Generac Generator User Manual
POWER SYSTEMS, INC.
PowerMaster Technical Manual
®
This manual should remain with the unit.
DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!
INTRODUCTION
Thank you for purchasing the PowerMaster Assembly
by Generac Power Systems, Inc.
Every effort was expended 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(s)
at any time without prior notice.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service
or operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing the
service are essential to preventing accidents.
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 informa-
tion that, if not followed, could endanger personal
safety and/or property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this 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.
OPERATION AND MAINTENANCE
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 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 contribute to the need for maintenance
service.
Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
Operating instructions presented in this manual
assume that the standby electric system has been
installed by an Authorized Service Dealer or other
competent, qualified contractor. Installation of this
equipment is not a “do-it-yourself” project.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
contact an Authorized Service Dealer for assistance.
Service technicians are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer about
parts and service, always supply the complete model
number of the unit as given on the front cover of this
manual or on the DATA LABEL affixed to the unit.
AUTHORIZED DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call:
1-800-333-1322
or visit the website at:
www.generac.com
Table of Contents
PowerMaster Technical Manual
Introduction ........................Inside Front Cover
Read This Manual Thoroughly ........................ IFC
Operation and Maintenance ............................ IFC
How to Obtain Service ..................................... IFC
Authorized Dealer Locator Number ................... IFC
Safety Rules ........................................................2
Section 1 – General Information ...................4
1.1 Introduction ..................................................4
1.2 Equipment Description .................................4
1.3 Unpacking the Box ........................................4
1.4 Enclosure Details ..........................................4
Section 2 – Installation ....................................4
2.1 Introduction to Installation ............................. 4
2.2 Mounting the Enclosure ................................. 4
2.3 Connecting the Source Voltage(s)
and Load(s) .................................................... 5
2.3.1 Load #1 Connection Instructions ....... 5
2.3.2 Load #2 Connection Instructions ....... 5
2.4 Connecting the Control Circuits ..................... 5
2.4.1 Control Circuit #1 Connections .......... 5
2.4.2 Control Circuit #2 Connections .......... 5
2.5 Installing the Auxiliary Switches
to the Transfer Switch .................................... 6
2.6 Connecting the Auxiliary Switches .................. 6
2.6.1 Generator Side Auxiliary Switch ......... 6
2.6.2 Utility Side Auxiliary Switch ................ 6
2.7 Restoring All Power Supplies ......................... 6
Section 3 – Operation ......................................7
3.1 Testing the PowerMaster Operation ................ 7
Section 4 – Electrical Data ..............................8
Section 5 – Exploded Views &
Parts Lists ................................... 10
Section 6 – Notes ........................................... 12
Section 7 – Warranty .....................Back Cover
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IMPORTANT SAFETY INSTRUCTIONS
PowerMaster Technical Manual
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries. The manufac-
turer suggests that these rules for safe operation be copied and posted in potential hazard
areas. Safety should be stressed to all operators and potential operators of this equipment.
The engine exhaust from this product
•
contains chemicals known to the state
This product contains or emits chemicals
•
known to the state of California to cause
cancer, birth defects or other reproductive harm.
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(s) 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,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the generator(s) unsafe.
WARNING:•
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:•
DANGER
Despite the safe design of the generator(s),
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator(s).
Parts of the generator(s) are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS
For safety reasons, the manufacturer requires that
•
the installation, initial start-up and maintenance
of this equipment is carried out by an Authorized
Dealer.
The engine exhaust fumes contain carbon monox-
•
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict compliance with applicable codes and standards.
Following installation, do nothing that might render the system unsafe or in noncompliance with
such codes and standards.
Keep hands, feet, clothing, etc., away from drive
•
belts, fans, and other moving or hot parts. Never
operate the unit with any drive belt or fan guard
removed.
Adequate, unobstructed flow of cooling and ventilat-
•
ing air is critical to correct generator(s) operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator(s).
When working on this equipment, remain alert
•
at all times. Never work on the equipment when
physically or mentally fatigued.
Inspect the generator(s) regularly, and repair or
•
replace all damaged or defective parts immediately. Always use factory-authorized parts.
Turn off the AC power to the battery charger before
•
disconnecting the battery to minimize the chance
of equipment damage.
Before performing any maintenance on the
•
generator(s), disconnect its battery cables to prevent accidental start-up. Remove control panel
fuse, then disconnect the cable from the battery
post indicated by a NEGATIVE, NEG or (–) first.
Reconnect that cable last, then reinstall control
panel fuse.
Never use the generator(s) 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
IMPORTANT SAFETY INSTRUCTIONS
PowerMaster Technical Manual
ELECTRICAL HAZARDS
All generators covered by this manual produce
•
dangerous electrical voltages and 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 before operating the generator(s). If working
around an operating unit, stand on an insulated,
dry surface to reduce 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.
The National Electrical Code (NEC) requires the
•
frame and external electrically conductive parts
of the generator to be connected to an approved
earth ground and/or grounding rods. Local electrical codes also may require proper grounding of the
generator electrical system.
After installing this standby electrical system, the
•
generator(s) may crank and start at any time without warning. When this occurs, load circuits are
transferred to the STANDBY (generator) power
source. To prevent possible injury if such a start
and transfer occur, always set the generator’s
AUTO/OFF/MANUAL switch to its OFF position
before working on equipment and remove the
negative battery lead.
In case of accident caused by electric shock, imme-
•
diately 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 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 equip-
•
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.
The enclosure door on this unit is grounded to the
•
chassis with a wire. The grounding wire must be
reconnected when the door is replaced to reduce
the risk of electric shock.
FIRE HAZARDS
For fire safety, the generator(s) must be installed
•
and maintained properly. Installation always must
comply with applicable codes, standards, laws
and regulations. 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(s) 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(s) at all
•
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for
use on the standby electric system. Keep the extinguisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
EXPLOSION HAZARDS
Do not smoke around the generator(s). Wipe up
•
any fuel or oil spills immediately. Ensure that no
combustible materials are left in the generator(s)
compartment, or on or near the generator(s), as
FIRE or EXPLOSION may result. Keep the area
surrounding the generator(s) clean and free from
debris.
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