Generac Power Systems CorePower?/ES Generators, CorePower/ES Generator Installation Manuallines
INSTALLATION
GUIDELINES
CorePower/ES 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!
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
Before You Begin ............................................................................3
Unit Handling .................................................................................3
Minimum Clearance Requirements .................................................4
Site Preparation and Generator Placement ......................................5
Coverting to LP Vapor ....................................................................6
Installing & Connecting Gas Lines ..................................................6
External Electrical Connections .......................................................8
Battery Installation..........................................................................9
Automatic Transfer Switch Electrical Connections .........................10
Operational Testing .......................................................................12
Notes ...........................................................................................13
Installation Diagrams ....................................................................16
Thank you for purchasing this compact, high performance, aircooled, 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, composite 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 aler t 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 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.
This manual contains pertinent installation information for model:
• 6 kW NG, 7 kW LP, single-cylinder OHV 432 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.
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, an odorless, colorless poison gas.
Breathing in carbon monoxide can cause
headaches, fatigue, diziness, nausea, vomitting, confusion, fainting, siezures or death.
GENERAL HAZARDS
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” in the Owner’s Manual for decal location.
Model No.__________________ Serial No. ______________
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.
• 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.
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.
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• 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.
CARBON MONOXIDE 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.
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.
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• 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.
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.
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.
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 is packaged with an
automatic transfer switch with built in load center.
• This UL listed, 2-pole transfer switch is rated at 50A AC
amperes at 250 volts maximum.
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.
1. Once the generator has been unpacked. To remove it from
the wooden shipping pallet, remove the four lag bolts and
shipping brackets from the four corners of the base.
2. DO NOT ATTEMPT TO MOVE THE UNIT BY PULLING OR
LIFTING ON THE ROOF OF THE ENCLOSURE.
3. Using the sides of the enclosure slide the generator to one
edge of the wooden pallet.
4. Cut off one side panel of the shipping carton to use as a
protective barrier.
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.
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.
5. Using a 2 wheeled hand truck place the cardboard between
the hand truck and the generator enclosure. Slide the
generator off the wooden pallet onto the hand truck. Wheel
the generator to the installation location.
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No windows or openings in the wall permitted
within 5 feet from any point of the generator.
Existing Wall
36” if the surface has a fire resistant rating of at least one hour per NFPA 37
These guidelines are based upon the
requirements of NFPA 37 and the
manufacturer’s requirement for air flow
for proper operation. Local codes may
be different and more restrictive than
what is described here.
60 inches Minimum Distance All Around
Top of Generator
Clearance from the ends and front of the generator
should be 36” minimum per NFPA 37. This would
include shrubs, trees and any kind of vegetation.
Clearance at the top should be a minimum of 60
inches from any structure, overhang or projections
from the wall. The generator should not be placed
under a deck or other structure that is closed in and
would limit or contain air flow.
60” Minimum
60” Recommended
Minimum From Ends
Generator
NOTE:
Failure to follow these minimum clearance guidelines may result in the generator failing inspection by the local
building, electrical or fire inspector requiring the generator be reinstalled in the correct location.
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