Installation Guidelines 60 Hz Air-Cooled Generators 9 kW to 22 kW 000918 WARNING This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury. (000209a) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) Para español, visita: http://www.generac.com/service-support/product-support-lookup Pour le français, visiter : http://www.generac.
Use this page to record important information about your generator set. Model: Serial: Prod Date Week: Volts: LPV Amps: NG Amps: Hz: Phase: Controller P/N: Record the information found on your unit data label on this page. For the location of the unit data label, see your owner’s manual. The unit has a label plate affixed to the inside partition, to the left of the control panel console.
Table of Contents Section 1: Safety Rules & General Information Section 5: Fuel Conversion / Gas Connections Introduction ..........................................................1 Fuel Requirements and Recommendations ... 17 Read This Manual Thoroughly ....................................1 Fuel Conversion ................................................ 17 How to Obtain Service .................................................1 Safety Rules .........................................................
Table of Contents Generator Tests Under Load ............................34 Checking Automatic Operation ........................35 Installation Summary ........................................35 Shutting Generator Down While Under Load ..35 Section 8: Troubleshooting System Diagnosis ..............................................37 Section 9: Quick Reference Guide System Diagnosis ..............................................
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction CAUTION 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. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Safety Rules & General Information General Hazards WARNING DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190) DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000191) WARNING Moving Parts. Do not wear jewelry when starting or operating this product.
Safety Rules & General Information Exhaust Hazards DANGER DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) DANGER WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator.
Safety Rules & General Information Fire Hazards Explosion Hazards DANGER WARNING Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury. (000217) (000192) DANGER WARNING Fire and explosion. Installation must comply with all local, state, and national electrical building codes. Noncompliance could result in unsafe operation, equipment damage, death or serious injury.
Safety Rules & General Information General Rules • Fully comply with all relevant NEC, NFPA, and DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190) DANGER Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.
Safety Rules & General Information 7. NFPA 68: Standard On Explosion Protection By Deflagration Venting * 8. NFPA 70E: Standard For Electrical Safety In The Workplace * 9. NFPA 110: Standard for Emergency and Standby Power Systems * 10. NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances * 11. NFPA 220: Standard on Types of Building Construction * 12. NFPA 5000: Building Code * 13. International Building Code ** 14. Agricultural Wiring Handbook *** 15.
Unpacking and Inspection Section 2: Unpacking and Inspection General NOTE: Carefully inspect the contents for damage after unpacking. It is advised to unpack and inspect the unit immediately upon delivery to detect any damage that may have occurred in transit. Any claims for shipping damage need to be filed as soon as possible with the freight carrier. This is especially important if the generator will not be installed for a period of time.
Unpacking and Inspection NOTE: The enclosed keys provided with this unit are intended for service personnel use only. 3. Two locks secure the lid; one on each side (A in Figure 2-4). Press down on the lid above the side lock, and unlock the latch to properly open the lid. 4. Repeat for the other side. The lid may appear stuck if pressure is not applied from the top. NOTE: Always verify that the side locks are unlocked before attempting to lift the lid. 5.
Unpacking and Inspection Intake Side Panel Removal 3. Lift the intake panel up and away from the generator. See Figure 2-5. The intake side panel (A) must be removed to access the battery compartment, fuel regulator, and sediment trap. NOTE: Always lift the intake side panel straight up before pulling away from enclosure. Do not pull the panel away from the enclosure before lifting up (D). 1. Raise the lid and remove the front panel. 2.
Unpacking and Inspection Generator Main Line Circuit Breaker Parts Shipped Loose A This is a 2-pole circuit breaker (generator disconnect) rated according to relevant specifications. See “A” in Figure 2-8. E B C D 001803 B A 001810 Figure 2-8. Generator Main Line Circuit Breaker The breaker can be locked in the OFF (OPEN) position for security during maintenance or transfer switch service.
Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection D 5 ft (1.52 m) B 3 ft (0.91 m) C E 5 ft (1.52 m) 3 ft (0.91 m) A B 3 ft (0.91 m) B F 001751 G D 001789 Figure 3-1. Installation Clearances ID Description Comments A Top of generator — B Front and end clearance Minimum clear distances cannot include shrubs, bushes, or trees. C Rear clearance 18 in (45.
Site Selection and Preparation Install the generator set, in its protective enclosure, outdoors where adequate cooling and ventilating air is always available (Figure 3-1). Consider these factors: • The installation of the generator must comply strictly with ICC IFGC, NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards. • Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc.
Site Selection and Preparation generator enclosure would not pose any ignition risk to nearby combustibles or structures, with or without fire service personnel response. Site Preparation • Locate the mounting area as close as possible to the transfer switch and fuel supply. • Leave adequate room around the area for service access (check local code), and place high enough to keep rising water from reaching the generator. • Choose an open space that will provide adequate and unobstructed airflow.
Site Selection and Preparation Transportation Recommendations Use a suitable cart or equipment to carry the generator, including the wooden pallet, to the installation site. Place cardboard between the hand cart and the generator to prevent any damage or scratches to the generator. IMPORTANT NOTE: Do not lift, carry, or move the generator by grasping the louvers. Doing so may bend or damage the sheet metal.
Generator Placement Section 4: Generator Placement Generator Placement All air-cooled generators come with a non-sinking direct to dirt (DTD) composite base pad. The DTD pad elevates the generator and helps prevent water from pooling around the base. (Figure 4-1). The DTD pad allows the generator to be placed on three types of surfaces: • directly on level, solid ground • on 4 in (102 mm) of compacted pea gravel • on a concrete pad 001804 Check local codes to see what type of site base is required.
Generator Placement Fascia Installation (If Applicable) • Locate the four threaded black rubber bumpers supplied with the loose parts. • Remove the four rubber mounts from the bag and screw them into threaded holes located inside the end pieces of the fascia (two each) opposite one another (A). • Once the mounts are installed, snap one of the end pieces into one of the front / rear pieces of fascia. Repeat this action with the other two remaining pieces of fascia.
Fuel Conversion / Gas Connections Section 5: Fuel Conversion / Gas Connections Fuel Requirements and Recommendations NFPA 58 or ICC IFGC for liquid propane applications. Verify fuel pressure NEVER drops below the required specification once the generator is installed. See the NFPA website at www.nfpa.org for further information regarding NFPA requirements. DANGER (000192) NOTE: Natural gas is lighter than air and will collect in high areas. LP gas is heavier than air and will settle in low areas.
Fuel Conversion / Gas Connections Fuel Consumption Generator Natural Gas Propane 1/2 Load Full Load 1/2 Load Full Load 9 kW 3.09 / 109 3.77 / 133 1.00 / 3.79 / 36 1.50 / 5.66 / 54 11 kW 3.48 / 123 5.64 / 166 1.19 / 4.49 / 43 2.01 / 7.62 / 73 16 kW 5.47 / 193 8.83 / 312 1.9 / 7.2 / 69 3.19 / 12.07 / 116 20 kW 5.8 / 205 8.72 / 308 2.23 / 8.45 / 81 3.85 / 14.57 / 140 22 kW 5.21 / 184 7.96 / 281 2.16 / 8.16 / 78 3.68 / 13.
Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct gas pipe size, find the kW rating of the generator in the left column, and trace to the right. The number to the right is the maximum length (measured in meters / feet) allowed for the pipe sizes on top. Pipe sizes are measured by inside diameter (ID) to include any fittings, valves (must be full flow), elbows, tees, or angles. NOTE: Add 2.5 ft (0.76 m) per any bend, tee, or angle in the pipe to the overall distance.
Fuel Conversion / Gas Connections Installing and Connecting Gas Lines Flexible Fuel Line DANGER (000192) IMPORTANT NOTE: Natural gas and LP vapor are highly volatile substances. Strictly adhere to all safety procedures, codes, standards, and regulations. Gas line connections should be made by a certified contractor familiar with local codes. Always use AGAapproved gas pipe and a quality pipe sealant or joint compound.
Fuel Conversion / Gas Connections Checking Gas Line Connections 1. Check for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. The solution should not be blown away or form bubbles. 2. Check gas pressure at the regulator in the generator by following these steps. • Close gas supply valve. • Remove the top gas pressure test port from the regulator (see Figure 5-4) and install the gas pressure tester (manometer).
Fuel Conversion / Gas Connections Natural Gas Vapor Installation (typical) F B A D C E J G H L K 001808 NG BTU = ft3/h X 1000 Megajoules = m3/h X 37.
Fuel Conversion / Gas Connections LP Vapor Installation (typical) F G B C A D J K M E H L 001809 NG BTU = ft3/h X 1000 Megajoules = m3/h X 37.
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Electrical Connections Section 6: Electrical Connections Generator Connections See Figure 6-1. The electrical wiring enclosure is located behind an access panel on the intake end of the unit. Remove the intake side panel as directed in Intake Side Panel Removal, and then remove the access panel. Connect wires according to the diagram and tables. 1. Remove the main AC / control wiring knock-out plugs from the back of the generator. 2.
Electrical Connections Control Wiring C1 B A C2 E1 E2 001817 J H D F G Figure 6-1. l Electrical Wiring Connections Table 6-1. Electrical Wiring Connection Points ID Description ID Description ID Description ID Description A Control wire terminal block C2 Wire tie for sense wires E2 Power lug E2 H Neutral stud B Sense wire terminal block D Neutral lug F Ground stud J Neutral bar C1 Wire tie for control wires E1 Power lug E1 G Ground lug — — Table 6-2.
Electrical Connections . Table 6-4. Ground and Neutral Connections (Copper or Aluminum Conductors) Refer to national and/or local codes to verify correct wire sizes. NOTE: Torque all wiring lugs, bus bars, and connection points to the proper torque specifications. Conductors of AC and DC circuits, rated 1000 volts nominal or less, shall be permitted to occupy the same equipment, cable, or conduit.
Electrical Connections Battery Requirements 12 volts, Group 26R-540CCA minimum, or Group 35AGM-650CCA minimum. Battery Installation B A + – WARNING 001832 (000137a) WARNING (000138a) • (Group 26R batteries only): Fill the battery with the proper electrolyte fluid if necessary. Figure 6-2. Battery Cable Connections NOTE: In areas where temperatures fall below 0°F (-18°C), it is recommended that a pad type battery warmer be installed to aid in cold climate starting.
Control Panel Start-Up/Testing Section 7: Control Panel Start-Up/Testing Control Panel Interface Generator Setup DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000191) • Press the OFF button on the control panel, remove fuses, and disconnect battery cables to prevent accidental startup before performing any maintenance on the generator.
Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Language English Troubleshooting + Use arrow keys to scroll to desired language. Press ENTER to select. Language can be changed later using the EDIT menu. Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER, the generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed. You will need to remove the 7.
Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Troubleshooting Activation is complete when all digits are entered above and your screen shows this display. Follow the controller prompts to continue setting the time function. Refer to your Owner’s Manual with questions. Select Hour (0-23) - 6 + What happens if “Wrong Passcode Try Again” appears? Re-enter the activation code. If a second attempt is unsuccessful, check the number against the code given on activategen.com.
Control Panel Start-Up/Testing Before Initial Start-up NOTE: The unit has been run and tested at the factory prior to being shipped and does not require any type of break-in. CAUTION Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. (000135) shutoff valves in the fuel supply lines must be open.
Control Panel Start-Up/Testing Power Up Unit Note: If language was previously programmed this goes directly to “Select Hour” FIRMWARE V 1.01 HARDWARE V 1.05 UP ARROW = Language Install Wizard + English + Espanol + Francais + Portuguese - Defaults to English if not selected.
Control Panel Start-Up/Testing Electrical Checks DANGER Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury. (000129) Proceed as follows to complete electrical checks: 1. Verify that the generator is off. 2. Set the generator main circuit breaker to OFF (OPEN). 3. Turn off all circuit breakers/electrical loads that will be supplied by the generator. 4.
Control Panel Start-Up/Testing 11. Verify gas pressure while under full load. Record loaded gas pressure: ______________. 12. When testing under load is complete, turn off electrical loads. 13. Set the generator MLCB (generator disconnect) to OFF (OPEN). Installation Summary 1. Verify the installation has been properly performed as outlined by the manufacturer and that it meets all applicable laws and codes. 14. Let the engine run at no-load for 2–5 minutes. 2.
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Troubleshooting Section 8: Troubleshooting System Diagnosis Problem Engine will not crank. Cause 1. Blown fuse. 2. Loose, corroded, or defective battery cables. 3. Defective starter contact. 4. Defective starter motor. 5. Discharged battery. Correction 1. Correct short circuit condition by replacing 7.5 amp fuse in generator control panel. If fuse continues to blow, contact an IASD for assistance. 2. Tighten, clean, or replace as necessary.* 3. *See #2. 4. *See #2. 5. Charge or replace battery.
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Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press the OFF button, ENTER button, then press AUTO. Contact an Independent Authorized Service Dealer (IASD) if the alarm reoccurs. Table 9-1. System Diagnosis Active Alarm LED NONE GREEN HIGH TEMPERATURE OVERLOAD REMOVE LOAD Problem Things to Check Solution Check MLCB Unit running in AUTO but (generator no power in house. disconnect). Check MLCB (generator disconnect). If it is ON, contact an IASD.
Quick Reference Guide Table 9-1. System Diagnosis (Continued) Active Alarm LED Problem Things to Check Solution UNDERSPEED RED Unit will not start in AUTO with utility loss. Check the LED’s / screen for alarms. Contact an IASD. STEPPER OVERCURRENT RED Unit will not start in AUTO with utility loss. Check the LED’s / screen for alarms. Contact an IASD. MISWIRE RED Unit will not start in AUTO with utility loss. Check the LED’s / screen for alarms. Contact an IASD.
Accessories Section 10: Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Cold Weather Accessories*— • Battery Pad Warmer Description • Recommended in areas where temperatures fall below 0 °F (-18 °C). (Not necessary for use with AGM-style batteries) • Oil Warmer • Breather Warmer • Recommended in areas where temperatures fall below 0 °F (-18 °C). • Recommended in areas where heavy icing occurs.
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Diagrams Section 11: Diagrams IInstallation Drawing (10000002487—1 of 2) MOUNTING TO CONCRETE PAD HOLE LCOATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 768.3 [30.2] 521 [20.5] 16.0 [5/8] DIA.CLEARANCE HOLE (3) PLACES, 3/8 DIA. MASONARY ANCHOR BOLTS RECOMMENDED 679.5 [26.8] 196.6 [7.74] FRONT OF UNIT 392.7 [15.5] 68.0 [2.7] 849.3 [33.4] 266.7 [10.5] 355.8 [14.
Diagrams Installation Drawing (10000002487—2 of 2) AIR INTAKE 457.2 [18.0] 914 [36.0] MINIMUM OPEN AREA ON SIDES AND FRONT AIR INTAKE AIR OUTLET TOP VIEW "DO NOT LIFT BY ROOF" This page intentionally left blank. RIGHT VIEW INTAKE PANEL REMOVED 30.2 [ 12] LIFTING HOLES 4 CORNERS 1218 [47.9] 76.2 [3.0] PEA GRAVEL MINIMUM 1232 [48.
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Part No. 0L6630 Rev. A 07/08/16 ©2016 Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) generac.
