Generac Power Systems QuietSource 004917-5, Installation And 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 5 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 11 2 10 Battery Installation 11 2 11 Preparation Before Start Up 12 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 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: ...rit 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 below a preset value and remain at such ...

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

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: ...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 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 Sections 2 5 and 2 6 The generat...

Page 11: ... 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 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate coo...

Page 12: ...aded when this isolation method is employed The following apply to the transfer switch in this type of system 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 2 7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and...

Page 13: ... until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation 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 othe...

Page 14: ...operly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Secti...

Page 15: ... two wire start circuit When a two wire start is issued the con trol board will immediately start and run the genera tor Whe the two wire start is removed the control board will immediately stop the generator NOTE If the generator is installed in conjunction with an engineered GTS type transfer switch refer to the applicable transfer switch manual for exact oper ating parameters and timing sequenc...

Page 16: ...s either in the AUTO or MANUAL modes The LED will flash at the rate of 1 2 second on 1 2 second off if the utility sensing level is below the transfer back threshold This secondary function is only available with dip switch two in the OFF position standard ATS appli cation 3 3 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMER GENCY power source side and start the engine...

Page 17: ...he utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 7 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator outp...

Page 18: ...xhaust system parts from this product get extremely hot and remain 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 4 3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is ...

Page 19: ...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 Do not attempt to adjust the governor Only qualified service facilities should adjust the g...

Page 20: ... 4 Setting the Spark Plug Gap 4 5 13 COOLANT CHANGE Every year have Authorized Service Facility drain flush and refill the cooling system See SPECIFICA TIONS Section 1 10 for cooling system recommen dations 4 6 MISCELLANEOUS MAINTENANCE 4 6 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse ...

Page 21: ...cked This should be done with an automotive type bat tery hydrometer 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 pro...

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

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

Page 28: ...ER SWITCH AUTO OFF MANUAL FUSE B C 4A AGC TYPE TERMINAL BLOCK INTERCONNECT TRANSFORMER 1 56 VA 240 16 VAC NEUTRAL BLOCK LEGEND CONT RL1 SW1 SW2 TR1 NB F2 ICT F1 RELAY 1 2 4 3 5 6 TRANSFER SWITCH 5 CUSTOMER CONNECTION 120 240V 1 PHASE CB1 E1 NB 00 DPE AS 2 CONNECTION N2 E3 N1 23 194 183 178 CB2 11 44 162 N1 N2 D1 BCW BA 55 AR 4 6 1 66 14 1 194 178 183 15 ICT N2 225A 183 178 23 194 224A TR1 N1 15 N1...

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

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: ...TO A SECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT 4 53 35 RADIATOR 33 4 25 16 6 1 53 4 36 4 48 4 4 4 4 18 4 26 4 8 4 A 22 9 12 13 55 17 49 4 4 9 9 4 52 B 20 53 10 15 14 19 51 21 46 28 43 4 1 2 PLCS TO B 24 55 17 41 4 17 18 23 48 48 4 4 4 4 40 26 44 10 39 18 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Compartment Drawing No 0F1141 B ...

Page 33: ... BACK 27 0E8001 1 MUFFLER BOX 28 0F5568 1 ROOF HSB AL ACOUSTIC 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 0F1131 1 BRACE FRONT BOT 3 0L FD ALUM 38 0E8415 1 DU...

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

Page 35: ... CONTROL PANEL 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 ITEM PART NO QTY DESCRIPTION 37 0C1127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL 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 0C5141 1 CONN DEUTSCH GASKET 8 12 POS DT 43 0C2699 11 SCR...

Page 36: ...4 51 69 5 25 60 REMOVE 88 15 78 87 21 47 46 20 49 46 4 4 43 38 85 36 42 1 47 42 6 7 2 81 42 32 48 42 41 44 45 31 28 72 35 8 40 REAR UPPER BAFFLE 5 36 37 29 12 34 3 8 10 82 33 36 42 73 34 27 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Engine Drawing No 0F6836 A 34 Generac Power Systems Inc ...

Page 37: ... X 65 G8 8 46 051769 3 WASHER LOCK M12 47 049808 2 WASHER FLAT M12 ITEM PART NO QTY DESCRIPTION 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 049226 7 WASHER LOCK M5 54 091526 3 SCREW PPHM M5 0 8 X 12 ZNC 55 093278 4 SCREW HHTT M5 0 8 X 25 BP 56 0F7000 1 HARN ENGINE 3 0L FORD HSB CAR NOT ...

Page 38: ... WATER PUMP 6 17 7 1 15 20 A 3 22 24 24 2 12 TO A 18 13 14 THERMOSTAT 30 33 29 12 33 34 HOUSING ENGINE TO TO 31 32 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Radiator Drawing No 0F6848 36 Generac Power Systems Inc ...

Page 39: ...S 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 BARBED STR 1 4 NPT X 3 8 26 0C7649 1 CLAMP HOSE 38 87 27 069860C 1 HOSE OIL DRAIN ASSY 21 28 0F6746 1 TUBE UPPER COOLANT C4 3 0L 29 0F6631 1 HOSE RADI...

Page 40: ... Inc B 31 10 16 4 2 17 5 9 1 7 6 29 32 30 11 29 15 8 3 6 13 R O LEANER 34 33 29 14 TO B 19 26 27 18 43 41 40 20 42 39 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Fuel System Drawing No 0F6849 ...

Page 41: ...CTUATOR 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 ID SINGLE BRAID 432mm 17 LONG 32 0A4121 1 VALVE PCV 33 0E6609 1 GROMMET ROCKER COVER ...

Page 42: ...ower Systems Inc 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Alternator Drawing No 0F5092 A ...

Page 43: ...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 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 0C3993 4 SCREW HHTT M4 0 7 X 25 BP 15 057192 4 SCREW ...

Page 44: ...12 0E8816 2 EXHAUST FLANGE 2 PIPE 13 085917 8 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 4 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 022259 4 NUT HEX 5 16 18 STEEL 21 022241 2 NUT HEX 3 8 16 STEEL MANIFOLD 10 16 15 6 20 8 16 10 17 2...

Page 45: ... 4 WASHER LOCK M5 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 0C8127 1 ELEMENT AIR CLEANER 6 022127 1 NUT HEX 1 4 20 STEEL 7 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 8 0A5547 1 COVER AIR CLEANER 9 037561 1 NUT WING 1 4 20 NYLK 8 9 1 7 6 2 5 4 3 Section 7 Exploded Views and Parts QUIETSOURCE Liquid cooled 30 kW Generators Air Cleaner Drawing No 0F6850 ...

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: ...fluid amounts Failures 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 collis...