 4 27 051751 4 SCREW HHC M6 1 0 X 50 G8 8 28 035685 2 CLAMP HOSE 28 1 32 2 25 29 057823 4 CLAMP HOSE 10 56 1 06 30 047290 1 HOSE 3 8 ID SINGLE BRAID 305mm 12 LONG 31 047290 1 HOSE 3 8 I...

Page 42: ...40 Generac Power Systems Inc 4 15 7 17 8 7 1 18 31 30 LEADS 5 2 6 21 9 3 20 11 12 10 19 14 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Alternator Drawing No 0E8660 B ...

Page 43: ...Y 3 0L HSB LG GEAR 6 0E6076 1 REVCOR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD 2 5L FORD 04576100BF 4 STUD M14 2 0 X 540 G5 ZINC 3 9L CHRYSLER 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 1 WASHER SHAKEPROOF INT 8 14 092980 4 SC...

Page 44: ... FLANGE 2 PIPE 13 085917 4 WASHER LOCK 3 8 SS 14 0D2611 4 SCREW HHC 3 8 16 X 1 3 4 SS 15 039253 2 SCREW HHC M8 1 25 X 20 G8 8 16 022145 5 WASHER FLAT 5 16 M8 ZINC 17 022129 7 WASHER LOCK M8 5 16 18 045771 3 NUT HEX M8 1 25 G8 YEL CHR 19 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS 20 039288 1 SCREW HHC M8 1 25 X 55 G8 8 21 044149 2 GASKET EXHAUST RING 22 022259 4 NUT HEX 5 16 18 STEEL MANIFOLD 11 4 2...

Page 45: ...UT HEX 1 4 20 STEEL 10 037561 1 NUT WING 1 4 20 NYLK ITEM PART NO QTY DESCRIPTION 11 049226 8 WASHER LOCK M5 12 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 13 052619 4 SCREW HHC M5 0 8 X 20 G8 8 14 051713 4 WASHER FLAT M5 15 051716 4 NUT HEX M5 0 8 G8 YEL CHR 16 022131 2 WASHER FLAT 3 8 M10 17 046526 2 WASHER FLAT M10 18 051755 2 SCREW HHC M10 1 5 X 16 G8 8 19 022145 2 WASHER FLAT 5 16 M8 ZINC 20 022129 2...

Page 46: ...44 Generac Power Systems Inc Section 8 Installation Diagram QUIETSOURCE Liquid cooled 30 kW Generators Installation Diagram Drawing No 0E8696 ...

Page 47: ...Generac Power Systems Inc 45 Section 9 Notes QUIETSOURCE Liquid cooled 30 kW Generators ...

Page 48: ...lures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandali...