Generac 6519 User Manual

Reference all appropriate documentation. This manual should remain with the unit.

NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT

INSTALLATION.

DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY!

LISTED

Owner’s Manual

Automatic Standby Generator

7 kW PowerPact™

To locate in Spanish, go to http://www.generac.com/service-support/product-support-lookup

To locate in French, go to http://www.generac.com/service-support/product-support-lookup

WARNING!

California Proposition 65

Engine exhaust and some of its constituents are known to the state of California to cause cancer,

birth defects, and other reproductive harm.

WARNING!

California Proposition 65

This product contains or emits chemicals known to the state of California to cause cancer,

birth defects, and other reproductive harm.

Use this page to record important information about your generator set.

Record the information found on your unit data label on this page. The generator unit data label plate is affixed to the engine divider panel inside the enclosure. The unit data label provides the following information:

• Model Number

• Serial Number

• Control Panel Part Number

• Voltage Rating of the unit

• Maximum Current Rating of the unit (AMPS) When contacting an Independent Authorized Service Dealer about parts

and service, always supply the complete model number and serial number of the unit.

Operation and Maintenance: Proper maintenance and care of the generator ensures a minimum number of problems and keeps operating expenses at a minimum. It is the operator’s responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Independent Authorized Service Dealer. Normal maintenance, service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage may contribute to the need for additional maintenance or service.

When the generator requires servicing or repairs, contact an Independent Authorized Service Dealer for assistance. Authorized service technicians are factory-trained and are capable of handling all service needs.

For any Frequently Asked Questions (FAQs) for your product, please go to: http://www.generac.com/service-support/faqs..

To find your Local Independent AUTHORIZED SERVICE DEALER

INDEPENDENT AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest INDEPENDENT

AUTHORIZED SERVICE DEALER,

please call this number:

1-800-333-1322

or, visit the dealer locator at:

www.generac.com/Service/Dealer Locator/

Section 1 — Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 — General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 — General Safety Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 — Exhaust Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.4 — Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 — Fire Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6 — Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Section 2 — General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 — The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 — Protection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 — Emission Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 — Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5 — Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Section 3 — Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 — Controller Lid Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 — Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 — Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 — Alarm Response Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.5 — Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.6 — Turning the Generator Off When Operating Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.7 — Manual Transfer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.8 — Side Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.9 — Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.10 — Setting the Exercise Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Section 4 — Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 — Performing Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 — Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 — Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 — Changing the Engine Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.5 — Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.6 — Valve Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.7 — Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.8 — Attention After Submersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.9 — Corrosion Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.10 — Out of Service Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Section 5 — Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Section 6 — Quick Reference Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

iii

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Section 1 Safety

INTRODUCTION: Thank you for purchasing this compact, high performance, air-cooled, engine-driven stationary automatic standby generator

set. Every effort was made to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product or manual at any time without prior notice.

This generator 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).

NOTE: When properly sized, this generator is suitable for supplying typical residential loads such as Induction Motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), Electronic Components (computer, monitor, TV, etc.), Lighting Loads and Microwaves.

READ THIS MANUAL THOROUGHL Y:

mends that the operator read and thoroughly understand the instructions and contents of this owner’s manual before attempting to use the equipment. If any portion of this publication is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.

SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.

SAFETY: Throughout this manual, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation, function or service that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS

Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTE: Notes contain additional information important to an operation or procedure.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:

This symbol points out important Safety Information that, if not followed, could endanger personal safety and/or property of others.

The operator is responsible for proper and safe use of this equipment. The manufacturer strongly recom-

INJURY.

This symbol points out a potential Explosion Hazard.

This symbol points out a potential Fire Hazard.

This symbol points out a potential Electrical Shock Hazard.

These “Safety Alerts” cannot eliminate the hazards that they signal. Strict compliance with these special instructions, plus common sense are major accident prevention measures.

Automatic Standby Generator Owner’s Manual 1

1.1 — General Safety

Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, ef ficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique the manufacturer does not specifically recommend, ensure that it is safe for personnel. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate and maintain this equipment.

Potentially lethal voltages are generated by these machines. Ensure steps are taken to make the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near a running generator.

The installation of this generator must always comply with applicable codes, standards, laws and regulations.

A running generator gives off DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even death.

The control panel for this unit is intended to be operated by qualified service personnel only.

1.2 — General Safety Hazards

• For safety reasons, this equipment should only be installed, serviced and repaired by a Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards, regulations and product Installation Manual guidelines. The operator also must comply with all such codes, standards, regulations and product Installation Manual guidelines.

• The engine exhaust fumes contain carbon monoxide, which can be DEADLY . This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. DO NOT alter or add to the exhaust system or do anything that might render the system unsafe or in noncompliance with applicable codes and standards.

• Install a carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.

• Adequate, unobstructed flow of cooling and ventilating air is critical for correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The generator MUST be installed and operated outdoors only.

• Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

• Inspect the generator regularly, and contact the nearest Dealer for parts needing repair or replacement.

• Before performing any maintenance on the generator, remove the control panel fuse and disconnect the Negative (—) battery cable to prevent accidental startup. When disconnecting battery cables always remove the NEGATIVE (NEG or “—”) cable first, then remove the POSITVE (POS, or “+”) cable. When reconnecting the cables, connect the POSITIVE cable first, and the NEGATIVE cable last.

• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

2 Automatic Standby Generator Owner’s Manual

1.3 — Exhaust Hazards

• Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness, sleepiness, inability to think clearly , fainting, unconsciousness or even death. If any carbon monoxide poisoning symptom is experienced, move into fresh air and immediately seek medical attention.

• This generator is designed for OUTDOOR installation ONLY. Never operate the generator inside any garage or other enclosed space.

1.4 — Electrical Hazards

• All generators covered by this manual produce dangerous electrical voltages that can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch, as does the standby generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc. while the unit is running. Ensure all appropriate covers, guards and barriers are in place, secured and/or locked before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential shock hazard.

• 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.

• This is an Automatic Standby Generator, the generator may crank and start at any time when utility is lost. When this occurs, load circuits are transferred to the STANDBY (generator) power source. To prevent injury, before working on this generator (for inspection, service or maintenance), always put the generator into the OFF mode and remove the 7.5 Amp ATO® fuse from the generator control panel.

• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components resulting in injury.

1.5 — Fire Hazards

• For fire safety, the generator must be installed and maintained properly. Installation MUST always comply with applicable codes, standards, laws, regulations and product Installation Manual guidelines. Adhere strictly to local, state, and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.

• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the standby generator. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department with any questions pertaining to fire extinguishers.

1.6 — Explosion Hazards

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install the fuel supply system according to applicable fuel-gas codes. Before placing the home standby electric system into service, fuel system lines must be properly purged and leak tested according to applicable code. After installation, inspect the fuel system periodically for leaks. No leakage can be permitted.

Automatic Standby Generator Owner’s Manual 3

If this generator is used to power electrical load circuits normally powered by a utility power source, it is

required by code to install a transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution system when the generator is operating (NEC 702). Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy.

4 Automatic Standby Generator Owner’s Manual

Section 2 General Information

Oil Fill/Dipstick

Control Panel/

Circuit Breaker

Spark Plug

Starter Motor

Alternator

Oil Drain Hose

Airbox

2.1 — The Generator

2.2 — Protection Systems

The generator may have to run for long periods of time with no operator present to monitor the engine/generator conditions. Therefore, the generator is equipped with a number of systems to automatically shut down the unit to protect it against potentially damaging conditions. Some of

these systems are as follows:

The control panel contains LEDs which alert the operator when a fault condition occurs. For more information about alarms and control panel operation, see Section 3 Operation.

• Low Oil Level Sensor

• High Temperature Sensor

• Overcrank Detection

• Overspeed Detection

• RPM Sensor

Figure 2-1: GA-420 Engine 7 kW Unit

• Underspeed Detection

• Charger Problem Detection

• Battery Problem Detection

• Fuse Problem Detection (missing or failed)

• Wiring Error Detection

Automatic Standby Generator Owner’s Manual 5

2.3 — Emission Information

The U.S. Environmental Protection Agency (EPA) requires that this generator comply with exhaust emission standards. This generator is certified to meet the applicable EPA emission levels, and is certified for use as a stationary engine for standby power generation. Any other use may be a violation of federal and/or local laws. To ensure that the engine complies with the applicable emission standards for the duration of the engine’s life, it is important to follow the maintenance specifications in the Section 4 Maintenance. This generator is certified to operate on Liquid Propane Vapor fuel or pipeline Natural Gas.

The Emission Control System on this generator consists of the following components:

• Air Induction System

• Airbox Assembly

• Air Cleaner

• Fuel Metering System

• Carburetor / Mixer Assembly

• Fuel Regulator

• Ignition System

• Spark Plug

• Ignition Module

• Exhaust System

• Exhaust Manifold

• Muffler

6 Automatic Standby Generator Owner’s Manual

2.4 — Specifications

2.4.1 — Generator

Output 7 kW Rated Voltage 240 Rated Maximum Load

Current (Amps) at 240 Volts (LP)*

Main Circuit Breaker 30 Amp Phase 1 Rated AC Frequency 60 Hz Battery Requirement Group U1, 12 Volts and 300 CCA Minimum (Generac Part No. OD4575) Weight (unit only in lbs./

kg) Enclosure Galvanneal Steel Normal Operating

Range

These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSA-C22.2 No. 100-04 Standard for Motors and Generators. * Natural Gas ratings will depend on specific fuel Btu/joules content. Typical derates are between 10-20% off the LP gas rating. ** Circuits to be moved must be protected by same size breaker. For example, a 15 Amp circuit in the main panel must be a 15 Amp circuit in the transfer switch.

This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 ºF (-29 ºC) to 122 ºF (50 ºC). For areas

where temperatures fall below 32 ºF (0 ºC) a cold weather kit is required. When operated above 77 ºF (25 ºC) there may be a decrease

in engine power. Please reference the engine spec ifications section.

29.2

280/127.3

2.4.2 — Engine

Type of Engine GA-420 Number of Cylinders 1 Displacement 420 cc Cylinder Block Aluminum w/Cast Iron Sleeve Recommended Spark Plug F7TC/ Champion N9YC Spark Plug Gap 0.76 mm (0.030 in) Starter 12 VDC Oil Capacity Including Filter Approx. 1.2 Qt/1.1 L Recommended Air Filter Generac Part No. 0E9371A Engine power is subject to and limited by such factors as fuel Btu/joules content, ambient temperature and altitude. Engine power decreases about

3.5 percent for each 1,000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 10 ºF (6 ºC) above 60 ºF (15 ºC) ambient temperature.

The specification sheet for your generator was included in the documentation provided with the unit at the time of purchase. For additional copies, consult your local Authorized Service Dealer for your specific generator model.

2.4.3 — Fuel Requirements

The engine has been fitted with a dual fuel carburetion system. The unit will run on natural gas or LP gas (vapor), but it has been factory set to run on natural gas. The fuel system will be configured for the available fuel source during installation.

Recommended fuels should have a btu content of at least 1,000 Btus per cubic foot (37.26 megajoules per cubic meter) for natural gas, or at least 2,500 Btus per cubic foot (93.15 megajoules per cubic meter) for LP gas (vapor).

NOTE: If converting to LP gas from natural gas, a minimum LP tank size of 250 gallons (946 liters) is recommended. See the Installation Manual for complete procedures and details.

Automatic Standby Generator Owner’s Manual 7

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