Owner's Manual 8 - 20kW Air-cooled, Automatic Standby Generators NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY! This manual must be used in conjunction with the Installation Manual before, and during installation! www.generac.
Table of Contents Introduction .............................................. 1 Read This Manual Thoroughly ................................................1 Operation ................................................ 17 3.1 Control Panel Interface .................................................17 3.2 Automatic Transfer Operation........................................18 Safety Rules ............................................. 1 3.3 Sequence of Automatic Operation .................................
Safety Rules This symbol points out potential electrical shock hazard. Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather, metal enclosure and is intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
Safety Rules SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the units installation site. Safety should be stressed to all operators and potential operators of this equipment. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owners Manual and with the unit.
Safety Rules • The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system. • After installing this home standby electrical system, the generator may crank and start at any time without warning. When this occurs, load circuits are transferred to the STANDBY (generator) power source.
General Information Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. After unpacking, carefully inspect the contents for damage. • This standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure that is intended for outdoor installation only.
General Information If during the installation of the home standby system the decision is made to provide back up power to a bedroom branch circuit, then the circuit breaker in the transfer switch should be replaced with an Arc Fault Circuit Interrupter. It is most important that breakers only be switched like for like. For instance, if replacing a 15A breaker, it MUST be replaced with a 15A AFCI breaker. Likewise, a 20A breaker MUST be replaced with a 20A AFCI.
General Information Figure 1.1 8kW, Single Cylinder, GH-410 Engine (door removed) 3MP (MTWXMGO (EXE 0EFIP WII WEQTPI Figure 1.2 10kW, V-twin, GT-530 Engine (door removed) 'MVGYMX &VIEOIV 'SRXVSP 4ERIP 3MP (MTWXMGO (EXE 0EFIP WII WEQTPI 'SRXVSP 4ERIP 'MVGYMX &VIEOIV )\LEYWX )RGPSWYVI %MV *MPXIV )\LEYWX )RGPSWYVI %MV *MPXIV *YIP -RPIX FEGO *YIP -RPIX FEGO *YIP 6IKYPEXSV 'SQTSWMXI &EWI 3MP *MPXIV &EXXIV] 'SQTEVXQIRX 'SQTSWMXI &EWI Figure 1.
General Information Model 8kW 10kW 13kW 14kW Rated Voltage 16kW 17kW 20kW 240 Rated Maximum Load Current (Amps) at 240 Volts (LP)* 33.3 41.6 54.1 58.3 66.6 70.8 83.
General Information The "Ready to Run" on the display is ready when all of the following conditions are true: 1. 2. 3. The AUTO/OFF/MANUAL switch is set to the AUTO position. The utility voltage being supplied to the unit is being sensed by the PCB. If the utility sense voltage is not connected to the unit or if it is below approximately 150-160 volts AC, then the system will display the message "No Utility Present".
General Information To reconfigure the fuel system from NG to LP, follow these steps: NOTE: To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.4): NOTE: The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to 0.43 psi) to the fuel inlet of the generator MUST BE SUPPLIED. 1. 2. 3. 4. 5. 6. 7. 8. Turn off the main gas supply (if connected). Open the roof and remove the door.
General Information 3. 4. Close the roof. Reverse the procedure to convert back to natural gas. Figure 1.7 - 13, 14, 16, 17, & 20kW, GT-990/GT-999 (Airbox Cover Removed) *YIP 7IPIGXMSR 0IZIV -R 4SWMXMSR JSV 2EXYVEP +EW *YIP Figure 1.8 - 13, 14, 16, 17, & 20kW, GT-990/GT-999 (Airbox Cover Removed) *YIP 7IPIGXMSR 0IZIV 3YX 4SWMXMSR JSV 0MUYMH 4VSTERI :ETSV *YIP The fuel system on this generator may be influenced by operation at higher altitudes.
General Information Allow sufficient room on all sides of the generator for maintenance and servicing. This unit must be installed in accordance with current applicable NFPA 37 and NFPA 70 standards; as well as any other federal, state and local codes for minimum distances from other structures. DO NOT install under wooden decks or structures unless there is at least five (5) feet of clearance above the generator, three (3) feet of clearance on sides and front, and 18 inches of clearance at back of unit.
General Information Figure 1.
General Information If the AUTO/OFF/MANUAL switch is not set to its OFF position, the generator can crank and start as soon as the battery cables are connected. If the utility power supply is not turned off, sparking can occur at the battery posts and cause an explosion. See the Specifications section for correct battery size and rating. Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it.
Post Installation Start-up and Adjustments Be sure the utility power supply is turned off and the 7.5A fuse is removed from the generator control panel, or sparking may occur at the battery posts as the cables are attached and cause an explosion. Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
Post Installation Start-up and Adjustments CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Escape If the wrong language is chosen, it can be changed later using the “edit” menu. Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER, your generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed.
Post Installation Start-up and Adjustments 6. 7. 8. 9. 10. 11. 12. 13. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-to-neutral voltage should be 120 volts AC. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer switch. On the generator panel, set the Auto/Off/ Manual switch to MANUAL.
Operation Interconnect System Self Test Feature (follow the on-screen prompts) 1. 2. 3. With the switch set to AUTO, the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove the fuses before working on or around the generator or transfer switch.
Operation The LCD display is organized as detailed below: • The “Home” page, this page is the default page which will be displayed if no keys are pressed for 30 seconds. This page normally shows the current Status message and the current date and time. The highest priority active Alarm and/or Warning will be automatically posted on this page as well as flashing the backlight when such an event is detected. In the case of multiple Alarms or Warnings, only the first message will be displayed.
Operation The transfer of load when the generator is running is dependent upon the operating mode as follows: 1. Manual – Will not transfer to generator if utility is present. – Will transfer to generator if utility fails (below 65% of nominal for 10 consecutive seconds. – Will transfer back when utility returns for 15 consecutive seconds. The engine will continue to run until removed from the Manual mode. 2. – – – – – – – 3. – – Auto Will start and run if Utility fails for 10 consecutive seconds.
Operation 5. 6. 7. Use the manual transfer handle inside the transfer switch to move the main contacts back to their UTILITY position, i.e., loads connected to the utility power source (Figure 3.2). Turn ON the utility power supply to the transfer switch using the means provided. Set the system to automatic operation as outlined in Automatic Transfer Operation section. Figure 3.4 Open Side Compartment : +*'- 3YXPIX %QT 3YXPIX &VIEOIV Local codes may require this compartment to be locked.
Operation Figure 3.5 Low Oil Pressure and High Temperature Switches 0S[ 3MP 7[MXGL ,MKL 8IQT 7[MXGL If the generator voltage rises above 110% of rating for greater than three (3) seconds, an alarm will be issued and the unit will shut down. If the generator voltage rises above 130% of rating for greater than 0.2 seconds, an alarm will be issued and the unit will shut down. Clear the alarm by setting the AUTO/OFF/MANUAL switch to the OFF position.
Maintenance NOTE: Since most maintenance alerts will occur at the same time (most have two (2) year intervals), only one will appear on the display at any one time. Once the first alert is cleared, the next active alert will be displayed. 4. 5. Turn on the Main Circuit Breaker. Turn on the Outlet Breaker if necessary. Figure 3.7 8 - 20kW Generator Control Panel 1%-2 *97) %14 To safely stop and start a loaded generator follow these steps. 1.
Maintenance 6. 7. For oil capacities, see the Specifications section. For engine oil recommendations, see the Engine Oil Recommendations section. When power outages necessitate running the generator for extended periods of time, the oil level should be checked daily. To check the engine oil level, proceed as follows (Figures 4.1, 4.2 and 4.3): 1. 2. 3. 4. 5. If the generator is running during a utility outage, first turn OFF all associated loads running in the residence.
Maintenance Figure 4.4 Oil Drain Hose and Filter 0S[ 3MP 7[MXGL 7% ) ,MKL 8IQT 7[MXGL ; 7] RXLI XMG ; 3MP *MPXIV 3MP (VEMR ,SWI Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure. To change the oil, proceed as follows: 1. Start the engine by moving the AUTO/OFF/MANUAL switch to MANUAL and run until it is thoroughly warmed up. Then shut OFF the engine by moving the switch to the OFF position. 2.
Maintenance Figure 4.7 8kW Engine Air Cleaner Location See "The Generator" section for the location of the air cleaner. Use the following procedure (Figure 4.6): 1. 2. 3. 4. 5. 6. 7. Lift the roof and remove the door. Turn the worm gear clamp screw counterclockwise to loosen. Pull the old filter off the divider panel hub. Wipe away dust or debris from the panel hub. Install the new air cleaner onto the hub. Turn the worm gear clamp screw clockwise to tighten. Replace the door and close the roof securely.
Maintenance The battery should be inspected per the "Service Schedule" section. The following procedure should be followed for inspection: 1. • Discharge static electricity from body before touching the battery by first touching a grounded metal surface. Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.
Maintenance Figure 4.10 Cooling Vent Locations When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. • Install new valve cover gasket. • Re-attach the valve cover. NOTE: Start all four screws before tightening or it will not be possible to get all the screws in place.
Maintenance To return the unit to service after storage, proceed as follows: 1. Verify that utility power is turned off and that the AUTO/OFF/ MANUAL switch is set to OFF. 2. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see the Engine Oil Recommendations section). If necessary, drain and refill with the proper oil. 3. Check the state of the battery.
Maintenance ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed. W = Weekly Inspect Change Clean M = Monthly Y = Yearly FUEL Fuel lines and connections* X M X M or 24 hours of continuous operation. LUBRICATION Oil level Oil X 2Y or 200 hours of operation.** Oil filter X 2Y or 200 hours of operation.
Troubleshooting Problem The engine will not crank. Cause Correction 1. Fuse blown. 1. 2. 2. 3. 4. 5. Loose, corroded or defective battery cables. Defective starter contactor. (8 kW) Defective starter motor. Dead Battery. 3. 4. 5. The engine cranks but 1. Out of fuel, or low fuel pressure. 1. will not start. 2. 3. Defective fuel solenoid (FS). Open #14 wire from engine control board. Fouled spark plug(s). Valve lash out of adjustment. Choke not operating. 2. 3. Replenish fuel.
Appendix To get to the MENU, use the "Esc" key from any page. It may need to be pressed many times before getting to the menu page. The currently selected menu is displayed as a flashing word. Navigate to the menu required by using the +/- keys. When the menu required is flashing, press the ENTER key. Depending on the menu selected, there may be a list of choices presented. Use the same navigation method to select the the desired screen (refer to the Menu System diagram).
Appendix 32
Drawing No.
Installation Diagrams 34 Drawing No.
Drawing No.
Installation Diagrams 36 Drawing No.
Drawing No.
Warranty U.S. EPA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty (ECS Warranty) on your new 2011 and later equipment. New equipment that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-smog standards for the federal government.
Warranty EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for equipment using small spark-ignited engines: (a) Applicability: This warranty shall apply to equipment that uses small off-road engines.
Warranty United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators) Warranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine.
Warranty United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators) Purchaser’s/Owner’s Recordkeeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc.
Part No. 0J7632 Revision B (03/13/12) Printed in U.S.A.
