Generac Power Systems QuietSource 005028-0 Owner's Manual
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Generac Power Systems QuietSource 005028-0 Owner's Manual

Generac Power Systems QuietSource 005028-0 Owner's Manual

15kw/20kw/25kw liquid-cooled, prepackaged standby generators
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number 005030-0 (15kW)
005028-0 (20kW)
005031-0 (25kW)
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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  • Page 1 Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 005030-0 (15kW) 005028-0 (20kW) 005031-0 (25kW) This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 2: Introduction

    DATA LABEL affixed to the unit. AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER, please call this number: 1-800-333-1322 Locate us on the web at:...

  • Page 3: Table Of Contents

    INTRODUCTION ...IFC Read this Manual Thoroughly...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Service Dealer Location ...IFC SAFETY RULES ...2 Standards Index...3 Section 1 — GENERAL INFORMATION ...4 Generator ...4 Transfer Switch ...4 ATS Mode (Automatic Operation) ...4 Engineered Transfer Switch (2-wire Start GTS Mode) ...4 Generator AC Connection Systems...4...

  • Page 4: Safety Rules

    Important Safety Instructions Liquid-cooled 15, 20 and 25 kW Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. SAVE THESE INSTRUCTIONS –...

  • Page 5: Standards Index

    ELECTRICAL HAZARDS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous volt- ages to the transfer switch as well as the standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as the transfer switch, if applicable.

  • Page 6: Section 1 - General Information

    These models are available. They are rated as follows: Model 005031-0: Provides 25,000 watts (25 kW) of single- phase power. Model 005028-0: Provides 20,000 watts (20 kW) of single- phase power. Model 005030-0: Provides 15,000 watts (15 kW) of single- phase power.

  • Page 7: Main Circuit Breaker

    Figure 1.1 - Generator AC Connection System (WHITE) NEUTRAL MAIN CIRCUIT BREAKER The generator’s main circuit breaker is included with the unit as shipped from the factory. The breaker for each unit is described in Figure 1.2. GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system.

  • Page 8: Unpacking

    Section 1 — General Information Liquid-cooled 15, 20 and 25 kW Generators Figure 1.5- High Coolant Temperature Switch 1.8.3 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown.

  • Page 9: Specifications

    Direct excited brush type Direct excited brush type 4 Wire Class F Class H NOTE: SYSTEM FOR LP VAPOR NOTE: Single-phase Single-phase 005028-0 005030-0 120/240 120/240 1800 Direct excited brush type 4 Wire 4 Wire Class F Class F Class H...

  • Page 10: Engine Oil Recommendations

    Section 1 — General Information Liquid-cooled 15, 20 and 25 kW Generators 2. Remove the carburetor fuel hose from the outlet port (Port 1) of the demand regulator (Figure 1.8). 3. Remove the brass hose fitting from the outlet port (Port 1) of the demand regulator.

  • Page 11: Section 2 - Installation

    STANDBY GENERATOR INSTALLATION DANGER Connecting this generator to an electrical sys- tem normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distri- bution system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility...

  • Page 12: Basic Standby Electric System

    Figure 2.1 – Basic Standby Electric System NOTE: The manufacturer recommends the use of a Generac Power Systems transfer switch in con- junction with this generator. EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator.

  • Page 13: Generator Ac Neutral Connections

    GENERATOR AC NEUTRAL CONNECTIONS The manufacturer uses an UNGROUNDED AC neu- tral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the exces- sive current opens the load circuit breaker or col- lapses the generator field.

  • Page 14: Engineered Transfer Switch

    Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators 2.10 ENGINEERED TRANSFER SWITCH (2-WIRE START GTS MODE) When required, the pre-packaged standby generator can be installed with an engineered W Type transfer switch which controls utility voltage sensing, weekly exercising and load transferring.

  • Page 15: Battery Installation

    Transfer Switch terminals N1 and N2 (also called Utility 1 and Utility 2) are the input utility AC power connections to the Transfer Switch. Transfer Switch terminals T1 and T2 (also called Load 1 and Load 2) are the transfer switch AC output power terminals that go to the load circuit distribution panel.

  • Page 16: Preparation Before Start-Up

    Section 2 — Installation Liquid-cooled 15, 20 and 25 kW Generators The recommended battery is Group 26, 12VDC, 550 CCA/75 AH minimum. All batteries must be at 100 percent state-of-charge before they are installed on the generator. When using maintenance-free batteries, it is not nec- essary to check the specific gravity or electrolyte level.

  • Page 17: Section 3 - Operation

    CONTROL CONSOLE COMPONENTS The components of a home standby generator control console (Figure 3.1) are as follows: Figure 3.1 - Generator Control Console OVER CRANK OVER SPEED LOW COOL. LEVEL HI COOL. TEMP. RISK OF ELECTRICAL SHOCK. DO NOT REMOVE COVER. NO USER SERVICEABLE PARTS INSIDE.

  • Page 18: Engine Governor Gain Adjustments

    Section 3 - Operation Liquid-cooled 15, 20 and 25 kW Generators Condition System Ready (Green) Generator Switch is in the OFF Mode. System Ready for Automatic Start Generator Switch is in the MANUAL Mode Weekly Exerciser is not set Battery Voltage <12.2V for >1 minute Battery Voltage <6V Unit Shutdown due...

  • Page 19: Manual Retransfer And Shutdown

    6. Reduce 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.

  • Page 20: Control Board Dip Switch Settings

    Section 3 - Operation Liquid-cooled 15, 20 and 25 kW Generators CONTROL BOARD DIP SWITCH SETTINGS Located on the control board is an eight position DIP switch (see Figure 3.2). The eight different switches, are used to configure the control board for the spe- cific engine and governor being used and are pre-set at the factory.

  • Page 21: Section 4 - Maintenance

    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.

  • Page 22: Cylinder Head Procedure

    Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators 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: •...

  • Page 23: Maintenance Owner/Operator Can Perform

    4.7.2 BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa- tors 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.

  • Page 24: Miscellaneous Maintenance

    Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators 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).
  • Page 25 4.9.3 BATTERY MAINTENANCE 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.

  • Page 26: Scheduled Maintenance

    Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators 4.10 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 27 Maintenance Level 1 Tasks Recom- mended to be done monthly 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level.
  • Page 28 Section 4 — Maintenance Liquid-cooled 15, 20 and 25 kW Generators Maintenance Level 1 Tasks Recom- mended to be done monthly 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating...

  • Page 29: Section 5 - Troubleshooting

    TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. Engine cranks but won't start 1.

  • Page 30: Section 6 - Notes

    Section 6 — Notes Liquid-cooled 15, 20 and 25 kW Generators...
  • Page 31 Section 6 — Notes Liquid-cooled 15, 20 and 25 kW Generators...

  • Page 32: Section 7 - Electrical Data

    Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B...
  • Page 33 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B...
  • Page 34 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B...
  • Page 35 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B...
  • Page 36 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B...
  • Page 37 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B...
  • Page 38 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B...
  • Page 39 Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B...

  • Page 40: Section 8 - Exploded Views And Parts Lists

    Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Mounting Base — Drawing No. 0F0104-B...
  • Page 41 ITEM PART NO. QTY. 0F1705 0E8834 0E9911 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0F0796 025507 060619 046526 022131 021991 038805G 050331 050331A 038804J 045771 022129 027482 075763 0E9748A 0F0795 0C2454 065852 045764 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators...
  • Page 42 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Enclosure — Drawing No. 0F1645-H...
  • Page 43 ITEM PART NO. QTY. 0F0783 0F0781 0F0780 0C2454 0F0779 0E0072AB 0E0072AC 0E0072AD 0E5912 0F0787 089961 0A2115 0E0072AE 0F0165A 0F0165 022097 022473 0E7570 0E7571 070015 0E7662 0F0164A 0F0164 0D2023 078115 0F2179 0F0788 0E7829B 0D3037A 0C7781 0F0786 0E0072Q 0D3037 0E0072Y 0E0072AF 0E0072AA 0F0782 026850 0912970064...
  • Page 44 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Control Panel (15kW and 20kW) — Drawing No. 0F2267-D...
  • Page 45 ITEM PART NO. QTY. 0F0790 0F0789 0F0791 0E9704 067680 0E6875A 0C3910 048468 0D5070A 057073 040213 0C2265 029673 0F0793 0E7890 0D5541* 0D5544** 0F1264 0F1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 REF. 0C2699 0C2212 047411 022097 022473 0E7358 064733 0F0798A...
  • Page 46 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Control Panel (25kW) — Drawing No. 0E7615-C...
  • Page 47 ITEM PART NO. QTY. 0F0790 0F0789 0F0791 0E9704 067680 0E6875A 0C3910 054450 0D5070A 057073 040213 0C2265 029673 0F0793 0E7890 0A2077 0F1264 0F1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 REF. 0C2699 0C2212 047411 022097 022473 0E7358 0F0798 0E6881 0C1127...
  • Page 48 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Engine — Drawing No. 0E9918-F...
  • Page 49 ITEM PART NO. QTY. DESCRIPTION 0E9909 ENGINE 2.5L FORD 0E9739 PULLEY, 2.5L FORD WATER PUMP 049814 SCREW HHC M10-1.5 X 25 G8.8 0F0001 CLUTCH, COOLING FAN 2.5L FORD 0D3488B SERPENTINE BELT - 40.85" LENGTH 0A8584 SWITCH,OIL PRESSURE,10PSI,2POL 0E0561 ASSY WATER LEVEL SENSOR C/E 0A6751 SW-TMP 245DEG 3/8NPT 035579...
  • Page 50 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Fuel System — Drawing No. 0E9980-D...
  • Page 51 ITEM PART NO. QTY. 0E8456 075580 0E9967 039253 022145 022129 045771 0F1570 0A6344 0F3994 REF. 0E1056 0F0397 0A5547 048031C 0D1509 16 * 0E0591 059402 037561 0E1028A 059401 21 * 091526 22 * 049226 026307 062522 022127 022259 050279 0A6125 0C2454 0E1104 0E0668 0E0590A...
  • Page 52 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Alternator — Drawing No. 0E8660-C...
  • Page 53 ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A 0F1660A 0F1658A 0F1656A 0E5094A 0E7412A 0E5706 0E5048 0E5048A 0E5048B 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 0C3993 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 8 - Exploded Views and Parts Lists...
  • Page 54 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Muffler — Drawing No. 0F2930-C ITEM PART NO. QTY. DESCRIPTION 0F2912 PIPE MUFFLER OUT 0F2869 PIPE EXHAUST 2.5L FORD 0F2823 MUFFLER 2.5L FORD 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH 022129...
  • Page 55 TO "A" CARBURETOR ARM (REF.) ITEM PART NO. QTY. 098290 098941A 0F0454 098942A 098225 043146 022097 0E7358 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Stepper Motor —...
  • Page 56 Section 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW Generators Radiator — Drawing No. 0E9965-F ITEM PART NO. QTY. DESCRIPTION 0E9769 SUPPORT RADIATOR 2.5L FORD 0F0779 SUPPORT RADIATOR 2.5L AL 0E9769A SUPPORT RADIATOR 2.5L FORD 0E9837 RADIATOR 2.5L FORD 0F0123...

  • Page 57: Section 9 - Installation Diagram

    Section 9 — Installation Diagram Liquid-cooled 15, 20 and 25 kW Generators Installation Diagram — Drawing No. 0F1022-A...

  • Page 58: Section 10 - Warranty

    Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
  • Page 59 Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market”...
  • Page 60 For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty Service Dealer, is found to be defective.

This manual is also suitable for:

005030-0, 005028-0, 005031-0Quietsource 005030-0Quietsource 005031-0

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