Generac Power Systems QuietSource 005031-2 Owner's Manual
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Generac Power Systems QuietSource 005031-2 Owner's Manual

Generac Power Systems QuietSource 005031-2 Owner's Manual

25kw liquid-cooled, prepackaged standby generators
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number: 005031-2 (25kW)
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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Summary of Contents for Generac Power Systems QuietSource 005031-2

  • Page 1 Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number: 005031-2 (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 AUTHORIZED SERVICE DEALER, please call this number: 1-800-333-1322 Locate us on the web at: www.generac.com...

  • 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 Generator AC Connection Systems ...4...

  • Page 4: General Hazards

    Important Safety Instructions Liquid-cooled 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. ...

  • Page 5: Fire Hazards

    • Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. • If personnel must stand on metal or concrete while install- ing, operating, servicing, adjusting or repairing this equip- ment, place insulative mats over a dry wooden platform.

  • Page 6: Section 1 - General Information Liquid-Cooled 25 Kw Generators

    120 and/or 240VAC, single-phase loads. This model is available and rated as follows: Model 005031-2: Provides 25,000 watts (25 kW) of single-phase power.  If this generator is used to power electrical load...

  • Page 7: Generator Fuel System

    GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is pre- ferred, refer to Section 1.12, Reconfiguring the Fuel System for LP Vapor. Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

  • Page 8: Unpacking

    Section 1 — General Information Liquid-cooled 25 kW Generators Figure 1.6 - Low Coolant Level Sensor 1.7.4 OVERSPEED SHUTDOWN Should AC frequency exceed about 72 Hz, cir- cuit board action will automatically shutdown the engine. 1.7.5 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking pro- cess when attempting to start the engine.

  • Page 9: Fuel Consumption

    4. Remove pipe plug from Port 2. 5. Install brass hose fitting into Port 2. Single-phase 6. Install pipe plug into Port 1. 005031-2 7. Connect carburetor gas hose to brass fitting. 8. Tighten all clamps and plugs. 120/240 9. Make sure fuel supply is of the proper pressure...

  • Page 10: Section 2 - Installation Liquid-Cooled 25 Kw Generators

    Section 2 — Installation Liquid-cooled 25 kW Generators  Any attempt to crank or start the engine before it has been properly serviced with the recom- mended oil may result in an engine failure. 1.14 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti-freeze and half deionized water.

  • Page 11: Generator Location

    Figure 2.1 – Basic Standby Electric System The manufacturer recommends the use of a Generac Power Systems transfer switch in con- junction with this generator. NOTE:...

  • Page 12: Emergency Circuit Isolation Method

    Section 2 — Installation Liquid-cooled 25 kW Generators EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capac- ity of the generator. If the generator is powering only critical loads, within its wattage/amperage capac- ity, during utility power outages, consider using the emergency circuit isolation method.

  • Page 13: Battery Installation

    • The control board WILL monitor all engine condi- tions and shut down on all the faults listed in this document. Pos2 OFF — ATS Application • The control board will perform all of the automatic features listed in this document. •...

  • Page 14: Section 3 - Operation Liquid-Cooled 25 Kw Generators

    Section 3 - Operation Liquid-cooled 25 kW Generators When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the inter- vals specified in Section 4, “Maintenance.” A nega- tive ground system is used. Battery connections are shown on the wiring diagrams.

  • Page 15: Control Console Components

    • After the engine starts and when the generator AC output voltage and frequency have reached a pre-set value, transfer switch circuits signal the transfer switch main contacts to actuate to the “Standby” power source side. Generator AC output then powers load circuits. •...

  • Page 16: Set Exercise Time Switch

    Section 3 - Operation Liquid-cooled 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 <12V for >1 minute Battery Voltage <6V Unit Shutdown due to Low Oil Pressure...

  • Page 17: Manual Transfer And Startup

    This secondary function is only available with DIP switch two in the OFF position (ATS - automatic transfer switch application). MANUAL TRANSFER AND START-UP transfer electrical loads (EMERGENCY) power source side and start the engine manually, refer to the Owner’s Manual of the particular transfer switch.

  • Page 18: Automatic Operation

    Section 3 - Operation Liquid-cooled 25 kW Generators AUTOMATIC OPERATION To set the system for fully automatic operation, pro- ceed as follows: • Check that load circuits are connected to the utility power supply. • Set the AUTO/OFF/MANUAL switch to its AUTO position.

  • Page 19: Voltage Regulator Adjustment

    Switch Position 8 — Selects whether the control is in the Normal Mode of operation or Test Mode. In the Normal Mode of operation, pre-determined governor gains are used and the gain trimpots on the control board (Gain, Stability, and Differential) are not active and have no effect on the gains.

  • Page 20: Exhaust Manifold Procedure

    Section 4 — Maintenance Liquid-cooled 25 kW Generators FIRST 100 OPERATING HOURS 1. Change engine oil and oil filter. After initial change, service engine oil and filter at 150 operat- ing hours or six months, whichever comes first. 2. Retorque cylinder head (see torque specs). 3.

  • Page 21: Overload Protection For Engine Dc Electrical System

     The exhaust system parts from this product get extremely hot and remains 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.

  • Page 22: Inspect Exhaust System

    Section 4 — Maintenance Liquid-cooled 25 kW Generators 4.8.7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage. 4.8.8 CHECK FAN BELT •...

  • Page 23: Miscellaneous Maintenance

    MISCELLANEOUS MAINTENANCE 4.9.1 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 effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt.

  • Page 24: Scheduled Maintenance

    Section 4 — Maintenance Liquid-cooled 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 25 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 26 Section 4 — Maintenance Liquid-cooled 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 27: Troubleshooting Points

    TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won’t crank. 1. 15 amp fuse blown. Loose or corroded or defective battery cables. Defective starter contactor. Defective starter motor. Dead or Defective Battery. 5 amp fuse blown. Engine cranks but won't start 1. Out of fuel. Fuel solenoid (FS) is defective Open Wire #14A from Engine Control circuit board.

  • Page 28: Section 6 - Electrical Data Liquid-Cooled 25 Kw Generators Wiring Diagram - 2.5L Engine (15Kw & 20Kw Units) -Drawing No. 0F2183-B

    Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B...
  • Page 29 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2183-B...
  • Page 30 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B...
  • Page 31 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F2184-B...
  • Page 32 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B...
  • Page 33 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1286-B...
  • Page 34 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B...
  • Page 35 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1287-B...

  • Page 36: Section 7 - Exploded Views And Parts Lists

    Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Mounting Base — Drawing No. 0F0104-B...
  • Page 37 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 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators...
  • Page 38 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Enclosure — Drawing No. 0F1645-H...

  • Page 39: Section 7 - Exploded Views And Parts Lists

    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 40 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Control Panel (15kW and 20kW) — Drawing No. 0F2267-D...
  • Page 41 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 42 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Control Panel (25kW) — Drawing No. 0E7615-C...
  • Page 43 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 44 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Engine — Drawing No. 0E9918-F...
  • Page 45 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 46 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Fuel System — Drawing No. 0E9980-D...
  • Page 47 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 48 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Alternator — Drawing No. 0F5092-B...
  • Page 49 ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048B 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 092980 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 7 - Exploded Views and Parts Lists...
  • Page 50 Section 7 - Exploded Views and Parts Lists Liquid-cooled 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 51 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 7 - Exploded Views and Parts Lists Stepper Motor — Drawing No. 0E9979-C "A"...
  • Page 52 Section 7 - Exploded Views and Parts Lists Liquid-cooled 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 VENTURI 16”...

  • Page 53: Section 8 - Installation Diagram

    Section 8 — Installation Diagram Liquid-cooled 25 kW Generators Installation Diagram — Drawing No. 0F1022-A...

  • Page 54: Section 9 - Warranty Liquid-Cooled 25 Kw Generators

    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 55: Emission Control System Warranty

    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 56 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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