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Generac Power Systems QuietSource 004917-5 Installation And Owner's Manual

Liquid-cooled, prepackaged standby generators 27 kw ng, 30 kw lp vapor.
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Installation and
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number
004917-5
27 kW NG, 30 kW LP Vapor
This manual should
remain with the unit.
!
!
Not intended for use in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

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   Summary of Contents for Generac Power Systems QuietSource 004917-5

  • Page 1

    Installation and Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 004917-5 27 kW NG, 30 kW LP Vapor This manual should remain with the unit. Not intended for use in life-support applications. DANGER DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

  • Page 2

    INTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac Power Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten.

  • Page 3: Table Of Contents

    Section 5 — TROUBLESHOOTING ...23 Section 6 — ELECTRICAL DATA ...24 Section 7 — EXPLODED VIEWS AND PARTS LISTS ...28 Section 8 — INSTALLATION DIAGRAM ...44 Section 9 — NOTES ...45 Section 10 — WARRANTY ...Back Cover Generac ® Power Systems, Inc.

  • Page 4: Safety Rules

    If using a procedure, work method or operating technique that Generac does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the genera- tor unsafe.

  • Page 5: Electrical Hazards, Fire Hazards, Explosion Hazards

    Keep the area surrounding the generator clean and free from debris. • Generac generator sets may operate using one of sev- eral types of fuels. All fuel types are potentially FLAM- MABLE and/or EXPLOSIVE and should be handled with care.

  • Page 6: Section 1 — General Information, Generator, Transfer Switch, Automatic System Operation, Generator Ac Connection Systems

    This generator system may include a matched auto- matic transfer switch which is intended to be used in conjunction with the Generac generator. It is supplied with a NEMA 3R enclosure. The NEMA 3R enclosure is weather proof and can be used indoors or out- doors.

  • Page 7: Generator Fuel System, Engine Protective Devices

    LED (Figure 1.6 on page 6). NOTE: Figure 1.4 - Low Oil Pressure Switch HIGH COOLANT TEMPERATURE SWITCH LOW COOLANT LEVEL SWITCH Generac ® Power Systems, Inc.

  • Page 8: Unpacking, Lifting The Generator

    If the engine fails to start after all six attempts, the start attempt is stopped and the overcrank LED turned on. Generac ® Power Systems, Inc. The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 11.0 VDC for one...

  • Page 9: Specifications, Fuel Consumption, Reconfiguring The Fuel System

    Figure 1.8 — Reconfigure the Fuel System Port 1 FUEL HOSE FUEL HOSE BRASS HOSE BRASS HOSE FITTING FITTING PORT 1 PORT 2 HOUSING HOUSING PORTS PORTS NG FUEL SYSTEM Generac ® Power Systems, Inc. Port 2 PLUG LP FUEL SYSTEM...

  • Page 10: Torque Specifications, Engine Oil Recommendations, Coolant Recommendations, Before Installation, Section 2 — Installation

    The critical (essential) loads may need to be grouped together and wired into a sepa- rate “emergency” distribution panel. This generator can be installed in conjunction with an engineered Generac “GTS” type transfer switch, if SAE 5W-20 necessary. SAE 5W-20...

  • Page 11: Generator Location, Generator Mounting And Support, Basic Standby Electric System

    For more information about the installation of a standby system, order Engine-Generator Standby Electric Power Systems Installer’s Guide and Reference Manual (part #046622) from the Generac Authorized Service Dealer. 2.1.1 NFPA STANDARDS The following published standards booklets pertain- ing to standby electric systems are available form the...

  • Page 12: Emergency Circuit Isolation Method, Total Circuit Isolation Method, Grounding The Generator, Generator Ac Neutral Connections

    Figure 2.2 – Generator Grounding Lug (typical) GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field.

  • Page 13: Battery Installation

    1,161 to 1,850 feet (565m) 2.9.2 GTS-TYPE ATS If the generator is to be installed with an automatic transfer switch, such as an engineered Generac GTS- type switch, it is necessary to connect the two-wire start control system. Connect the two-wire start signal from the automatic...

  • Page 14: Preparation Before Start-up

    (oil, coolant, fuel, etc.) may result in an engine failure. 12 Generac ® Power Systems, Inc. Before starting the generator for the first time, the installer must complete the following procedures.

  • Page 15: Section 3 — Operation, Control Console Components

    USING AN ENGINEERED “GTS” TRANSFER SWITCH When required, the pre-packaged standby generator can be installed with an engineered Generac “GTS” type automatic transfer switch. In this application, the GTS is responsible for utility sensing, weekly exercising, and load transferring.

  • Page 16: Manual Transfer And Startup, Engine Governor Adjustments

    This secondary function is only available with dip switch two in the OFF position (standard ATS appli- cation). 14 Generac ® Power Systems, Inc. MANUAL TRANSFER AND START-UP To transfer electrical loads to the Standby (EMER- GENCY) power source side and start the engine man- ually, refer to the Owner’s Manual of the particular...

  • Page 17: Retransfer And Shutdown, Automatic Operation, Weekly Exercise Cycle

    LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set. Figure 3.2 - “Set Exercise” Switch FUSE BAT. CHARGER EXERCISE TIME Generac FUSE MAIN AUTO MANUAL ® Power Systems, Inc. 15...

  • Page 18: Section 4 — Maintenance, Maintenance Performed By Authorized Service Facilities, Cooling System

    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. 16 Generac ® Power Systems, Inc. OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board.

  • Page 19: Maintenance Owner/operator Can Perform

    If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an authorized Generac Service Dealer. Inspect cooling system and coolant recovery system for leaks. MAINTENANCE OWNER/ OPERATOR CAN PERFORM 4.5.1 CHECK ENGINE OIL LEVEL...

  • Page 20: Miscellaneous Maintenance

    Clean by scraping or washing using a wire brush and com- mercial solvent. Do not blast the spark plugs to clean. 18 Generac ® Power Systems, Inc. 2. Remove the spark plugs and check the condition.

  • Page 21

    PERIODIC REPLACEMENT PARTS Part Name Oil Filter Radiator Cap Air Cleaner Spark Plug Generac 525 @ 0 deg. F 600 @ 0 deg. F NOTE: Generac’s Part Number # 0E7180 # 046627 # 0C8127 # 0E7079 ® Power Systems, Inc. 19...

  • Page 22: Scheduled Maintenance

    QUIETSOURCE™ Liquid-cooled 30 kW Generators SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for Generac 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 23

    Comp. (Date- 3 months/ (Date- Initials) Break-in Initials) Level 3 Level 4 Required Task to be done Comp. Required Semi- (Date- to be done annually Initials) Annually Generac ® Power Systems, Inc. 21 Task Comp. (Date- Initials)

  • Page 24

    20. Perform a 5 minute no-load operational run of the unit looking for any post service problems. 21. Return the unit to standby setup for operation when required. 22 Generac ® Power Systems, Inc. Level 2 Task Required Task Comp.

  • Page 25: Section 5 — Troubleshooting

    2. Reconnect/close wire. 3. Replace board. 1. Reset to ON or CLOSED. 2. Reset and replace, if necessary. 3. Set to GENERATOR position. 4. Contact an Authorized Generac facility. 5. Auto-reset - Wait five minutes and attempt restart. Generac ®...

  • Page 26: Section 6 — Electrical Data

    BULKHEAD CONNECTOR 1 (ENGINE) CB1 - CIRCUIT BREAKER (OUTPUT) CB2 - CIRCUIT BREAKER (EXCITATION) D1 - DIODE [FIELD BOOST] F1 - FUSE, BAT. POWER (15A AGC TYPE) 24 Generac ® Power Systems, Inc. 225A 224A STATOR NEUTRAL LEGEND {CONT.]: F2 -...

  • Page 27

    1 1 1 HIGH COOLANT TEMP SWITCH IGNITION COIL IGNITION MODULE (ON DISTRIBUTOR) JUNCTION 1 (ON PCB) JUNCTION 2 (ON PCB) JUNCTION BLOCK (RUN POWER) LOW OIL PRESSURE SWITCH STARTER MOTOR COOLANT LEVEL SWITCH Generac ® Power Systems, Inc. 25...

  • Page 28

    CIRCUIT BREAKER (EXCITATION) D1 - DIODE [FIELD BOOST] DPE - DISPLACED PHASE EXCITATION TRANSFER SWITCH CUSTOMER CONNECTION CONNECTION 120/240V 1-PHASE 26 Generac ® Power Systems, Inc. LEGEND {CONT.]: F1 - F2 - ICT - NB - RL1 - SW1 -...

  • Page 29

    ( + ) LEGEND [CONT.]: IC - IGNITION COIL IM - IGNITION MODULE (ON DISTRIBUTOR) LOS - SWITCH LOW OIL PRESSURE SC - CONTACTOR, STARTER MOTOR SM - STARTER MOTOR WLS - SENSOR, COOLANT LEVEL Generac ® Power Systems, Inc. 27 BLACK...

  • Page 30

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Mounting Base — Drawing No. 0E6266-E 28 Generac ® Power Systems, Inc.

  • Page 31

    BATTERY POST COVER BACLK - BATTERY POST COVER RED + SCREW HHC M8-1.25 X 60 G8.8 FT NUT TOP LOCK FL M8-1.25 HOLD DOWN BATTERY HOLD DOWN BATTERY NUT HEX LOCK M8-1.25 NY INS Generac ® Power Systems, Inc. 29...

  • Page 32

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Compartment — Drawing No. 0F1141-B 30 Generac ® Power Systems, Inc.

  • Page 33

    AI ROOF PANEL 2 AI SUPPORT RH PANEL KIT INSULATION 3.0L HSB AI ROOF PANEL 1 AI DOOR PANEL AI CORNER POST PANEL 1 AI CORNER POST PANEL 2 SCREW HHC M6-1.0 X 12 G8.8 ® Generac Power Systems, Inc. 31...

  • Page 34

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7118-K 32 Generac ® Power Systems, Inc.

  • Page 35

    022158 022985 038750 0A2115 0C2454 0F6146 SHOWN) * ITEMS INCLUDED AS PART OF I/N 39 Generac QTY. DESCRIPTION DECAL AVR COVER COVER PLATE, AVR HARNESS CNTRL PNL (NOT SHOWN) SCREW PPPH HI-LO #4-24 X 3/8 SCREW HHTT M5-0.8 X 10 BP...

  • Page 36

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Engine — Drawing No. 0F6836-A 34 Generac ® Power Systems, Inc.

  • Page 37

    0F5966 022985 036261 0F6658 0F6809 * NOT SHOWN-USED TO HOLD OIL DRAIN ASSEMBLY. ** NOT SHOWN Generac QTY. DESCRIPTION WASHER SHAKEPROOF INT 1/2 NUT HEX M12-1.75 G8 YEL CHR COIL IGNITION 3.0L FORD BRACKET IGN COIL 3.0L FORD WASHER LOCK M5 SCREW PPHM M5-0.8 X 12 ZNC...

  • Page 38

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Radiator — Drawing No. 0F6848 36 Generac ® Power Systems, Inc.

  • Page 39

    HOSE RADIATOR ENGINE SUPPORT TUBE RADIATOR CLAMP VINYL 1.31 X .281 Z SCREW HHC M6-1.0 X 25 G8.8 WASHER LOCK M6-1/4 NUT HEX M6 X 1.0 G8 YEL CHR SCREW HHC M6-1.0 X 16 G8.8 Generac ® Power Systems, Inc. 37...

  • Page 40

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Fuel System — Drawing No. 0F6849 38 Generac ® Power Systems, Inc.

  • Page 41

    SCREW HHC M6-1.0 X 16 G8.8 WASHER LOCK M6-1/4 WASHER FLAT 1/4-M6 ZINC ASSY THROTTLE 27MM VENTURI HOLDER W/32MM ACTUATOR O-RING 47.625 ID X 2.38 WIDTH VENTURI, 27 ID THROTTLE W/CHOK O-RING 45.63 ID X 2.62 WIDTH Generac ® Power Systems, Inc. 39...

  • Page 42

    Section 7 - Exploded Views and Parts QUIETSOURCE™ Liquid-cooled 30 kW Generators Alternator — Drawing No. 0F5092-A 40 Generac ® Power Systems, Inc.

  • Page 43

    SCREW HHC M16-2.0 X 45 G8.8 WASHER LOCK #8-M4 WASHER FLAT #8 ZINC CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER) CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD) BALL BEARING-45 MM SLIP RING -MACHINED- Generac ® Power Systems, Inc. 41...

  • Page 44

    SCREW HHC M8-1.25 X 55 G8.8 0E5914 BRACKET MUFFLER 3.0L FORD 0E8726 STRAP MUFFLER 0E0170 EXHAUST BLANKET 750MM 036797 BOLT U 5/16-18 X 2.25 080762 BOLT U 3/8-16 X 2.62 42 Generac ® Power Systems, Inc. COMPARTMENT MANIFOLD ITEM MANIFOLD PART NO. QTY. DESCRIPTION 0E8816 EXHAUST FLANGE 2"...

  • Page 45

    ADAPTER CARBURETOR W/PVC CONN WASHER LOCK M5 SCREW HHC M5-0.8 X 16 G8.8 ELEMENT AIR CLEANER NUT HEX 1/4-20 STEEL STUD TH 1/4-20 X 4-1/2 G2 ZNC COVER - AIR CLEANER NUT WING 1/4-20 NYLK Generac ® Power Systems, Inc. 43...

  • Page 46: Section 8 — Installation Diagram

    Section 8 — Installation Diagram QUIETSOURCE™ Liquid-cooled 30 kW Generators Installation Diagram — Drawing No. 0E8696 44 Generac ® Power Systems, Inc.

  • Page 47: Section 9 — Notes

    Section 9 — Notes QUIETSOURCE™ Liquid-cooled 30 kW Generators Generac ® Power Systems, Inc. 45...

  • Page 48

    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.

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