Generac Power Systems QuietSource 005031-2, Owner'S Manual

Page 1: ...Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Number 005031 2 25kW ...

Page 2: ...sion 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 The manufacturer strongly recom mends that the operator reads this Owner s Manual and thoroughly understands all instructions before using this equipment The manufacturer also strong ly recommends instructing other us...

Page 3: ... Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Using a GTS Transfer Switch 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 12 Section 3 OPERATION 12 3 1 GTS Transfer Switch 12 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 15 3 4 Engine Governor Gain Adjustments 15 3 5 Manual Retransfer and Shutdown ...

Page 4: ...ess or even death For that reason adequate ventilation must be provided Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the instal...

Page 5: ... conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaini...

Page 6: ...ch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors If a transfer switch is not included one may be pur chased separately from an Authorized Dealer 1 3 ATS MODE AUTOMATIC OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator control panel constantly monitors utility power sourc...

Page 7: ...ally shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 Figure 1 3 Engine Protective Devices 1 7 1 LOW OIL 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 clo...

Page 8: ...g colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 8 2 INSPECTION Upon delivery carefully inspect the generator for any damage that may have occurred during shipment If loss or damage is noted at the time of delivery have the person s making delivery note all damage on the freight bill or affix their signature under the consign or s memo of loss or ...

Page 9: ...ort 2 5 Install brass hose fitting into Port 2 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure and type for configuration not to exceed 14 inch es water column 10 Move DIP switch position 4 on the control board to the off position LP vapor see Figure 3 2 and Section 3 8 11 Reverse the pr...

Page 10: ...con trols all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION DANGER Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric system by th...

Page 11: ...eet allowance of space is recom mended Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MA...

Page 12: ...lified electrician for grounding requirements in the area Grounding procedures must meet local regulations DANGER Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against elec trical shock in the event of a ground fault condition in the generator or in connected electrical devices In ...

Page 13: ... Do not permit fluid to contact eyes skin clothing 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 e...

Page 14: ...ounted in strict compliance with applicable codes 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 volume and b is properly purged and leak tested according to code No fuel leakage is permitted 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to th...

Page 15: ... LA SORTIE DE ATRICE A UN COMMUTATEUR DE CALIBRE APPROPRIE CONFORMENENT AU CANADIEN DE L ECTRICITE PREMIERE PARTIE WARNING CAN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE Y REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATTE SERVICING WARNING THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR OUTDOOR INSTALLATION ONLY 0E7193 USE OF SYNTHETIC OIL IS RECOMMENDED ON 0F2629 THEN THE UNIT WILL START...

Page 16: ... switch is in the MANUAL or OFF positions The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is 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 Section 3 Operation Liquid cooled 25 kW Generators Condition System Low Low High Over ...

Page 17: ...duce load to 3 4 1 2 1 4 and no load Decrease the stability pot if there is instability at any load point 7 Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot If it is set too high it may introduce oscillations at some load It can be set to zero full CCW if a small amount causes oscillations at some load 8 Leave DIP switch 8 i...

Page 18: ...m 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 switched to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set 3 8 CONTROL BOARD DIP SWITCH SETTINGS Locate...

Page 19: ...Check the reading on the AC frequency meter 7 Turn the voltage regulator s VOLTAGE ADJUST pot to obtain a line to line voltage of A 240 VAC if the generator has been configured for 60 Hertz operation B 200 VAC if the generator has been configured for 50 Hertz operation 8 If the RED REGULATOR LED is flashing adjust the STABILITY pot in either direction until the flashing stops 9 Apply an electrical...

Page 20: ... the cylinder head Both sur faces must be clean and flat Figure 4 1 2 Clean and lightly oil the manifold bolt stud threads Figure 4 1 Intake Manifold Installation 3 Install a new lower intake manifold gasket 4 Position the lower intake manifold to the cylinder head 5 Install retaining bolts studs finger tight 6 Tighten all bolts studs to specifications in the tightening sequence shown First pass 7...

Page 21: ... in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 4 7 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coo...

Page 22: ...taining clip 4 Turn OIL FILTER Figure 4 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters After refilling the...

Page 23: ...NANCE The battery should be inspected per Section 4 7 Scheduled Maintenance The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and c...

Page 24: ...ery 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 break in service inspection of the generator set to insure it is ready to operate ...

Page 25: ...ssary 5 Check the natural gas 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 wiring for loose conn...

Page 26: ...ting 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 filter s on diesel...

Page 27: ...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 Defective Low ...

Page 28: ...26 Section 6 Electrical Data Liquid cooled 25 kW Generators Wiring Diagram 2 5L Engine 15kW 20kW units Drawing No 0F2183 B ...

Page 29: ...27 Section 6 Electrical Data Liquid cooled 25 kW Generators Wiring Diagram 2 5L Engine 15kW 20kW units Drawing No 0F2183 B ...

Page 30: ...28 Section 6 Electrical Data Liquid cooled 25 kW Generators Electrical Schematic 2 5L Engine 15kW 20kW units Drawing No 0F2184 B ...

Page 31: ...29 Section 6 Electrical Data Liquid cooled 25 kW Generators Electrical Schematic 2 5L Engine 15kW 20kW units Drawing No 0F2184 B ...

Page 32: ...30 Section 6 Electrical Data Liquid cooled 25 kW Generators Wiring Diagram 2 5L Engine 25kW unit Drawing No 0F1286 B ...

Page 33: ...31 Section 6 Electrical Data Liquid cooled 25 kW Generators Wiring Diagram 2 5L Engine 25kW unit Drawing No 0F1286 B ...

Page 34: ...32 Section 6 Electrical Data Liquid cooled 25 kW Generators Electrical Schematic 2 5L 25kW unit Drawing No 0F1287 B ...

Page 35: ...33 Section 6 Electrical Data Liquid cooled 25 kW Generators Electrical Schematic 2 5L 25kW unit Drawing No 0F1287 B ...

Page 36: ...34 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Mounting Base Drawing No 0F0104 B ...

Page 37: ...HC M12 1 75 X 80 G8 8 16 0536210261 1 ASSY WIRE 0 12 00 17 074906 1 SCREW HHTT M6 1 0 X 20 BP 18 077483 REF BATT 12VDC 75 AH 26 NOT SHOWN 19 0F0796 3 BRACKET CONTROL PANEL SUPPORT 20 025507 3 WASHER SHAKEPROOF EXT 7 16 STL 21 060619 1 SCREW SHC M10 1 50 X 40 G12 9 22 046526 1 WASHER LOCK M10 23 022131 1 WASHER FLAT 3 8 M10 ZINC 24 021991 1 EARTH STRAP 25 038805G 1 CABLE BATT BLK 1 X 41 50 26 05033...

Page 38: ... FAR SIDE 17 LATCH DETAIL 30 31 31 32 34 32 3 45 18 39 38 40 4 7 47 DETAIL SEE LATCH 9 B 29 46 11 18 17 43 8 13 1 18 SECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT 25 4 5 33 2 25 36 4 32 39 33 4 15 48 17 22 12 4 4 10 4 42 18 17 21 35 29 11 B 21 14 19 20 10 20 37 26 28 6 44 18 41 17 9 42 40 17 18 42 23 24 37 17 4 2 PLCS TO B 39 39 18 10 ...

Page 39: ...INGE TYPE A W STUDS PIN 25 0D2023 3 GASKET CLIP ON SELF GRIPPING 84 LG 26 078115 8 WASHER SELF LOCKING DOME 27 0F2179 1 KIT SAE FOAM 2 5L QUIET SOURCE 28 0F0788 1 ROOF 2 5L FORD AL 29 0E7829B 2 AI DOOR PANEL 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0F0786 1 SUPPORT LH SIDE AL 2 5L 33 0E0072Q 2 AI INSULATION RAD SUPPORT PANEL 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E00...

Page 40: ...38 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Control Panel 15kW and 20kW Drawing No 0F2267 D ...

Page 41: ...403C 1 FUSE ATO TYPE 15 AMP BLUE 22 0E2514 1 FITTING CONDUIT STR 1 1 2 23 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 24 023897 4 WASHER FLAT 10 ZINC 25 022152 2 WASHER LOCK 10 26 051716 2 NUT HEX M5 0 8 G8 YEL CHR 27 082573 1 SWITCH ROC DPST 125V SPD 28 0E4494 1 SWITCH ROC DPDT ON OFF ON 29 0C4167 REF BLOCK TERM 20A 14 X 6 X 1100V 30 0C2699 4 SCREW PHTT 6 32 X 3 8 ZYC 31 0C2212 1 SCREW PHTT M4 0 7 X 16 ...

Page 42: ...12 16 31 39 12 2 9 12 24 25 12 15 14 8 33 24 38 12 23 6 34 35 32 21 30 41 4 11 17 42 12 12 2 20 18 43 1 27 28 5 7 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Control Panel 25kW Drawing No 0E7615 C ...

Page 43: ...YPE 5 AMP TAN 21 0E7403C 1 FUSE ATO TYPE 15 AMP BLUE 22 0E2514 1 FITTING CONDUIT STR 1 1 2 23 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 24 023897 4 WASHER FLAT 10 ZINC 25 022152 2 WASHER LOCK 10 26 051716 2 NUT HEX M5 0 8 G8 YEL CHR 27 082573 1 SWITCH ROC DPST 125V SPD 28 0E4494 1 SWITCH ROC DPDT ON OFF ON 29 0C4167 REF BLOCK TERM 20A 14 X 6 X 1100V 30 0C2699 4 SCREW PHTT 6 32 X 3 8 ZYC 31 0C2212 1 SCR...

Page 44: ...9 FOR HARNESS GROUND 5 3 22 17 68 15 19 10 38 22 31 0 HSG 20 3 47 45 20 49 1 16 39 50 34 35 65 33 57 18 37 18 20 16 38 RADIATOR CAP 62 TO 58 39 STEPPER MOTOR UNITS ONLY 17 12 A 11 67 24 23 61 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Engine Drawing No 0E9918 F ...

Page 45: ...FLEXPLATE HSB 33 0E9680 1 GASKET 2 5L FORD EXHAUST MAN 34 0E9609 1 MANIFOLD EXHAUST MACHINED ITEM PART NO QTY DESCRIPTION 35 0E9930 1 HEAT SHIELD EXHAUST MANIFOLD 36 049821 3 SCREW SHC M8 1 25 X 30 G12 9 37 0E9747 1 STARTER 12 VOLT 38 043116 5 SCREW HHC M6 1 0 X 12 G8 8 39 022473 6 WASHER FLAT 1 4 M6 ZINC 40 045772 2 NUT HEX M10 1 5 G8 YEL CHR 41 064416 2 SCREW HHC M10 1 5 X 45 G8 8 42 0F0252 1 SP...

Page 46: ...8 1 8 20 33 31 32 17 34 26 6 38 30 16 25 24 18 4 29 15 9 5 27 6 4 CARBURETOR ASSY 0E1028A I N 19 CONVERSION 35 41 OUT 2 PORT L P VAPOR 3 40 1 11 3 40 7 2 6 11 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Fuel System Drawing No 0E9980 D ...

Page 47: ... GASKET 21 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 22 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0C2454 3 SCREW TH FRM M6 1 X 16 N WA Z JS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38...

Page 48: ...46 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 Lists Liquid cooled 25 kW Generators Alternator Drawing No 0F5092 B ...

Page 49: ... 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 092980 4 SCREW PPHM M4 0 7 X 25 15 057192 4 SCREW SHC M10 1 5...

Page 50: ...2568 4 SCREW HHC M6 1 0 X 20 G8 8 14 022097 4 WASHER LOCK M6 1 4 15 022473 8 WASHER FLAT 1 4 M6 ZINC 16 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 17 039253 2 SCREW HHC M8 1 25 X 20 G8 8 18 045771 2 NUT HEX M8 1 25 G8 YEL CHR 19 0A4010 1 SCREW HHC M8 1 25 X 60 G8 8 FT 20 022145 5 WASHER FLAT 5 16 M8 ZINC 21 022131 2 WASHER FLAT 3 8 M10 ZINC 22 085917 2 WASHER LOCK 3 8 SS 23 0D2611 2 SCREW HHC 3 8 16 X 1...

Page 51: ... NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 1 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 6 7 9 10 10 5 4 RE...

Page 52: ... NO QTY DESCRIPTION 15 0E9833 1 HOSE 2 5L FORD LOWER RADIATOR 16 035461 1 BARBED STR 1 4 NPT X 3 8 17 069860C 1 HOSE OIL DRAIN ASSY 21 18 0A7275 4 FOAM 1 5 X 1 ADHESIVE BACKING 21 5 LG 19 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 20 065852 1 SPRING CLIP HOLDER 37 62 21 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 24 0C2454 6 SCREW TH FRM M6 1 X 16 N WA Z JS 25 022287 4 SCREW HHC 1 4 20 X 3 4 G5 26 077992 ...

Page 53: ...51 Section 8 Installation Diagram Liquid cooled 25 kW Generators Installation Diagram Drawing No 0F1022 A ...

Page 54: ...may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Dealer as soon as a problem occurs ...

Page 55: ...repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no char...

Page 56: ...mounts 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 collision the...