CUMMINS Onan GSAA Series, Onan GSAA A, Onan GSAA C Installation Manual
Installation Manual
Home Standby Generator Set
GSAA (Spec A & C)
English−Orignal Instructions 6−2012 983−0603 (Issue 10)
!!
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
Table of Contents
SECTION PAGE
IMPORTANT SAFETY INSTRUCTIONS iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Installation Considerations 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
specifications 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Codes and Standards for Safety 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. STEP-BY-STEP OUTLINE OF INSTALLATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating the Site 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Clearances 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Site 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting and Moving Generator Set 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Staking Generator Set In Place 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring connections 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Line Connections 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. MECHANICAL 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Access 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Natural Gas Fuel System 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propane Fuel System 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. ELECTRICAL CONNECTIONS 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC POwer Supply Connections 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory Supply Connections 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet Connections (Optional) 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. STARTUP AND CONFIGURATION 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Review 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Configuration 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Adjustments 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
SECTION PAGE
APPENDIX A. OPERATION A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In-Home Operator Panel A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Operation A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Enable / Disable Standby A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Manually Start / Stop Generator Set A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault, Maintenance and New Event Screens A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Status A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Setup and Software Info A-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event Log A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Log A-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet Settings A-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise Settings A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Setup A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Management A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDIX B. INTERNET / EMAIL INTERFACE B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Page B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Time and Date B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Exercise Schedule B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Control (Management) B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event Log B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Log B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Setup B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix C. Cummins Onan Model RS12000 Generator Set Network Setup Guide . . .
C-1
Setting up In-Home Network Access to the Generator Set C-2 . . . . . . . . . . . . . . . . . .
Setting up Console Internet Access to the Generator Set C-3 . . . . . . . . . . . . . . . . . .
Setting up Email Alerts from the Generator Set C-4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Help Hotline C-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequently Asked Questions C-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix D. Communication Troubleshooting D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In-Home Network Access to Generator Set Troubleshooting D-1 . . . . . . . . . . . . . . . .
Remote Internet Access to Generator Set Troubleshooting D-2 . . . . . . . . . . . . . . . . .
Email Alert Troubleshooting D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix E. Specifications E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix G. Outline
and System Drawings F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual
contains important instructions that should be followed during installation and maintenance of the
generator and batteries.
Before operating the generator set (genset),
read the Operator Manual (983−0104) and become
familiar with it and the equipment.
Note: Safe and efficient operation can be achieved
only if the equipment is properly operated and main-
tained. Many accidents are caused by failure to fol-
low fundamental rules and precautions.
The following symbols, found throughout this
manual, alert you to potentially dangerous condi-
tions to the operator, service personnel, or the
equipment.
DANGER
hazards which will result in severe personal in
jury or death.
WARNING
unsafe practice which can result in severe per-
sonal injury or death.
This symbol warns of immediate
This symbol refers to a hazard or
Lead-acid batteries emit a highly explosive
hydrogen gas that can be ignited by arcing,
sparking, smoking, etc.
EXHAUST GASES ARE DEADLY
WARNING
constituents are known to the state of California
to cause cancer, birth defects, and other repro-
ductive harm.
Be sure the unit is well ventilated.
Provide an adequate exhaust system to
Exhaust height should be tall enough to
Do not use exhaust gases to heat a compart-
ment.
Visually and audibly inspect the exhaust daily
for leaks per the maintenance schedule.
Make sure that exhaust manifolds are se-
Engine exhaust and some of its
properly expel discharged gases away from
enclosed or sheltered areas and areas
where individuals are likely to congregate.
help clear gases, avoid accumulation of
snow or in accordance with local mechani-
cal code.
cured and not warped.
CAUTION
unsafe practice which can result in personal in-
jury or product or property damage.
This symbol refers to a hazard or
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can re-
sult from improper practices.
All persons handling propane are required to
be trained and qualified, according to NFPA
code.
Natural gas is lighter than air, and will tend
to gather under hoods. Propane is heavier
than air, and will tend to gather in sumps or
low areas.
Be sure all fuel supplies have a positive shutoff
valve.
Be sure battery area has been well-ventilated
prior to servicing near it.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Do not wear loose clothing or jewelery and
keep your hands away from all moving parts.
Loose clothing and jewelry can become
caught in moving parts.
If adjustment must be made while the unit is
running, use extreme caution around hot
manifolds, moving parts, etc.
Before starting work on the generator set, dis-
connect battery charger from its AC source,
then disconnect starting batteries, negative (-)
cable first. This will prevent accidental starting.
To prevent accidental air starting, make sure
the air supply line is connected until the generator set is ready to start.
Make sure that fasteners on the generator set
are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts,
etc.
iii
BATTERIES CAN EXPLODE CAUSING
SEVERE SKIN AND EYE BURNS AND
RELEASE TOXIC ELECTROLYTES
Wear safety glasses.
Do not smoke.
Do not dispose of the battery in a fire.
The battery is capable of exploding.
Do not open or mutilate the battery.
Released electrolytes has been known to
be harmful to the skin and eyes, and be
toxic.
Remove watches, rings and other metal ob-
jects, and use tools with insulated handles.
Batteries present the risk of high short cir-
cuit current.
To prevent arcing when disconnecting the bat-
tery, first disconnect the battery charger, then
the negative (−) battery cable and finally the
positive (+) cable.
To prevent arcing when reconnecting the bat-
tery, first reconnect the positive (+) cable, then
the negative (−) cable, and finally, reconnect
the battery charger.
When replacing the generator set battery, al-
ways use a 26 R, maintenance free, 12 volt
battery with a minimum battery CCA of 530.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
DANGER
on electrical components. High voltages can
cause injury or death. DO NOT tamper with in-
terlocks.
Follow all applicable state and local electrical
codes. Have all electrical installations per-
formed by a qualified licensed electrician. Tag
and lock open switches to avoid accidental clo-
sure.
Use extreme caution when working
isolation switch or an approved paralleling device.
Remove electric power before removing pro-
tective shields or touching electrical equipment.
Use rubber insulative mats placed on dry wood
platforms over floors that are metal or concrete
when around electrical equipment.
Do not wear damp clothing (particularly wet
shoes) or allow skin surface to be damp when
handling electrical equipment.
Do not wear jewelry.
Jewelry can short out electrical contacts
and cause shock or burning.
MEDIUM VOLTAGE GENERATOR SETS
(601V to 15kV)
DANGER
sult in severe personal injury or death.
Special equipment and training is required to
work on or around medium voltage equipment.
Operation and maintenance must be done
only by persons trained and qualified to work
on such devices.
WARNING
ment, as this can cause severe personal injury
or death.
Plan the time for maintenance with authorized
personnel so that the equipment can be de-en-
ergized and safely grounded.
Due to the nature of medium voltage electri-
Unauthorized personnel must not be permitted
near energized equipment.
Improper use or procedures will re-
Do not work on energized equip-
cal equipment, induced voltage remains
even after the equipment is disconnected
from the power source.
Do not connect the generator set directly to
any building electrical system.
CAUTION
the generator set into the utility line. This
creates a potential for electrocution or property
damage. Connect only through an approved
Hazardous voltages can flow from
iv
GENERAL SAFETY PRECAUTIONS
WARNING
changer pressure cap while the engine is running.
DO NOT open a radiator or heat ex-
Make sure generator set is mounted in a man-
ner to prevent combustible materials from accumulating under the unit.
Remove all unnecessary grease and oil from
the unit.
Allow the generator set to cool and bleed the
system pressure first.
Coolants under pressure have a higher boil-
ing point than water.
WARNING
Used engine oils have been identi-
fied by some state or federal agencies as caus-
ing cancer or reproductive toxicity.
When checking or changing engine oil, take
care not to ingest, breathe the fumes, or con-
tact used oil.
Keep multi-class ABC fire extinguishers
handy.
Class A fires involve ordinary combustible
materials such as wood and cloth
(ref. NFPA No. 10)
Class B fires, combustible and flammable
liquid fuels and gaseous fuels
(ref. NFPA No. 10)
Class C fires, live electrical equipment.
(ref. NFPA No. 10)
Make sure that rags are not left on or near the
engine.
Accumulated grease and oil can cause
overheating and engine damage which
present a potential fire hazard.
Keep the generator set and the surrounding
area clean and free from obstructions. Re-
move any debris from the set and keep the
floor clean and dry.
Do not work on this equipment when mentally
or physically fatigued, or after consuming any
alcohol or drug that makes the operation of
equipment unsafe.
WARNING
Substances in exhaust gases have
been identified by some state or federal agen-
cies as causing cancer or reproductive toxicity.
Take care not to breathe or ingest or come into
contact with exhaust gases.
Do not store any flammable liquids, such as
fuel, cleaners, oil, etc., near the generator set.
A fire or explosion could result.
Wear hearing protection when going near an
operating generator set.
WARNING
Avoid contact with hot metal parts
such as the radiator, turbo charger and exhaust
system to prevent serious burns.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
v
THIS PAGE INTENTIONALLY LEFT BLANK
vi
1. Introduction
ABOUT THIS MANUAL
This manual is a guide for the installation of the gen-
erator set(s) listed on the front cover. Proper instal-
lation is essential for top performance, reliable op-
eration and safety. The installation must comply
with all applicable building codes. Read through this
manual before starting the installation.
Information For After Installation
WARNING
severe personal injury, death and damage to
equipment. The installation must comply with
all applicable building codes. It is strongly rec-
ommended that the installer be properly trained
and licensed to perform electrical and mechani-
cal equipment installations, however a person
with the proper knowledge and experience in
installing electrical and mechanical equipment
installations may also install this genset.
Refer to Appendix E. Specifications for specific in-
formation about the system and its components.
Refer to Appendix F. Outline and System Drawings
for specific information about the installation and the
wiring connections.
See the Operator Manual for operation and mainte-
nance instructions.
Improper installation can result in
PRE-INSTALLATION CONSIDERATIONS
The location of the generator set affects all other as-
pects of the installation, such as the lengths of elec-
tric wiring and gas lines, and is one of the first deci-
sions to be made. The installation cannot be com-
pleted without connections to an automatic transfer
switch and a source of fuel, Natural Gas or Propane,
which must be inspected by the gas and electric uti-
lities.
Decide where to locate the generator set and auto-
matic transfer switch, how fuel supply will be pro-
vided, what materials are required (wiring, fuel lines,
etc.), and what site preparations are necessary (ac-
cess to and preparation of the site, trenches, etc.).
Prior co-ordination will reduce delays and the
amount of time power has to be interrupted.
IMPORTANT NOTICE: Depending on the locality
and use of the generator set, it may be necessary to
obtain an air quality emissions permit before instal-
lation begins. Check with the local pollution control
or air quality authority.
Automatic Transfer Switch
The Model GSAA generator set is for installation
only with Cummins Onan Model RSS automatic
transfer switches. Use of other makes and models
of transfer switches voids the Model GSAA genera-
tor set Warranty.
Note: Manuals are updated from time to time to re-
flect changes in the equipment and its specifica-
tions. See an authorized Cummins Onan representa-
tive for current manuals.
Install the transfer switch in accordance with its
Installation Manual and make connections to the
generator set in accordance with Section 4. Electri-
cal Connections.
1-1
SPECIFICATIONS
FUEL CONSUMPTION:
@ 1/2 Load
@ Full Load
Fuel Supply Pressure
Recommended LP Tank Size (necessary to run the
generator set for seven days)
GENERATOR: Brush-Type, 2-Pole Rotating Field, Single-Bearing
Power (@1.0 power factor) 10.5 kW 12 kW
Voltage 120/240 120/240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Output Current 87.5/43.75 Amps 100/50 Amps
Circuit Breaker 50 amp, 2-pole 50 amp, 2-pole
ENGINE: 2-Cylinder-V, OHV, Air-Cooled, 4-Stroke, Spark Ignited, 3600 RPM
Displacement 40.9 in3 (720 cc)
Compression Ratio 8.3:1
Spark Plug Gap
Spark Plug Type
Spark Plug Tightening Torque
Cylinder Compression Test 180 psi (12.4 bar)
Valve Lash: Intake & Exhaust (cold)
Oil Capacity
CONTROLLER: Integrated Microprocessor-Based Engine, Generator and Transfer Switch Controller
DC SYSTEM:
Nominal Battery Voltage
Battery Group
Battery Type
Minimum Battery CCA (Cold Cranking Amps)
WEIGHT (WET): 460 lbs (209 kg)
SIZE (L x W x H): 48 x 43 x 31.5 in (1219 x 864 x 800 cm)
SOUND LEVEL: Less than 64 dB(A) @ 23 ft (7 meters) and 12 kW of Load
Natural Gas Installation
(1000 BTU/ft3)
122 ft3/hr (3.5 m3/hr)
191 ft3/hr (5.4 m3/hr)
5−11 H2O
500 Gallon (Contact you local gas company to verify
the tank size required for your application)
0.030 in (0.76 mm)
NGK-BPR6ES (P/N 167−1658)
10 ft-lbs (13.5 N-m)
0.004in (0.10 mm)
1.7 quart (1.6 liter)
12 volts
26 R
Maintenance Free
Propane Installation
(2500 BTU/ft3)
53 ft3/hr (1.5 m3/hr)
88 ft3/hr (2.5 m3/hr)
7−11 H2O
530
1-2
Generator Set Location
WARNING
doors, windows and other openings into the house and where the exhaust gases will disperse away
from the house.
EXHAUST GAS IS DEADLY! Install the generator set out-of-doors only, away from
PALATE
(PLACE GENSET
ON STABLE,
LEVEL GROUND)
FIGURE 1-1. GENERATOR SET LOCATION
5 FEET (1.6 METERS)
FROM ALL OPENINGS
TO THE HOUSE
Generator set (genset) location is critical for safety and good performance. Follow the guidelines below :
Install out-doors only.
Call the local utilities to mark the loca-
tions of buried utility services (gas, electric,
telephone) before digging trenches for fuel and
electric lines.
Locate the genset as far away as practical from
Do not locate the genset where snow
drifts, plant growth, lawn clippings and other
objects are likely to block the ventilation open-
ings.
noise sensitive areas such as bedrooms, living
Ask the homeowner for the location of
any other buried components.
Locate and orient the genset such that the pre-
vailing winds will carry exhaust gases and fuel
leaks away from the house.
Genset must be at least 5 feet (1.6 me-
ters) away from all openings to the house.
Do not locate the genset in a three-
sided niche of the house, under an overhang or
in a low-lying area or next to a basement.
room windows and neighbors.
Locate the genset where it will be protected
from vehicular traffic and vandalism.
Locate the genset as close as practical to the
house to reduce the lengths electric wiring and
fuel lines.
Place the genset on stable ground, not subject
to flooding.
Note: The area should be leveled and compacted with
sand or pea gravel.
1-3
Natural Gas Supply
The Natural Gas supply meter may need to be exchanged for a higher capacity meter to supply the
additional gas consumed by the generator set. At
full load, the generator set alone requires 191,000
BTU/hr. To determine the required meter capacity,
generator set consumption must be added to the
gas consumed for heating, cooking, clothes drying,
etc. A typical installation might require a
400,000 BTU meter.
Consideration should also be given to utilizing high
pressure gas supply (2 psi), if available, to reduce
the required size, and therefore cost, of gas piping,
especially if the location of the generator set re-
quires a long supply line.
Note: The wire size varies, depending on distance (see Table 4-1).
10. Communications Wiring Connectors: Up to
twelve UL listed 18 AWG fork terminals for Item
9 wires (Cummins Part Number 0332−2527).
11. DC Conduit for Item 9 wires.
12. One or two 12 volt relays for load management
(optional)
Note: It is recommended that the two 18AWG wires
from Generator set terminals TB1-7 and TB1-8 for
load management be pulled along with the other con-
trol/communications wires at the time of installation
so that they are available if it is determined later that
load management is necessary.
Tools Required
Note: An older site might require upgrading and re-
pair of the gas supply system, which should be
scheduled to minimize power and gas supply inter-
ruptions.
Materials Required
The installer must provide the following materials to
complete the installation:
1. Gas line and step down regulators (as re-
quired) for gas connections:
A. Natural Gas at 191,000 BTU/hour
B. Propane at 220,000 BTU/ hr or 2.4 gallons/
hour
C. Gas pressure at generator set: 5−11 inch
WC
2. UL listed pipe dope
3. Electrical Conduit sealing putty
4. Cat 5 Ethernet cable (optional)
5. Four wall anchors and 4 No. 6 black screws for
mounting the Operator Panel.
6. AC Power Output Wiring: Four 8 AWG 90C
wires for runs up to 125 feet. (L1, L2, N and
GND)
7. AC Accessory Supply Wiring: Two 12 AWG
90C wires for runs up to 125 feet. (Hot and
Neutral)
8. AC Conduit for Items 6 and 7, which may be run
in the same conduit.
9. Control/Communications Wiring: Up to twelve
18 AWG wires, depending on Transfer Switch.
(Generator set TB1-1 through TB1-12)
Use a forklift to move the generator set and set it in
place. Alternatively, a one-man hand dolly designed
to fit the generator set base is available to move the
generator set and set it in place (P/N 0541-1624).
Hand tools required include the following:
1. Wire stripper and lug crimper for terminating
the twelve communications wires.
2. Rachet set with 10 mm socket and extension.
3. Two pipe wrenches for gas connections.
4. Phillips-head and flat-blade screwdrivers.
Loose Parts Shipped With the Generator
The following loose parts are shipped with the
GSAA generator set.
Oil Drain Hose (P/N 0503−2151)
Flexible Fuel Hose Assembly
(P/N 0501−0776−06)
Four Base Spikes (Ground Stakes)
(P/N 0403−4365)
Snap Bushing (P/N 0508−0208−05)
In-Home Display (P/N 0300−6385)
Pigtail Harness for In-Home Display
(P/N 0338−5023)
LP Orifice for LP Fuel Changeover (Wire tied to
the engine lifting bracket) (P/N 0148−1385)
Two Keys (P/N A026G567)
Quick Connect Guide (located in the battery
box)
Literature − Operator Manual, Installation
Manual, Setup Guide, and Warranty Statement
1-4
INSTALLATION CODES AND STANDARDS
FOR SAFETY
WARNING
sole responsibility for following all applicable
local codes and regulations.
The following list of Installation Codes and Stan-
The generator set installer bears
TABLE 1-1. INSTALLATION CODES AND SAFETY RECOMMENDATIONS
dards for Safety applies to the installation and operation of standby generator sets. This list is for reference only and not intended to be inclusive of all
applicable codes and standards. The address of
each agency is listed so that copies of the codes
may be obtained for reference. Installation codes
and recommendations are subject to change, and
may vary by location or over time.
NFPA 70 National Electric Code
NFPA 37 Installation and Use of Stationary Combus-
tion Engines and Gas Turbines
NFPA 54 National Fuel Gas Code
NFPA 58 Storage and Handling of Liquefied Petro-
leum Gases
CSA Electrical Bulletin
CSA C22.2 No. 100
CSA C22.2 No. 14
California Administrative Code - Title 25 Chapter 3 State of California
Underwriters Laboratories
UL2200 Stationary Engine Generator Assemblies
National Fire Protection Association,
470 Atlantic Avenue
Boston, MA 02210
Canadian Standards Association,
Housing and Construction Materials Section
178 Rexdale Blvd.
Rexdale, Ontario, Canada M9W 1R3
Documents Section
P.O. Box 1015
North Highlands, CA 95660
Underwriters Laboratories, Inc.
333 Pfingsten Road
Northbrook, IL 60062-2096
1-5
2. Step-by-Step Outline of Installation
INTRODUCTION
WARNING
plying with all applicable installation codes and
safety requirements.
This section is a step-by-step overview of a typical
installation. This section includes:
Locating the site
Generator set Clearances
Preparing the site
Moving the generator set
Placing the generator set
The installer is responsible for com-
Connecting the generator set
Review this section, then refer to the detailed in-
structions that are given in the following sections for
specific procedures and important safety precau-
tions before starting the installation.
LOCATING THE SITE
These generator sets are housed in a weather-pro-
tective enclosure for installation out-of-doors on a
non-combustible base.
Choose a site close to the electric service and Natu-
ral Gas meter or Propane tank. The main distribu-
tion, transfer switch, and sub-panels are usually in-
side the house.
ELECTRIC
METER
GENERATOR
UNDERGROUND
ELECTRIC
SERVICE
SET
TRANSFER
SWITCH
DISTRIBUTION
PANEL
GAS
METER
GAS
SHUTOFF
VALVE
UNDERGROUND
GAS SERVICE
FIGURE 2-1. TYPICAL GENERATOR SET SITE
2-1
GENERATOR SET CLEARANCES
The generator set must be a minimum of 3 ft
(915 mm) from combustible material (NFPA 37).
Leave at least 3 ft (915 mm) all around the generator set enclosure for access to the inside (NEC Art.
110-26a, Art. 110-26b). The generator set must be
at least 5 ft (1524 mm) from any opening (window,
door, vent, etc.) in the wall, and the exhaust must not
be able to accumulate in any occupied area.
Refer to the Outline Drawing (page F-7) for the
clearance required to fully open the maintenance
and service doors.
PREPARING THE SITE
If the site is not on level ground prepare an area
large enough to easily hold the generator set so that
it can be mounted level. If you add fill to the site, be
sure to tamp the ground until it is firm and stabilized.
Prepare a site at least 48 in by 34 in (1219 mm by
864 mm) on firm ground. Sites on inclines require
more area. Add a layer of sand or pea gravel deep
enough so that you can level the generator set. Remove any combustible material that would be under
and around the generator set.
5 FT (1.6 M) MIN TO
ANY OPENING
FIGURE 2-2. GENERATOR SET CLEARANCES
2-2
LIFTING AND MOVING GENERATOR SET
WARNING
ping the generator set can cause severe personal injury or death. Keep feet and hands clear
when lifting the generator set.
CAUTION
in the crankcase. Keep it upright.
The generator set is heavy and must be handled
with care. Use a forklift to move the generator set
and set it in place. Alternatively, a one-man hand
dolly designed to fit the generator set base is avail-
able to move the generator set and set it in place.
The generator set is heavy. Drop-
The generator set is shipped with oil
STAKING GENERATOR SET IN PLACE
WARNING
gas, or telephone service lines can result in se-
Pounding the stakes into electric,
vere personal injury or death. Observe the utility
company markings.
Set the generator set in place and pound the four
corner stakes into the ground to secure the generator set in place.
ELECTRICAL WIRING CONNECTIONS
Refer to Appendix F Outline and System Drawings
for the locations of the electrical conduit openings
on the side of the generator set and the alternative
stub-up opening in the base for all power and com-
munications wiring connections between the gener-
ator set and transfer switch.
Route the wires from the transfer switch through
conduit and connect the wires to the mating termi-
nals in the generator set terminal board compart-
ment. Two separate conduits are required. One is
for all A/C voltage connections on TB2 and TB3.
The other is for all TB1 and ethernet cables.
CORNER
STAKE
WIRING TERMINAL BOARD
COMPARTMENT
ELECTRICAL WIRING
STUBUP OPENING
FIGURE 2-3. ELECTRICAL WIRING TERMINAL BOARDS AND STUBUP OPENING
2-3
GAS LINE CONNECTIONS
WARNING
explosion that can result in severe personal injury or death. Do not smoke or allow any flame,
spark, pilot light, or other ignition sources near
fuel or in the installation area. Read the impor-
tant safety precautions in the Fuel System sec-
Fuel presents the hazard of fire or
tion.
Refer to Appendix F Outline and System Drawings
for the location of the fuel supply connection through
the side of the generator set. A flexible fuel hose is
packaged inside the generator set (Assembly part
number: 0501−0776−06). Connect it between the
3/4 NPT fitting on the generator set and the fuel sup-
ply line.
MEASURE INLET FUEL
PRESSURE HERE
FLEXIBLE FUEL HOSE
(P/N 0501−0776−06)
FIGURE 2-4. GAS LINE CONNECTIONS
2-4
3. Mechanical
LOCATION AND ACCESS
These generator sets are designed for installation
out-of-doors in its weather-protective enclosure.
Factors to consider when deciding where to locate
the generator set include:
Proximity of generator set, transfer switch,
loads and Natural Gas fuel lines or Propane
tanks.
Access for maintenance and service. Refer to
the Outline Drawing (page F-7) for the clear-
ance required to fully open the maintenance
and service doors.
Security from vandalism, flooding and vehicu-
lar traffic.
Noise levels and proximity of property lines.
Safe dispersal of engine exhaust and cooling
air away from buildings, habitable areas, and
people.
Possible obstructions to ventilation caused by
snowdrifts, plant growth, lawn clippings, falling
leaves, etc.
See Locating the Site in Section 2.
FUEL SYSTEM
WARNING
qualified service technicians. Improper installa-
tion presents hazards of fire and improper op-
eration, resulting in severe personal injury or
property damage.
The generator set name plate is marked to indicate
the fuel type, Natural Gas or Propane.
WARNING
explosive and can cause severe personal injury
or death. Do not smoke if you smell gas or are
near fuel tanks or fuel-burning equipment or are
in an area sharing ventilation with such equip-
ment. Keep flames, sparks, pilot lights, electri-
cal arcs and arc-producing equipment and all
other sources of ignition well away. Keep a type
ABC fire extinguisher handy.
In all fuel system installations, cleanliness is of the
upmost importance. Make every effort to prevent
entrance of moisture, dirt, excess thread sealant, or
contaminants of any kind. Clean all fuel system
components before installing.
Fuel systems must be installed by
Gaseous fuels are flammable and
ENGINE EXHAUST
The exhaust system of this generator set was de-
signed for this engine and is complete. Do not
modify or add to the exhaust system of this genera-
tor set.
WARNING
haust system must terminate away from build-
ing vents, windows and doors and sheltered
spaces that may not have ample fresh air ven-
tilation.
Do not use generator set discharge air or engine ex-
haust for heating a room or enclosed space.
WARNING
carry carbon monoxide gas (odorless and invisible) which can cause asphyxiation and death.
Never use engine discharge air or exhaust for
heating a room or enclosed space.
EXHAUST GAS IS DEADLY! The ex-
Engine discharge air and exhaust
The section of flexible fuel hose supplied with the
generator set must be used between the engine’s
fuel system and fuel supply line to protect the fuel
system from damage caused by vibration, expan-
sion and contraction. The fuel hose must be
installed according to all applicable codes and stan-
dards.
Gaseous-fuel supply system design, materials,
components, fabrication, assembly, installation,
testing, inspection, operation and maintenance
must comply with the applicable codes. See NFPA
Standards No. 37, No. 54, and No. 58.
Most codes require a manual shutoff valve ahead of
a flexible fuel hose. The manual valve should be of
the indicating type. The generator set has an electric (battery-powered) shutoff valve included between the fuel supply and the carburetor.
Until the generator set is connected, cap the fuel line
stub-up at the generator set to prevent dirt from en-
3-1
tering and gas discharging if the gas supply shutoff
valve is opened inadvertently.
Refer to Appendix E. Specifications for the fuel inlet
size.
NATURAL GAS FUEL SYSTEM
(191 cubic feet/hr) delivered to the generator set inlet at 5−11 inches (28 mm) WC (Water Column). If
the meter serves other gas appliances such as a furnace, water heater, or stove, you must consult with
the local Natural Gas utility to determine whether
the Natural Gas meter is adequate.
The generator set requires an adequate fuel supply
to operate correctly at full load. The length of the fuel
supply pipe from the gas service entrance to the
generator set must be known to determine the cor-
rect fuel pipe size. Refer to Table 3-1 to find the fuel
supply requirement for your generator set. Pipe
must be minimum of schedule 40 subject to the au-
thority having jurisdiction.
Natural Gas Supply Line Size
The generator set requires up to 191,000 BTU/hr
It is important to consider other loads operated from
the fuel supply pipe. Other loads, such as space
heating and water heating equipment, must also be
determined to correctly size the fuel pipe. Use the
total load requirement of the fuel supply line to de-
termine the size of the fuel supply pipe. Use
Table 3-1 to determine the correct pipe size. (typi-
cally, 1 ft
Note: When the fuel delivery value falls between two
columns, use the larger value.
GENERATOR SET
3
/hr =1000 BTU/hr, )
SHUTOFF VALVE
GAS METER
FIGURE 3-1. TYPICAL NATURAL GAS INSTALLATION
TABLE 3-1. NATURAL GAS PIPE CAPACITY—CUBIC FEET OF GAS PER HOUR
NOMINAL IRON
PIPE SIZE
(INCHES)
3/4 360 250 200
1 680 465 375 320 285 260 240 220 205 195
1-1/4 1400 950 770 660 580 530 490 460 430 400 360 325 300 280
Maximum pipe capacity in cubic feet per hour of 0.60 specific gravity Natural Gas with a pressure drop of 0.5 inches (1.27 mm)
WC over the length
10 20 30 40 50 60 70 80 90 100 125 150 175 200
LENGTH OF PIPE IN FEET
3-2
PROPANE FUEL SYSTEM
WARNING
NFPA Standard No. 58 requires all
persons handling and operating Propane to be
trained in proper handling and operating procedures.
WARNING
Fuel leaks can lead to explosive ac-
cumulations of gas. Propane sinks in air and
can accumulate inside housings, basements
and other below-grade spaces. Prevent gas
leaks and the accumulation of gaseous fuel in
the event of a leak.
Converting from Natural Gas to Propane
(Vapor Withdrawal)
The generator set leaves the factory set up for Natu-
ral Gas. The generator set must be converted as fol-
lows for use with Propane vapor:
1. Disconnect the fuel hose at the gas/air mixer
and thread in the gas orifice wire-tied to the en-
gine lifting bracket (Figure 3-2).
2. Insert the air orifice supplied with the flexible
gas hose into the inlet of the air intake resonator
(Figure 3-3). (Orifice used only on spec A units)
3. Configure the control for Propane (page
5−1).
RIGHT
HAND
DOOR
AIR
ORIFICE
FIGURE 3-3. INSTALLING THE AIR ORIFICE
INTAKE
RESONATOR
(SPEC A ONLY)
GAS
ORIFICE
SPEC A
GAS/AIR MIXER
FIGURE 3-2. INSTALLING THE PROPANE GAS
ORIFICE
3-3
Propane Vapor Fuel Supply Line Size and
Pressure
Fuel line size depends on the amount of fuel needed
to run the generator set at full load at the distance
the fuel must be moved. The generator set requires
3
88 ft
/hr of Propane Vapor at full load delivered to
GENERATOR
SET
SHUTOFF
VALVE
REGULATOR
SECONDARY
REGULATOR
the generator set inlet at 7−11 inches WC (Water
Column) gas pressure. Figure 3-4 shows a typical
Propane Vapor installation and Table 3-2 lists fuel
capacity for given distances and pipe size.
Size the fuel line so that the Propane vapor pressure
drops no more than 2 inches WC from no load to full
load.
PRIMARY
PROPANE
TANK
FIGURE 3-4. TYPICAL PROPANE VAPOR WITHDRAWAL INSTALLATION
TABLE 3-2. PROPANE VAPOR PIPE CAPACITY—CUBIC FEET OF GAS PER HOUR
NOMINAL IRON
PIPE SIZE
(INCHES)
3/4 227 157 126 107 95
1 428 293 236 201 179 164 151 138 129 123 110 101
1-1/4 882 598 485 416 365 333 308 289 207 252 230 204
1-1/2 1323 920 743 624 567 570 472 434 409 390 346 315
2 2488 1732 1386 1197 1058 958 882 819 768 724 642 598
Maximum pipe capacity in cubic feet per hour of Propane vapor with a pressure drop of 0.5 inches (1.27 mm) WC over the
10 20 30 40 50 60 70 80 90 100 125 150
LENGTH OF PIPE IN FEET
length
3-4
Fuel Pressure
WARNING
cause gas leaks which can lead to fire and severe personal injury or death. Gas supply pressure must be adjusted to Specifications by
trained and experienced personnel.
Satisfactory performance requires that the Propane
Vapor be supplied at a pressure within the range of
7-11 inches WC (water column).
When measuring supply pressure, the most accu-
rate reading would be on the input side of the sole-
noid valve.
High gas supply pressure can
Recommended Fuel
Use clean, fresh HD-5 grade Propane or equivalent
product consisting of at least 90 percent Propane.
Commercial Propane may contain more than 2.5
percent butane which can result in poor fuel vapor-
ization and low tank pressure resulting in poor en-
gine starting in low ambient temperatures (below
32F (0C).
WARNING
or explosion that can cause severe personal in-
jury or death. Do not permit any flame, spark,
Propane presents the hazard of fire
arc-producing equipment, switch, pilot light,
cigarette, or other ignition source near the fuel
system. Keep an ABC type fire extinguisher
nearby.
Propane Tank Size
To assist in the proper selection of the Propane tank,
follow the guidelines below.
Propane tanks are sized by the number of gal-
lons of water they can hold, not the amount of
fuel they hold. See Table 3-3.
Propane tanks are generally filled to only 80%
of their water capacity. Therefore, a 500 lb tank
results in 400 lb tank capacity.
Low ambient temperatures affect the amount of
fuel available from the Propane tank.
Approximately 60% of the fuel (in gallons) filled
in the tank can be effectively used. Therefore,
a 500 lb tank results in 300 gallon capacity.
Propane tanks must be fitted with a pressure
reducing regulator before connection to the
generator set to prevent fuel system damage.
Propane tanks must be located at least 10 ft
(3048 mm) from any source of combustion (in-
cluding the generator set).
TABLE 3-3. REQUIRED PROPANE TANK SIZE IN GALLONS (LITERS) FOR INDICATED TEMPERATURES
WHEN KEPT AT LEAST HALF FULL
LOWEST AVERAGE WINTER TEMPERATURE
WITHDRAWAL RATE 32F(0C) 20F(−7C) 10F(−12C) 0F(−18C) −10F(−23C) −20F(−29C) −30F(−34C)
100 cfh (250,000 BTU/hr)
[2.8 m3/hr (264 MJ/hr)]
150 cfh (375,000 BTU/hr)
[4.2 m3/hr (395.6 MJ/hr)]
200 cfh (500,000 BTU/hr)
[5.7 m3/hr (527.5 MJ/hr)]
300 cfh (750,000 BTU/hr)
[8.5 m3/hr (791.2 MJ/hr)]
250
(945)
300
(1135)
400
(1515)
750
(2840)
250
(945)
400
(1515)
500
(1890)
1000
(3785)
250
(945)
500
(1890)
750
(2840)
1500
(5675)
400
(1515)
500
(1890)
1000
(3785)
2000
(7570)
500
(1890)
1000
(3785)
1200
(4540)
2500
(9460)
1000
(3785)
1500
(5675)
2000
(7570)
4000
(15140)
1500
(5675)
2500
(9640)
3500
(13250)
5000
(18925)
3-5
Testing Fuel System for Leaks
Before operating the set, test the Propane fuel system for leaks. Energize the fuel solenoid from a separate 12-volt DC source before testing the fuel system. Testing must conform to procedures listed in
NFPA-58, or to the UL recommended test procedure, as follows:
After assembly and before initial operation, all fuel
system connections, hose valves, regulators, and
fittings must be tested and proven free of leaks us-
ing a soap-and-water (or equivalent) solution while
the system is under gas or air pressure of at least
1.5 times the supply pressure or 3 psi (20.7 kPa)
minimum.
Other approved methods of detecting leaks can be
used if appropriate. DO NOT use a flame to test for
gas leaks.
WARNING
plosion or fire which can result in severe per-
sonal injury or death. Do not smoke or allow any
flame, spark, pilot light, arc-producing equip-
ment, switch, or other ignition sources around
fuel or fuel components.
Propane presents the hazard of ex-
3-6
4. Electrical Connections
AC POWER SUPPLY CONNECTIONS
WARNING
made by a licenced electrician. Improper instal-
lation can lead to electrocution and damage to
property.
Automatic startup of the generator set during
installation can cause severe personal injury or
death. Push the control switch Off and discon-
nect the negative (−) cable from the battery to
keep the generator set from starting.
Electrical connections must be
Wiring
Refer to the requirements of The National Electrical
Code (NFPA No. 70) for all AC wiring connections.
For access to the wiring connection terminal
boards, open the top of the generator set, swing the
left service door wide open and remove the cover
from the terminal board compartment (Figure 4-1).
Use 8 AWG 90C conductors for the four AC power
output wires (L1, L2, N and GND), connect them to
the AC output terminal board (TB-2). Torque the
termninals to 25 lb−inch (2.8 N−m).
Refer to Appendix F. Outline and System Drawings
for connections at the transfer switch.
The wires must be routed to the transfer switch in
approved liquid-tight conduit. The conduit can be
stubbed up through the bottom stubup opening or
connected to the conduit opening on the side of the
generator set. If the stubup opening is used, fill in
the stubup opening with duct seal or mastic tape to
keep out insects and rodents.
Note: See ACCESSORY SUPPLY WIRING (page 4-2)
for AC wiring that may share the same conduit as AC
output wiring.
CAUTION
in control and communications wiring. Do not
route in the same conduit.
AC wiring can induce false signals
WIRING TERMINAL
BOARD COMPARTMENT
ELECTRICAL WIRING
STUBUP OPENING
FIGURE 4-1. WIRING TERMINAL BOARDS
4-1
ACCESSORY SUPPLY CONNECTIONS
To supply 120 VAC to power the GFCI outlet on the
side of the generator set, optional battery heater
(P/N 0333−0770) and optional engine oil and carburetor heater (P/N 0333-0771), connect two 12 AWG
90C wires to generator set terminal block TB3 (Hot
and Neutral) from a 15 amp protected circuit in the
main distribution panel in the house. The wires may
be run through the same conduit as the power sup-
ply wires.
Grounding
The generator set, transfer switch, power supply
wiring, and all connected electrical equipment must
be bonded to a common grounding point in accor-
dance with applicable codes or standards (Figure
4-2).
WARNING
The generator set grounding terminal (TB2-4) must be connected to the grounding
terminal in the transfer switch. Do not provide a
separate grounding rod for the generator set.
Note that generator neutral is not grounded at the
generator set, but at the common system grounding
point.
WARNING
Contact with electrical equipment
can result in severe personal injury or death. It is
extremely important that bonding and equip-
ment grounding be properly done. All metallic
parts that could become energized under ab-
normal conditions must be properly grounded.
4-2
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