Generac Power Systems Air-cooled Generators Installation Manuallines
INSTALLATION
GUIDELINES
Air-cooled Generators
THIS MANUAL MUST BE USED IN
CONJUNCTION WITH THE OWNERS
MANUAL.
www.generac.com or 1-888-GENERAC
NOT INTENDED FOR USE IN CRITICAL LIFE
SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
Table of Contents
Introduction ......................................................... Inside Front Cover
Read this Manual Thoroughly ..............................................IFC
Contents ................................................................................1
Operation and Maintenance ....................................................1
How to Obtain Service ............................................................1
Safety Rules ...................................................................................1
Standards Index .....................................................................2
Unpacking/Inspection .....................................................................3
NEC Requirements .........................................................................3
Before You Begin ............................................................................3
Site Preparation and Generator Placement ......................................4
Coverting to LP Vapor ....................................................................5
Installing & Connecting Gas Lines ..................................................6
External Electrical Connections .......................................................7
Generator Activation .......................................................................8
Activation Chart .....................................................................9
Generator Connections - EZ Switch ................................................8
Appendix A - EZ Switch Installation & Operational Testing ..............10
Battery Installation................................................................12
Operational Testing ...............................................................13
Appendix B - RTSX and RTSD Transfer Switch
Installation & Operational Testing ...............................................15
Selected Circuit Coverage .....................................................16
Whole-house Circuit Coverage .............................................16
Electrical Connections ..........................................................17
Operational Testing ...............................................................17
Appendix C - Digital Load Managment (DLM) ...............................20
Appendix D - Digital Load Managment (DLM) Modules .................20
Connecting Load Shed Module (LSM) Connections ...............20
Functional Tests and Adjustments .........................................22
Appendix E - Setting the Automatic Exercise Function ...................22
Electrical Data ..............................................................................23
Notes ...........................................................................................35
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:
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.
If any portion of this manual is not understood, contact the nearest 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 operation 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 INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure and will
be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they indicate.
Common sense and strict compliance with the special instructions while
performing the action or 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 information 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 Owners Manual and thoroughly understand all
instructions before using this equipment. The manufacturer also
strongly recommends instructing other users to properly star t and
operate the unit. This prepares them if they need to operate the
equipment in an emergency.
This manual contains pertinent owner’s information for these
models:
• 7 kW NG, 8 kW LP, single-cylinder GH-410 Engine
• 9 kW NG, 10 kW LP, V-twin GT-530 Engine
• 13 kW NG, 13 kW LP, V-twin GT-990 Engine
• 13 kW NG, 14 kW LP, V-twin GT-990 Engine
• 16 kW NG, 16 kW LP, V-twin GT-990 Engine
• 16 kW NG, 17 kW LP, V-twin GT-990 Engine
• 18 kW NG, 20 kW LP, V-twin GT-999 Engine
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 a
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 a Dealer for service aids and accessories.
When the generator requires servicing or repairs, contact a Dealer
for assistance. Service technicians are factory-trained and are
capable of handling all service needs. For assistance locating a
dealer, call 1-888-436-3722.
When contacting a Dealer 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. See section
“The Generator” for decal location.
Model No.__________________ Serial No. ______________
Safety Rules
Save These Instructions The manufacturer
suggests that these rules for safe operation
be copied and posted near the units installation site. Safety should be stressed to all
operators and potential operators of this
equipment.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owners
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, ensure that it is
safe for others. 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 all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
Installation must always comply with applicable codes, standards, laws and regulations.
A running generator gives off carbon monoxide, and odorless, colorless poison gas.
Breathing in carbon monoxide can cause
headaches, fatigue, diziness, nausea, vomitting, confusion, fainting, siezures or death.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
1
Safety Rules
GENERAL HAZARDS
• 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 battery operated carbon monoxide alarm indoors, according to
manufacturer’s instructions/recommendations.
• 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.
• 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, disconnect its
battery cables to prevent accidental start up. Disconnect the cable
from the battery post indicated by a NEGATIVE, NEG or (–) first, then
remove the POSITIVE, POS or (+) cable. When reconnecting the
cables, connect the POSITIVE cable first, 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.
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, 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 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. Local electrical codes also may require proper
grounding of the generator electrical system.
• After installing this home standby electrical system, the generator 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 7.5A 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 causing injury.
FIRE HAZARDS
• For fire safety, the generator must be installed and maintained
properly. Installation must always 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 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 electric system. Keep the extinguisher properly
charged and be familiar with its use. Consult the local fire depar tment
with any questions pertaining to fire extinguishers.
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 is permitted.
In the absence of pertinent standards, codes, regulations and laws, the
published information listed below may be used as installation guide for
this equipment.
1. NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS
TURBINES, available from the National Fire Protection Association,
470 Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH
CARE FACILITIES, available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE, available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR STORAGE
AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same as
Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC CODE,
available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available from the American
Insurance Association, 85 John Street, New York, N.Y. 10038.
2
7. AGRICULTURAL WIRING HANDBOOK, available from the Food and
Energy Council, 909 University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRICAL SYSTEMS, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI
49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE,
available same as Item 1.
Only qualified electricians or contractors
should attempt such installations, which must
comply strictly with applicable codes, standards and regulations.
After unpacking, carefully inspect the contents for damage.
• This standby generator set is ready for installation with a factory
supplied and pre-mounted base pad and has a weather protective
enclosure that is intended for outdoor installation only.
• This UL listed standby generator set may be packaged with an
automatic transfer switch with built in load center. The combination
transfer switch and load center is pre-wired with a two foot and 30
foot conduit. Circuit breakers for emergency circuit connections are
included (if equipped).
• This UL listed, 2-pole switch is rated at 100 or 200 AC amperes at
250 volts maximum. The 100 Amp transfer switch is for indoor use
only. The 200 Amp transfer switch is for indoor/outdoor use (if
equipped).
General Information
Local code enforcement may require that AFCI’s be incorporated
into the transfer switch distribution panel. The Transfer Switch
provided with this generator has a distribution panel that will
accept AFCI’s.
Siemens Part No. Q115AF - 15A or Q120AF - 20A can be
obtained from a local electrical wholesaler and will simply replace
any of the single pole circuit breakers supplied in the Transfer
Switch distribution panel.
Contact the local inspector or City Hall to be aware of all federal,
state and local codes that could impact the installation. Secure all
required permits before starting the job.
Carefully read and follow all of the procedures and safety
precautions detailed in the installation guide. If any portion of the
installation manual, technical manual or other factory-supplied
documents is not completely understood, contact a dealer for
assistance.
Fully comply with all relevant NEC, NFPA and OSHA standards
as well as all federal, state and local building and electric codes.
As with any generator, this unit must be installed in accordance
with current NFPA 37 and NFPA 70 standards as well as any other
federal, state, and local codes for minimum distances from other
structures.
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 700, 701 & 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.
If any loss or damage is noted at time of delivery, have the person(s)
making the delivery note all damage on the freight bill or affix their
signature under the consignor’s memo of loss or damage.
If a loss or damage is noted after delivery, separate the damaged
materials and contact the carrier for claim procedures.
“Concealed damage” is understood to mean damage to the contents of a
package that is not in evidence at the time of delivery, but is discovered
later.
To properly open the roof, press down on the center top lip and release
the latch. If pressure is not applied from the top, the roof may appear
stuck. Always verify that the side lock is unlocked before attempting to lift
the roof.
3
General Information
3. Inspect the generator for shipping damage and if necessary,
file a claim with the shipper.
Remove the bands holding the generator to the wooden pallet.
1. Locate the mounting area as close as possible to the transfer
switch and fuel supply.
Leave adequate room around the area for service access
(check local code), and place high enough to keep rising
water from reaching the generator.
Choose an open space that will provide adequate and
unobstructed airflow (see the “Location” section in the
Owner’s Manual).
2. Place the unit so air vents won’t become clogged with leaves,
grass, snow or debris. Make sure exhaust fumes will not enter
the building through eaves, windows, ventilation fans or other
air intakes.
Dig a rectangular area approximately five inches deep and
about six inches longer and wider than the footprint of the
generator. Cover with polyurethane film and fill with pea gravel
or crushed stone. Compact and level the stone. A concrete
pad can be poured if desired.
4. Make sure the lifting equipment to be used has sufficient
capacity to safely handle the weight of the generator.
Use nylon lifting straps and connect them to the lifting eyes
on each corner of the base frame to avoid damaging the
enclosure.
5. Set the generator onto the pad so that the gravel bed extends
several inches beyond the generator on all sides.
Make sure the generator is level within ½ inch.
4
6. Connect an approved ground strap to the grounding lug on the
base frame and to an approved earth ground or grounding rod
as specified by local regulations.
7. Check the engine oil and, if necessary, add enough of the
recommended oil to bring the level up to the FULL mark on
the dipstick. Be careful not to overfill the crankcase.
General Information
3. On 10 kW units, open the roof, loosen the forward clamp
on the air inlet hose, and slide the hose away from the hose
fitting.
1. The generator was configured for natural gas operation at the
factory. Switching over to LP Vapor is a simple procedure.
On models with a single cylinder engine, begin by
disconnecting and removing the battery if installed.
2. Take the plastic T-handle fuel selector in the poly bag supplied
with the generator and locate the selector tab on the air box
cover. Insert the pin end into the hole in the selector tab
and pull outward to overcome spring pressure. Then twist
clockwise 90 degrees and allow the selector to return in once
aligned with the LP position.
4. Slide the fuel selector pin on the carburetor out towards the
back of the enclosure.
5. Replace the inlet hose and tighten the clamp securely.
6. On all other models, simply remove the air cleaner cover and
slide the fuel selector pin outward from the natural gas to the
LP position.
5
General Information
1. Both natural gas and LP Vapor are highly volatile substances,
so strict adherence to all safety procedures, codes, standards
and regulations is essential.
Gas line connections should be made by a certified plumber
familiar with local codes. Always use AGA-approved gas pipe
and a quality pipe sealant or joint compound.
Verify the capacity of the natural gas meter or the LP tank in
regards to providing sufficient fuel for both the generator and
other operating appliances.
3. When connecting the gas line to the generator, use the
provided section of UL Listed or AGA-approved flexible fuel
line in accordance with local regulations. The purpose of the
flexible fuel line is to ensure that vibration from the generator
does not cause a gas leak at one of the connection points, so
it’s important that the line be installed with as few bends as
possible. Installing a sediment trap is also recommended.
4. Never bend the flexible fuel line to avoid using an elbow.
Bending the flexible line decreases its ability to absorb
vibrations and defeats its purpose as well as constricts the
actual fuel flow.
2. Most applications will require an external manual shutoff valve
on the fuel line.
6
5. After checking for leaks, check the gas pressure at the
REGULATOR to make sure there’s enough gas pressure for
generator operation. See Owner’s Manual for fuel pressure
specifications. If not within these limits, contact your local gas
supplier.
6. When finished checking the gas pressure, close the manual
shutoff valve.
General Information
2. Remove the knockout in the back of the connection box, feed
the wires through the back of the box and secure the conduit
with the lock nut.
Seal the hole with silicone caulk. Don’t forget to caulk the hole
inside the house as well.
4. Replace the protective cover plate and retaining screw, and
lock the connection box.
5. For 10-20 kW models, locate the metal hasp that is packaged
in the owner’s manual bag. Insert the hasp in the slot located
on the left side of the external circuit breaker box. Be sure that
the clip of the hasp is facing toward the front of the generator.
If desired, lock the external box.
7
General Information
When battery power is applied to the generator during the
installation process, the controller will light up. However, the
generator still needs to be activated before it will automatically run
in the event of a power outage.
Activating the generator is a simple one time process that is
guided by the controller screen prompts. Once the product is
activated, the controller screen will not prompt you again, even if
you disconnect the generator battery.
After obtaining your activation code, please complete the following
steps at the generator’s control panel in the Activation Chart
(shown on the following page).
3. Remove the two screws securing the connection area cover,
and remove the cover.
4. Feed the wires through the back of the generator and secure
the conduit with the lock nut.
5. Run the power leads through the strain relief provided.
1. If the generator comes with an external connection box and
5’ seal-tite whip pre-wired and connected to the generator, no
additional connections are necessary at the generator. Skip
the following section and proceed with Appendix A, EZ Switch
Installation & Operational Testing.
2. If the EZ Switch was purchased separately from the generator,
the 5’ seal-tite whip will need to be connected to the
generator. To complete the wiring, run the ¾” conduit for the
power leads and control wires from the external connection
box to the generator.
6. The circuit breaker is attached to the exterior access panel.
7. Remove the plastic plugs inside the main breaker access area
to allow connection of the power leads to the circuit breaker.
8
General Information
CHOOSE LANGUAGE TROUBLESHOOTING
Display Reads: Use ARROW keys to scroll to desired
language. Press ENTER to select.
Escape Enter
If the wrong language is chosen, it can be
changed later using the “edit” menu.
Display Reads: Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER,
your generator will only run in manual mode
(for test purposes) and NOT ACTIVATED will
be displayed. You will need to remove the
generator control panel fuse AND disconnect
the T1, N1 and N2 connector in the external
Escape Enter
connection box (if equipped); or disconnect
utility input (main breaker) to the transfer
switch for 3-5 seconds and reconnect, then
begin with Step 1.
Display Reads: If you do not have your activation code,
go to www.activategen.com or call
1-888-9ACTIVATE (922-8482).
If you already have your activation code, wait
3-5 seconds for the next display.
Escape Enter
ENTER ACTIVATION CODE (Passcode) TROUBLESHOOTING
Display Reads: Use ARROW keys to scroll and find the first
number of your Activation Code.
Press ENTER to select.
Repeat this step until all digits have been
entered.
Escape Enter
Use ESCAPE to correct previous digits.
Display Reads: Activation is complete when all digits are
entered above and your screen shows this
display.
Follow the controller prompts to continue
setting the time function. Refer to your
Escape Enter
Owner’s Manual with questions.
What happens if “Wrong Passcode Try
Again” appears?
Reenter the activation code. If a second
attempt is unsuccessful, check the number
against the code given on activategen.com. If
it is correct and the generator will not accept
it, contact 1-888-9ACTIVATE (922-8482).
9
Appendix A
8. Now connect the red and black power leads to the circuit
breaker. Since this is a single-phase application, it doesn’t
matter which wire is connected to which lug.
9. Connect the green equipment ground wire to the ground bus
bar and torque to 35 inch lbs. The torque values are:
• 10-14 AWG = 35 in/lbs
• 8 AWG = 40 in/lbs
• 4-6 AWG = 45 in/lbs
NOTE:
In order to maintain separation of circuits, the DC control wires
must be separated from the AC control wires. A piece of fiberglass sleeving has been provided in the manual kit to achieve
this. Slide the sleeving over the AC wires OR the DC wires, but
not both, from the wire landing area to the outside of the generator. Use the cable tie locations to hold the sleeving in place.
12. An improperly connected control wire can damage the
generator control board.
Neutral
Ground
Cable Tie Location
10. Connect the white neutral wire to the neutral bus bar and
torque to 35 inch lbs. The torque values are:
• 10-14 AWG = 35 in/lbs
• 8 AWG = 40 in/lbs
• 4-6 AWG = 45 in/lbs
11. Connect the control wires to the correct terminals. The
terminals are clearly marked N1 and N2 for utility sensing; 23
and 194 for transfer relay control; and T1 and 0 for battery
charge. On pre-wired switches, the 0 (zero) wire will not be
present/required.
10
1. Before beginning any installation, make sure power is shut
OFF to the main distribution panel and carefully read the
Owner’s Manual that came with the transfer switch.
The distributed load center switch must be mounted close
enough to the main distribution panel to accommodate the
two-foot, pre-wired conduit. Make sure no water or corrosive
substances can drip onto the transfer switch enclosure.
2. Always inspect the switch for shipping damage. Never mount
a transfer switch that shows any evidence of damage.
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