Generac 7.5 KW Powerpact Owner’s Manual

Owner’s Manual

60 Hz Air-Cooled Generators

7.5 kW PowerPact™

001036

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.com/service-support/product-support-lookup

SAVE THIS MANUAL FOR FUTURE REFERENCE

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 Safety Rules & General Information. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Figure 2-1. For directions on how to open the top lid and remove the front panel, see Operation.

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. Generac recommends that the equipment be 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, Generac recommends contacting an Independent Authorized Service Dealer for assistance. Authorized service technicians are factory-trained and are capable of handling all service needs.To locate the nearest independent authorized service dealer, please visit the dealer locator at:

www.generac.com/Service/DealerLocator/.

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.	(000004)

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.	(000005)

ii	Owner’s Manual for 7.5 kW PowerPact™

Table of Contents

Table of Contents

Section 1: Safety Rules & General
Information
Introduction ..........................................................	1
Read This Manual Thoroughly ....................................	1
How to Obtain Service .................................................	1
Safety Rules .........................................................	1
General Hazards .........................................................	2
Exhaust Hazards .........................................................	3
Electrical Hazards .......................................................	3
Fire Hazards ................................................................	3
Explosion Hazards ......................................................	4
Section 2: General Information
The Generator ......................................................	5
Protection Systems .............................................	7
Emissions .............................................................	7
Fuel Requirements ..............................................	7
Battery Requirements .........................................	7
Battery Charger ....................................................	7
Engine Oil Requirements ....................................	7
Section 3: Operation
Site Prep Verification ...........................................	9
Controller Lid .......................................................	9
Circuit Breaker .....................................................	9
Control Panel .....................................................	10
Alarm Response Procedures ............................	11
Clearing an Alarm/Warning Condition .......................	11
Setting the Exercise Timer ................................	11
Battery Charger ..................................................	11
Manual Transfer Operation ...............................	11
Transfer to Generator Power Source ........................	11
Transfer Back to Utility Power Source .......................	12
Automatic Transfer Operation ..........................	12

Automatic Sequence of Operation ..................	13
Utility Failure ..............................................................	13
Cranking ....................................................................	13
Cold Smart Start ........................................................	13
Load Transfer ............................................................	13

Shutting Generator Down While Under Load . 13

To turn the generator OFF (while running in AUTO and

online): ......................................................................	13
To turn the generator back ON: .................................	13

Section 4: Maintenance

Maintenance .......................................................	15
Performing Scheduled Maintenance ...............	15
Clearing a Maintenance Due Condition ...........	15
Service Schedule ...............................................	16
Checking Engine Oil Level ...............................	18
Engine Oil Recommendations ...................................	18
Changing the Oil ................................................	19
Changing the Engine Air Cleaner ....................	19
Spark Plug ..........................................................	19
Valve Clearance Adjustment ............................	20
Check Valve Clearance .............................................	20
Adjust Valve Clearance .............................................	20
Battery Maintenance .........................................	21
Attention After Submersion .............................	21
Corrosion Protection ........................................	21
Remove From, and Return To Service Procedure
22
Remove From Service ...............................................	22
Return to Service .......................................................	22

Section 5: Troubleshooting

Section 6: Quick Reference Guide

Owner’s Manual for 7.5 kW PowerPact™

iii

Table of Contents

This page intentionally left blank.

iv	Owner’s Manual for 7.5 kW PowerPact™

Safety Rules & General Information

Section 1: Safety Rules & General Information

Introduction

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 that is intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

NOTE: When sized properly, 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 Thoroughly

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.(000100a)

If any portion of this manual is not understood, contact the nearest Independent Authorized Service Dealer for starting, operating and servicing procedures.

This manual must be used in conjunction with the appropriate Installation Manual.

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

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

DANGER

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

(000001)

WARNING

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

(000002)

CAUTION

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

(000003)

NOTE: Notes provide additional information important to a procedure or component.

These safety warnings cannot eliminate the hazards they indicate. Observing safety precautions and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that if the operator is also the owner, to read the Owner’s Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

How to Obtain Service

When the generator requires servicing or repairs, Generac recommends contacting an Independent Authorized Service Dealer (IASD) for assistance. Service technicians are factory-trained and are capable of handling all service needs. For assistance locating a dealer, go to www.generac.com/Service/DealerLocator/.

When contacting an IASD about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator. Refer to Figure 2-1 for decal location. Record the model number and serial numbers in the spaces provided on the inside front cover of this manual.

Safety Rules

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently 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, verify that it is safe for others. Also, make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

Owner’s Manual for 7.5 kW PowerPact™

1

Safety Rules & General Information

General Hazards

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

This unit is not intended for use as a prime power source. It is intended for use as an intermediate power supply in the event of temporary power outage only. See individual unit specifications for required maintenance and run times pertaining to use. (000247)

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)

WARNING

(000187)

WARNING

Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death

or serious injury.	(000130)

WARNING

(000182)

WARNING

Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and damage to equipment or property. (000155)

WARNING

Moving Parts. Do not wear jewelry when

starting or operating this product. Wearing jewelry while starting or operating this product

could result in death or serious injury.

(000115)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000111)

WARNING

Hot Surfaces. When operating machine, do not

touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces
could result in severe burns or fire.	(000108)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe

operation or damage to the generator.	(000146)

WARNING

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result

in death or serious injury.	(000215)

WARNING

Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation,

and could result in death or serious injury. (000216)

Inspect the generator regularly. Generac recommends contacting the nearest Independent Authorized Service Dealer for parts needing repair or replacement.

2	Owner’s Manual for 7.5 kW PowerPact™

Safety Rules & General Information

Exhaust Hazards

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)

WARNING

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so

could result in death or serious injury.

(000178a)

•Adequate, unobstructed flow of cooling and ventilating air is critical to 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.

Electrical Hazards

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000144)

DANGER

Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury. (000150)

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator when electrical utility is the primary power source. Failure to do so will result in death,

serious injury, and equipment damage.	(000131a)

DANGER

Electrocution. Verify electrical system is properly grounded before applying power. Failure to do so will result in death or serious injury. (000152)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will

result in death or serious injury.

(000188)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000104)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000144)

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will

result in death or serious injury.

(000145)

Fire Hazards

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)

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.

(000218)

WARNING

Fire hazard. Use only fully-charged fire extinguishers rated “ABC” by the NFPA. Discharged or improperly rated fire extinguishers will not extinguish

electrical fires in automatic standby generators. (000219)

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.(000100a)

Owner’s Manual for 7.5 kW PowerPact™

3

Safety Rules & General Information

WARNING

Risk of electrocution. Refer to NFPA 70E for safety equipment required when working with

with a live electrical system. Failure to use required safety equipment could result in

death or serious injury.

(000221)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury. (000147)

Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, verify 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.

Explosion Hazards

DANGER

(000192)

DANGER

Connection of fuel source must be done by a qualified professional technician or contractor. Incorrect installation of this unit will result in death, serious injury, and damage

to equipment and property damage.

(000151)

DANGER

Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.

(000174)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000110)

4	Owner’s Manual for 7.5 kW PowerPact™

General Information

Section 2: General Information

The Generator

A B G

C

H

I

D J

K L M

E

F

O

					001037
		Figure 2-1. GA-420 Engine 7.5 kW Unit
A.	Controller Lid	F.	Control Panel	K.	Air Box
B.	Top Lid	G.	Data Label	L.	Spark Plug
C.	Customer Connection Box	H.	Battery Access Panel	M.	Exhaust Enclosure
D.	Front Panel	I.	Oil Drain Hose	N.	Alternator
E.	Circuit Breaker	J.	Oil Fill / Dipstick	O.	Starter Motor

Owner’s Manual for 7.5 kW PowerPact™

5

General Information

Specifications

Generator

	Model	7.5 kW
	Rated Voltage	240
	Rated Maximum Load Current	31.25
	(Amps) at 220 Volts (LP)*
	Main Circuit Breaker	35 Amp
	Phase	1
	Rated AC Frequency	60 Hz
	Battery Requirement	Group U1, 12 Volts and 300 CCA Minimum (see Replacement Parts)
	Enclosure	Galvanneal Steel
	Unit Weight	280 lb (127.3 kg)
	Normal Operating Range	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
		recommended. When operated above 77 ºF (25 ºC) there may be a decrease in engine power.
		(Please reference the engine specifications section.)
	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 joules/Btu 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.

Engine

Model	7.5 kW
Type of Engine	GA-420
Number of Cylinders	1
Displacement	25.6 in3 (420 cc)
Cylinder Block	Aluminum w/ cast iron sleeve
Recommended Spark Plug	see Replacement Parts
Spark Plug Gap	0.030 in (0.76 mm)
Valve Clearance	0.002 - 0.004 in
	(0.05 - 0.1 mm)
Starter	12 VDC
Oil Capacity	Approx. 1.2 qt (1.1 L)
Recommended Air Filter	see Replacement Parts

Engine power is subject to and limited by such factors as fuel Btu/joules, ambient temperature and altitude. Engine power decreases about 3.5 percent for each 1000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 10 °F (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 Independent Authorized Service Dealer for your specific generator model.

6	Owner’s Manual for 7.5 kW PowerPact™